CEMENT/CONCRETE

Portland Cement – Its name is derived from its similarity to Portland stone which was
quarried on the Isle of Portland in Dorset, England. It was named by Joseph
Aspdin who obtained a patent for it in 1824. However, his son William Aspdin is
regarded as the inventor of "modern" Portland cement due to his developments in
the 1840s

Two major components of concrete:

- Paste
- Mineral aggregates

MOLDS:
Cylinder Mold Dimension = 6”Ø x 12” (3 layers, 25 blows each)
Beam Mold Dimension = 6” x 6” x 21” (2 layers 63 blows each)
Slump Cone Dimension = 4ӯ (top)
8ӯ (bottom)
12” (height)

Thickness Determination of Concrete Core:

Individual measurements in excess of the specified thickness more than 5mm will be
considered as specified thickness + 5mm

Individual measurements less than the specified thickness by more than 25mm shall
not be included in the average

 Concrete core sample must be submerge in under water before subjecting

them to compression at least 40 Hrs.

 Basis of acceptance of concrete pavement = both core & beam samples

Purpose of capping concrete cylinder prior to testing is to:

 Provide smooth, flat ends that are perpendicular to axis of the sample.

Slump of Concrete:
Vibrated between 10 and 40mm (1/2” and 1 1/2”)
Not Vibrated between 40 and 75mm (1 1/2” and 3”)
Concrete Piling 150mm to 200mm

Flexural Strength (Concrete):

Third Point 3.80 Mpa (550 psi)
Middle Point 4.50 Mpa (650 psi)

 1 set of 3 beam samples shall represent a 330 m2 of pavement, 230mm

depth, or fraction thereof placed each day
 Volume of concrete not more than 75 cu.m.

Compressive Strength Portland Cement:

7 days not less than 19.30 Mpa
14 days 24.10 Mpa (3500 psi)

Compressive Strength of Mortar (for consideration of 3 and 7 days acceptance) if:

7 days not less than 23.46 Mpa
For Compressive Strength:
Cylinder only
P /A A = pi/4 (D) 2
D = 6”
Rate of loading of Compressive Strength of Cylinder Concrete = 20-50 Psi
= 0.14-0.34 Mpa/sec
For Flexural Strength:
Beam only
PL / bd2 fails w/in middle third
3Pa / 2 b d2 tested at mid point
L = 18”
b = 6”
D = 6”
Rate of loading of Flexural Strength of Beam Concrete = 125-175 Psi
= 861-1207 Kpa/min

Minimum Compressive Strength of Hydraulic Cement Type 1 = 25 Mpa

Minimum Compressive Strength:

Class A 20.70 MPa
Class B 16.50 MPa
Class C 20.70 MPa
Class Seal 20.70 MPa
Class P 37.70 MPa

Class A - Used for all superstructures and heavily reinforced substructures.

Slabs, beams, girders, columns arch ribs, box culverts, reinforced
Abutments, retaining walls and reinforced footings.

Class B - Footings, pedestals, massive pier shafts, pipe bedding, gravity walls,
unreinforced or with only a small amount of reinforcement

Class C - Thin reinforced sections, railings, precast RC Piles, and cribbing and
for filler in steel grid floors

Class P - Pre-stressed Concrete Structures and Members

Class Seal - Concrete deposited in water

Class Water Cement Ratio Cement Factor (content)

Class A 0.53 9.10
Class B 0.58 8.00
Class C 0.55 9.50
Class P 0.49 11.00
Seal 0.58 9.50

 Water-Cement Ratio of Portland Cement Mortar Cubes = 0.485

 Amount of water in a 1 bagger mixer (1:2:4 concrete mix) = 20 liters

 Elapse time between obtaining the first and final portions of the composite
sample of fresh concrete shall not exceed = 15 minutes

 Mixed Concrete Time Elapse:

Agitating Trucks 90 mins.
Non-Agitating Trucks 45 mins. Max.
  Concrete shall be cured for a minimum time of 72 hrs. (3 days)

 Concrete Curing promotes cement hydration

 Initial setting time of Portland Cement = 460 mins.

 Dowels shall be Plain Round Bars

 Tie Bars shall be Deformed Bars

SAMPLE:

Grab Sample – a sample of chemical admixtures for concrete obtained in a

single operation

Composite Sample - a sample of chemical admixtures for concrete obtained by

combining three or more grab samples

Minimum volume of each grab sample of a liquid admixture for concrete = 0.50L
Minimum volume of composite sample of a liquid admixture for concrete = 4.0L

Cement Mortar Mixture:

Stone Masonry 1 part cement 2 parts Sand
Rip-rap 1 part cement 3 parts Sand
Reflective Studs 1 part cement 2 parts Fine Aggregates

For Sump, Trench and Box Grates (Steel Grating w/ Frame):

503.3 Strength Classification and loading Conditions
Class A Test Load 10 KN
Class B Test Load 80 KN
Class C Test Load 150 KN
Class D Test Load 210 KN
Class E Test Load 400 KN
Class F Test Load 600 KN
Class G Test Load 900 KN

CONCRETE SURFACE FINISHING:

Class 1 Surface Finish - Ordinary Finish

Class 2 Surface Finish - Rubbed Finish
Class 3 Surface Finish - Floated Finish

DEFINITION OF TERMS:

Flash Set - Cement stiffens without strength development

Tremmie – this shall consist of a tube having a diameter of not less than
250mm constructed in sections having flanged coupling fitted
with gaskets w/ a hoper at the top used for depositing
concrete submerged in water

Chanter – common method used to percent spalling and edge

chipping of concrete

Upheavel - Localized upward displacement of a pavement due

to swelling of subgrade.
Calcium Chloride - Commonly added to concrete mixture to accelerate
setting time

Accelerator - Admixture that can reduce water content by 25% to

35%

Concrete Vibrators - must be inserted in a vertical position for not more than
15 seconds
- Shall operate at a frequency of 8,300-9,600 impulses per
minute
- Spacing not less than 60cm
Permeability - Porosity/perviousness of the mixture
- Dependent on pore size, a dense graded mix which
prevents water from entering the base through the surface
- Property of concrete not modified by admixture

Three (3) meter straight edge – used to measure pavement surface irregularity

Ravelling – not a PCCP distress

Ultrasonic Tester – new technology used in the non-destructive testing of the quality
and strength of concrete

 A transverse construction joint is used when the paving operation is

interrupted for longer than 30 minutes. These joints are commonly used at
the end of the paving operation each day and may be retro-fitted to tie an
existing slab into a new pavement

 Transverse contraction joints are constructed perpendicular to the direction

of paving at locations that line up across adjacent lanes and produce
panels with appropriate dimensions

 The surface of a concrete pavement shall be uniform broom finish with a

depth of corrugation of not more than 1.50mm

 Item 406 – Pre-stressed Concrete Structures:

Post and Pre stressing reinforcements shall not commence until test on
concrete cylinder has attained a compressive strength of at least 28 MPa

 Rebound Hammer (Schmidt) test for concrete:

Can be used as a substitute to direct methods of compressive strength
determination such as test on core sample.

 The amount of materials passing sieve #50 and #100 is important to concrete
aggregate because the maximum amount of these fine sand sizes are
required to ensure that the surface can be finished easily to an acceptable
degree of smoothness.

 For Concrete Joint Sealer Hot-Poured Elastic Type, sample portion added to
and heated in the melter shall weigh 800 + 5g

 Sample needed for testing Joint Sealant Cold Application is 3.785

 Minimum mass of composite sample of a non-liquid admixture for concrete

= 2.30 kg.

 Before Concrete paving, base of roadway should be kept in moist condition

and saturated with water for at least 2 Hrs.
 Vibratory Rolling = Max. 3 Passes at 100°C

 Minimum thickness of conventional pavement = 150mm

 Temperature of concrete during mixing and transport or placing is not

permitted to rise above 36°C

 Maximum requirement of autoclave expansion of cement = 0.80

 Maximum requirement for Loss on Ignition (LOI) and Insoluble Residue (IR) of
Cement is 3 and 0.75

 The range of PH Values of water suitable concrete construction is 6 and 8

 The layer of thickness of each shotcrete application is limited to = Maximum

50mm

 Ideal specific gravity of Portland Cement Type I = 3.15

 Maximum percentage permitted for fly ash as partial replacement of

Portland Cement = 30%

 Finishing Forms used on ornamental work, railing, parapets and exposed

vertical surfaces shall be removed in not less than 12 nor more than 48 hrs.
depending upon weather condition.

 Minimum number of hours wherein the post of guardrail remain undisturbed

from the time they are embedded in a concrete foundation block = 48 hrs.

 Minimum age a pre-stressed concrete girder must attain before allowing it

to be shipped = 14 days

 Minimum Compressive strength of a lean concrete prior to the placing of

reinforcing bar = 13.80 Mpa

 2 layers and 20 Tamps = Number of layer and tamps needed in making

mortar
 sample of fine aggregates (FA)

 Mortar for Item 506 – Stone Masonry shall be used within 90 mins after its
preparation

 Concrete is said to be rich when many cement was added in the mix
MISCELLANEOUS
CONCRETE HOLLOW BLOCKS (Concrete Masonry):

CHB specification (Strength Requirements)

Load Bearing, ASTM C-90
Individual 5.50 Mpa (800 psi) min.
Average 6.90 Mpa (1000 psi) min.
Absorption 240 kg./cu.m. max.
Moisture Content 45% Max.

Non-Load Bearing, ASTM C-129

Individual 3.45 Mpa (500 psi) min.
Average 4.14 Mpa (600 psi) min.

 Allowable tolerance of length, height and width of CHB = + 3mm

GABIONS:

 Tolerance of gabion size from ordered size prior to filling = + 5%

 Permissible height of Gabions = 0.5m to 1.0m
 Diameter tolerance of galvanized wire to be used in the fabrication of
gabion and mattresses = + 0.10 mm
 The shape of mesh formed by gabion’s steel wire = hexagon
 Maximum Tensile Strength of gabion’s wire mesh = 586.10 Mpa

MATTRESSES:

Tolerance of revet mattress from ordered size prior to filling:

Width and length shall not differ more than + 5%
Height shall not differ more than + 10%

 Required width of Mattresses = 2.00 m.

REINFORCING STEEL BARS:

Minimum Requirements for 25mmØ Grade 60 Reinforcing Steel bars:

Tensile Strength 550 Mpa
Yield Strength 415 Mpa
Ave. height of lugs 1.10mm

Required lapped lengths of splices of reinforcing bars as per Item 404:

Grade 60 = 36 bar diameter (Tension)
= 24 bar diameter (Compression)

Grade 40 = 24 bar diameter (Tension)

= 20 bar diameter (Compression)

Lapped Length = 300 mm

 Minimum separation of the splices of reinforcing bars as per Item 404

= 40 bar diameters
 Length of 12.5mmØ bar for testing = 100 cm

 Phosphorous content requirement for rebars = maximum 0.06

 Carbon content of rebars maximum percent = 0.26
  Reduced section of Structural Steel, Tension Test w/ 50mm gauge length
must have a width of = 12.5 + 0.25mm

FILLET WELDS:

Minimum effective length of fillet weld use:

Formula = 4 x thickness

12mm thk. material = 48mm

10mm thk. material = 40mm
6mm thk. material = 24mm

Maximum size of fillet weld used along the edge of:

20mm thk. material = 18.5mm
10mm thk. material = 8.5mm
5mm thk. material = 6mm

Maximum longitudinal spacing of stich welds for members composed of two or

more rolled shapes in contact with one another = 600mm

Dimension of Reflectorized Thermoplastic Rumble Strips:

Height - 4mm to 13mm
Width - 50mm to 100mm
Spacing - 200mm to 500mm

 Retro-reflectometer – equipment being used to test the reflectivity of road

signs
Recommended length of road section where Thermoplastic Rumble Strips are to be
installed = 20m to 30m

CHEVRONS:

Installed above the ground at a height of:

Rural Areas 1.50m.
Urban Areas 2.20m.

Minimum lateral offset of the Chevron Signs from the edge of the pavement is
1.80m and shall be visible for at least 150m to provide the road user with adequate
time to react to the change in alignment

Reflective sheeting of Chevron signs shall perform effectively for a min. of 7 years
from date of fabrication

Aluminum - Preferred material for sign panels.

Five (5) years - Design life span of flash surface reflector

Reflective sheeting of Chevron signs must retain at least 70% of its original
brightness for regular and fluorescent sheeting respectively at the end of 7 years

Minimum thickness being required to sign panels for warning regulatory and
information signs = 3mm
DEFINITION OF TERMS:

Distortion - Result of asphalt layer instability or granular base or

subgrade weakness
- Pavement usually twists out of shape

Workability - Ease by which material can be placed to its desired

uniformity and compacted to the required density

Oakum - being used for joints in bell and spigot pipes and shall be made from
hemp line or Benares Sunn fiber or from a combination of these fibers

Geofoam - Alternative embankment materials made of Expanded

Polystyrene (EPS)
- Width not less than 305mm

 Recommended static load increment in pile testing = 5 tonnes

 Minimum penetration of pile in pile driving = 3

 Materials shall be tested in accordance with T250

 Minimum thickness of cement mortar embedded to contact surface of

stones of grouted rip-rap = 20mm

 Max. projection of rock faces beyond pitch line of Stone Masonry = 50mm

 Minimum center to center spacing of weepholes of wall abutment = 2.00 m.

 Maximumum center to center spacing of weepholes installed in wet cobble

masonry = 3.00 m.

 Used to Stabilized Slope except Grass Cover

 Required density of compacted earth berm = 90%

 Minimum thickness of Coconet in Item 622 – Coconet Bio-eng’g.= 10.0 +

1.0mm

 When using nuclear density gauge, it is not a requirement for operators to

use thick clothes

 Subsoil Drainage – Provided for the purpose of counteracting moisture

movement within the structure either by seepage or capillary action

 Maximum width at top portion of a precast curb = 200mm

 Maximum width at bottom portion of a precast curb = 250mm

 Recommended thickness of a preformed joint filler for Item 601 – Sidewalk =

5mm

 Minimum number of Elastomeric Bearing Pads selected at random from a lot

of 54 bearings = 7
 Tensile Strength of Plain Elastomeric Bearing Pad = 15.50 Mpa Min.
  Maximum water absorption of precast unit for Item 502 – Manholes, inlets
and catch basins = 7 %

 Minimum Tensile Stress of Rubber Water Stop is 17 MPa

 Minimum Tensile Stress of Plastic Water Stop is 9.60 MPa

 In Item 603, bolts shall be drawn tight. Bolts shall be of sufficient length to
extend beyond the nuts at least 5mm but not more than 10mm

 Maximum width of paint brush to be used for traffic paints = 100mm (4”)

 In Item 502 – Manholes, Inlets & Catch Basins, structural concrete used shall
attain a minimum 28-day compressive strength of = 20.682 Mpa

 The limit (by weight of soil) wherein Polymer-based chemical soil additive
must not exceed = 2%

Item 408 – Steel Bridges

Item 409 – Welded Structural Steel
Item 410 – Treated and Untreated Timber
ASPHALT / ASPHALT MATERIALS

Item 301 - Bituminous Prime Coat

Item 302 - Bituminous Tack Coat
Item 303 - Bituminous Seal Coat
Item 304 - Bituminous Surface Treatment
Item 304A - Slurry System for Road Surface Treatment
Item 305 - Bituminous Penetration Macadam Pavement
Item 306 - Bituminous Road Mix Surface Course
Item 307 - Bituminous Plant-Mix Surface Course
Item 308 - Cold Asphalt Plant Mix
Item 309 - Bituminous Plant-Mix (Stockpile Maintenance Mixture)
Item 310 - Bituminous Concrete Surface Course
Item 313 - Rock Asphalt, Hot-Laid

Range of Tolerance(s):
For Asphalt Cement in Job Mix Formula + 0.40%
For Temperature of Asphalt Mix upon delivery + 10°C
For Aggregates passing #4 and larger in the Job Mix Formula + 7%

For Item 308, amount to be added in a bituminous Pant:

Emulsified Asphalt - 6 to 10%
Cutback Asphalt - 4.5 to 7%

 Amount of Asphaltic Material to be added to the soil aggregate by mass

percent of the dry soil aggregate = 4 – 7%

 Accuracy of weighing scales use in concrete batching plant = 0.5%

 Required density of the compacted pavement in the construction of

bituminous plant-mix surface = 97%

 Mass percent air voids of the bituminous mixture for the construction of
bituminous plant-mix surface = 3% - 5%

 Asphalt Joint Sealant safe heating temperature = 225°C

 Asphalt Joint Sealant pouring point temperature = 224°C

Rate of Application:
Tack Coat 0.20-0.70 L/m2
Prime Coat / Cutback 1.00-2.00 L/m2
Type 1 Bituminous Curing Seal 0.20-0.50 L/m2
Type 2 Bituminous Seal Coat 0.51-1.00 L/m2
Type 3 Bituminous Seal Coat 1.01-1.50 L/m2
Bituminous Road Mix Surface Coarse 0.20 – 10.00 L/m2

Bituminous Curing Seal 0.50-1.00 L/m2

DEFINITION OF TERMS:

Cement Making - Test in Emulsified Asphalt which determines the

resistance of the emulsion to break when mixed with
mineral aggregates

Marshall Stability Test – resistance to deformation of a compacted asphalt

concrete mix.
– determines the suitability of an asphaltic concrete mix
with single test procedure
Rock Asphalt - Asphalt formed by natural process of evaporation

Wet Stability - Compressive strength of duplicate specimens that have been

immersed in water under prescribed conditions

Bitumen - Actual cementing power in asphalt

Asphalt Cement - another name for Hot Asphalt

Cationic Emulsion – Type of emulsified asphalt that works better w/ wet

aggregates and in cold weather.

Stability (immersion-Compression Method) is a method which covers measurement

of loss of cohesion resulting from the action of water on compacted bituminous
mixtures

TESTS:

Distillation - Test used to determine the amount of asphalt cement in a

liquid asphalt

Extraction - Test used to determine the amount of asphalt present in a

bituminous mix

Ductility - Test used to measure by the distance by which it will elongate

before breaking when two (2) ends of a briquette with
specimen are pulled apart at a specified speed and
temperature

Flow Index - Used to measure resistance to deformation of bituminous

mixture

Spot Test – Test of overheating during manufacture

 The primary quality control mechanism for the production of asphalt

mixtures which will have a high degree of uniformly that will satisfy job
requirements is called Job Mix Formula

 Stone Mastic Asphalt shall be placed at a temperature not less than 135°C

 Cellulous fibers additive for Stone Mastic Asphalt = 0.30-0.40 (3.00-4.00

kg/M.T.

 Bituminous Mix shall be placed at not less than 107°C temperature

 Minimum Dry Compressive Strength of Bituminous Mix – 200 psi

  Properties of asphalt mix can be determined in an asphalt core sample
except Index of Retained Strength (IRS)

 Minimum compressive strength of porous asphalt = 1.40 MPa

 Required density of a rock asphalt hot-laid pavement = 97%

 Desired shape of aggregate in bituminous mixture - angular and rough-

textured particles
 Minimum duration a prime coat be left undisturbed = 24 hrs.

Getting specific gravity of aggregates: (asphalt mix)

100% mix / Gs mix = (% asphalt/Gs Asphalt) + (% agg. / Gs agg)
SOIL / AGGREGATES

COMPACTION:
AASHTO T99 METHOD C - 2.50 kg. Rammer -For Item 104 Embankment
12” Drop (304.80 mm)
3 Layers, 25 Blows

AASHTO T180 METHOD D - 4.54 kg. Rammer

18” Drop (457 mm)
5 Layers, 56 Blows

COMPACTION TRIAL:
Item 104 - Every 500 sq.m.
FDT - Every 500 sq.m.
CBR - Soaked for 93 Hrs.

 A Dry compacted soil when compacted again in the same extent and
added with water, Density will get higher because air is forced out of soil

WEIGHT OF STONE RIP-RAP (Item 505:

Class A Stone - 15 kg. min. to 25 kg. max. at least 50% weighing more than
20 kg.

Class B Stone - 30 kg. min. to 70 kg. max. at least 50% weighing more than
50 kg.

Class C Stone - 60 kg. min. to 100 kg. max. at least 50% weighing more than
80 kg.

Class D Stone - 100 kg. min. to 200 kg. max. at least 50% weighing more than
150 kg.

Test required for Rip-rap Boulders:

1. Stone sizes or weight test
2. Inspection report on assessment of stone soundness

Item 201:
Passing sieve #40:
LL not greater than 25
PI not greater than 6

Retained at sieve #10:

Max. % wear (abrasion) – 50

¾ sieve:
Soaked CBR = not less than 80%

ABRASSION:
Grade No. of Spheres
A 12
B 11
C 8
D 6

Weight of Spherical Ball = 390 – 455 grams

Rotated speed of LA Machine (Abrassion) = 30 – 33 rpm
The difference in composition of Item 201 – Aggregate Base Course and Item 200 –
Aggregate Subbase Course is:
 Item 200 contains more binder and bigger size of gravel than item 201

 Number of hours to immerse the coarse aggregate at room temperature for

the testing of specific gravity = 15 to 19 hrs.

 Improper compaction of an embankment material will not decrease void

spaces

 Permitted variation from designed thick layer of aggregate base course = +

20mm

 If soil is not compacted at Maximum Dry Density it will increase permeability

 In Item 510 – Concrete Slope Protection, concrete slabs shall not be greater
than 4m x 4m and shall have between slabs, vertical straight joints with no
joint filler or sealer

 Approval of preliminary samples from the same source shall not be

considered or guarantee of acceptance of all materials from the source.

 Sampling of soil aggregates at stockpile: bottom, middle & top

 Allowed maximum ambient and grout temperature for Item 727 – Non Shrink
Grout = 32°C

 Grading is the determination of the relative proportion of various particle

sizes of mineral aggregates in a mix, if it conforms to the Job-Mix
Formula/Specifications

 Dry Stability determines the compressive strength of freshly molded and

cured specimens

 When fine aggregates is subjected to five (5) cycles of the sodium sulphate
soundness test, weight loss shall not exceed 10 mass percent

 When course aggregates is subjected to five (5) cycles of the sodium

sulphate soundness test, weight loss shall not exceed 12 mass percent

 CBR Value of subgrade = 4%

 Maximum size of aggregates to be used in structural concrete of Grading A

= 2”

 The sample of mineral filler is being reduced to a minimum size of 2.50kg. to

submit for testing, using method of quartering

Based on mass of total dry aggregates:

 How much emulsified asphalt must be added in the construction of
bituminous road-mix surface course= 6% - 10%

 How much hydrated lime must be added to the aggregates during mixing
operation = 0.50% - 1.00%
TOPSOIL:

The Contractor shall notify the Engineer at least 5 days before he intends to start
topsoil stripping operations

Topsoil shall be evenly spread on the areas and to the line and level shown on the
plans and compacted with a light roller to a depth of not less than 100mm

SPRIGGING:

Not more than 24 hrs shall elapse between harvesting and planting sprigs.

The quantity of sprigging to be paid for shall be number of unit of 100 sq.m.
measured on the ground surface, completed and accepted

SODDING:

Item 203 – Lime Stabilized Road Mix Base Course

Item 610 - Laying of Sod
Item 612 – Reflective Thermoplastic Stripping Materials

Size of sod to be cut into uniform squares = 300mm x 300mm

Thickness of sod = 40mm

Soil area to be sodded shall be loosed and brought to a reasonable fie texture to a
depth of not less than 30mm

Minimum thickness of Sod = 40mm