SERIES 1700 STRUCTURAL CONCRETE...Angeles coefficient as specified in BS EN 1097-2 and declared in accordance with the relevant category specified in Table 12 of BS EN 12620, shall

MANUAL OF CONTRACT DOCUMENTS FOR HIGHWAY WORKSVOLUME 1 SPECIFICATION FOR HIGHWAY WORKS

SERIES 1700STRUCTURAL CONCRETE

ContentsClause Title Page1701 (05/04) Concrete - General 2

1702 (05/04) Concrete - Constituent Materials 2

1703 (05/04) Concrete - Exposure Classes 2

1704 Concrete - General Requirements 3

1705 (05/04) Concrete - Requirements forDesigned Concrete 3

1706 Concrete - Production 4

1707 (05/04) Concrete - Conformity andIdentity Testing 4

1708 Concrete - Surface Finish 4

1709 (05/01) Concrete - SurfaceImpregnation 6

1710 Concrete - Construction General 8

1711 (05/01) Concrete - Grouting and DuctSystems For Post-tensioned Tendons 12

1712 (05/01) Reinforcement - Materials 17

1713 (05/02) Carbon Steel Reinforcementand Stainless Steel Reinforcement -Bar Schedule Dimensions - Cuttingand Bending 18

1714 Reinforcement - Fixing 18

1715 Reinforcement - Surface Condition 18

1716 (05/01) Reinforcement - Laps andJoints 18

1717 Reinforcement - Welding 19

1718 Prestressing Tendons - Materials 19

1719 Prestressing Tendons - Handling andStorage 19

1720 Prestressing Tendons - SurfaceCondition 20

1721 Prestressing Tendons - Straightness 20

1722 Prestressing Tendons - Cutting 20

1723 Prestressing Tendons - Positioning ofTendons, Sheaths and Duct Formers 20

1724 Prestressing Tendons - Tensioning 20

1725 Prestressing Tendons - Protection andBond 22

1726 Stainless Steel Dowels - Materials 22

1727 Inspection and Testing of Structuresand Components 22

1Amendment - May 2006

Volume 1Specification for Highway Works

Series 1700Structural Concrete

STRUCTURAL CONCRETE

2

1701 (05/04) Concrete - General

(05/04) Specification of Concrete

1 (05/04) Concrete shall conform to the requirementsof BS 8500-2. Unless otherwise described inAppendix 17/4, concrete shall be specified as designedconcrete. Details of the structural concrete in thePermanent Works are given in Appendix 17/1.

Design Concrete

2 (05/04) The specification for designed concrete shallcontain:

(a) the basic requirements given in 4.3.2 ofBS 8500-1;

(b) the additional requirements given in 4.3.3 ofBS 8500-1 where required.

1702 (05/04) Concrete - Constituent Materials

Cement

1 (05/04) Cement types as defined in BS 8500 (seeTable A.17 of BS 8500-1 or Table 1 of BS 8500-2)shall comprise one of the following, unless otherwisedescribed in Appendix 17/4:

CEM I, CEM II/A-S, CEM II/B-S, CEM II/A-V1,CEM II/B-V1, CEM III/A, CEM IV/B1 and SRPC.

Combinations as defined in BS 8500 shall comprise oneof the following:

CIIA-S, CIIB-S, CIIA-V1, CIIB-V1, CIIIA andCIVB-V1.

1 The pfa used shall have a maximum colour index of 7(Colour comparator disc reference no. 296570) whentested using the Lovibond Colour Comparator systemas referred to in Annex A.7 of BS 3892 : Part 1.

(05/04) Aggregates

2 (05/04) Unless otherwise specified inAppendix 17/4, aggregates shall conform to the BritishStandards listed in 4.3 of BS 8500-2 except thatrecycled concrete aggregate (RCA) and recycledaggregate (RA) shall not be used.

The flakiness index of the coarse aggregate whendetermined by the method described in

BS EN 933-3 shall not exceed FI35 except when natural,uncrushed aggregates are used for concrete of strengthclasses lower than C32/40, when the flakiness indexshall not exceed FI50. No limit is relevant to strengthclass C12/15 concrete or below.

When required, the resistance to fragmentation of thecoarse aggregate, determined in terms of the LosAngeles coefficient as specified in BS EN 1097-2 anddeclared in accordance with the relevant categoryspecified in Table 12 of BS EN 12620, shall meet therequirements for LA40.

Note: Aggregates with LA coefficient values above 40may also perform satisfactorily in normal concrete buttheir strength performance shall be established inconcrete trials before use.

Chloride levels of the aggregates shall be determineddaily, in accordance with the Volhard reference methodin BS EN 1744-1, or less frequently when the long termvariability has been established.

Admixtures and Pigments

3 (05/04) Admixtures shall conform to BS EN 934-2,unless otherwise described in Appendix 17/4. Where aspecified coloured concrete requires a pigment, thepigment shall conform to BS EN 12878.

In all cases the Contractor shall record the followinginformation:

(a) the detrimental effects caused by adding agreater or lesser quantity of admixture orpigment;

(b) the chemical name(s) of the main activeingredient(s);

(c) whether or not the admixture leads to theentrainment of air.

1703 (05/04) Concrete - Exposure Classes

(05/04) Selection of Exposure Classes

1 (05/04) Guidance is provided in Clause NG 1703.

Amendment - May 2004



3

1704 (05/04) Concrete - General Requirements

(05/04) Compressive Strength Class of Concrete

1 (05/04) Guidance is provided in Clause NG 1704.

(05/04) Minimum Cement Content and MaximumWater/Cement Ratio

2 (05/04) The cement content shall be not less than,and the water/cement ratio shall be not greater than,described in Appendix 17/1. See sub-ClausesNG 1704.2 to NG 1704.11 for guidance on selection ofthese parameters.

Amendment - May 2004

(05/04) Maximum Cement Content

3 (05/04) The cement content shall not exceed550 kg/m3 unless otherwise described inAppendix 17/1.

Maximum Chloride Content

4 The chloride content class shall conform to thefollowing requirements:

TABLE 17/1: (05/04) Chloride content classes

Type or use of concrete Chloride content Maximum total chloride contentclass expressed as % of chloride ion by

mass of cement (inclusive of ggbsor pfa when these are used ascement)

Prestressed concrete, heat-cured concrete Cl 0,10 0.10%containing embedded metal

Concrete containing embedded metal and Cl 0,20 0.20%made with cement conforming to BS 4027

Concrete containing embedded metal and Cl 0,30 0.30%made with other permitted cements

(05/04) Control of Alkali-Silica Reaction

5 (05/04) The concrete producer shall take action tominimize damaging alkali-silica reaction by applyingone of the sets of conditions given in 5.2 of BS 8500-2.

High alkali Portland cement, with an acid-soluble alkalicontent greater than 0.75% sodium oxide equivalent,shall not be used, except where it is CEM I and used incombination with the appropriate quantity of ggbs orpfa as prescribed in BS 8500.

Extremely reactive aggregates, comprising thoseaggregates containing detectable quantities of opal,glass and calcined flint, shall not be used alone or incombination with other aggregates. The definition ofrock types shall be as in BS EN 932-3.

(05/04) Buried Concrete Exposed to Sulfates

6 (05/04) Guidance is provided in sub-ClauseNG 1704.11.

1705 (05/04) Concrete - Requirements forDesigned Concrete

(05/04) Conformity Criteria

1 (05/04) The conformity criteria for a concrete shallbe in accordance with BS EN 206-1.

(05/04) Suitability of Proposed Constituent MaterialProportions

2 (05/04) The Contractor shall record, prior to thesupply of any designed concrete, the followinginformation:

(i) the nature and source of each material;

(ii) either:

(a) (05/04) appropriate existing data asevidence of satisfactory previousperformance for target mean strength,current margin, consistence and water/cement ratio; or




(b) (05/04) full details of initial tests carriedout in accordance with Annex A ofBS EN 206-1;

(iii) (05/02) the quantities of each material percubic metre of fully compacted concrete.

Any change in the source of material or in constituentmaterial (except changes in cement content of not morethan 20 kg/m3 and pro-rata changes in aggregatecontents) shall be subject to a re-assessment of theconcrete in accordance with this sub-Clause.

1706 Concrete - Production

(05/04) Production Control

1 (05/04) All concrete shall be subject to productioncontrol under the responsibility of the producer, asspecified in clause 9 of BS EN 206-1 and clause 11 ofBS 8500-2.

Consistence At Delivery

2 (05/04) In general water or admixtures shall not beadded to delivered concrete. In special cases, water oradmixtures may be added where this is theresponsibility of the producer and used to bring theconsistence to the specified value provided that thelimiting values, permitted by the specification, are notexceeded and the addition of admixture is included inthe design of the concrete. The quantity of anyadditional water or admixture added to the truck mixershall be recorded on the delivery ticket in all cases(see sub-Clause NG 1706.2).

1707 (05/04) Concrete - Conformity andIdentity Testing

General

1 (05/04) Sampling and testing of fresh and ofhardened concrete shall comply with BS EN 206-1unless otherwise described in Appendix 17/4.

(05/04) Identity Testing

2 (05/04) Where identity testing for compressivestrength is required, as described in Appendix 17/4, itshall be in accordance with the requirements given inAnnex B of BS EN 206-1. Where identity testing forslump, flow and air content on individual batches ofconcrete, is required it shall be as described inAppendix 17/4. Guidance on the need for and rates ofidentity testing is given in Clause NG 1707.

1708 Concrete - Surface Finish

Trial Panels

1 (05/04) When required in Appendix 17/3 and beforecommencing concreting the Contractor shall prepare atrial panel of a suitable size that will demonstrate thatthe required surface finish can be achieved by themethods proposed.

The panel shall contain representative reinforcementand shall be filled with the proposed concretecompacted by the method to be used in the work. Assoon as practicable after compaction, the forms shall beremoved to check that the required surface finish andcompaction has been achieved.

Reference panels have also been produced showingtypical Class F2 and F4 Surface finishes made withlocal materials in each region of the UK and they canbe viewed at various sites throughout the UK asdescribed in sub-Clause NG 1708.4(ii).

Control of Colour

2 When stated in Appendix 17/1 each constituentmaterial shall be obtained from a single consistentsource. The aggregates shall be free of any impuritiesthat may cause staining. The mix proportions and thegrading, particularly of the sand (ie fine aggregate),shall be maintained constant. The same type of plywoodor timber shall be used in formwork throughout similarexposed areas.

Release Agents

3 (05/01) Release agents for the formwork shallenable the formwork to be removed without damage tothe concrete surface. There shall be no adverse residualeffect from the release agent on the concrete surface.Where a concrete surface is to be permanently exposed,only one agent shall be used throughout the entire area.Release agents shall be applied evenly and shall not bepermitted to come into contact with reinforcement,prestressing tendons and anchorages. Any such contactareas shall be washed free of contamination.

Where the concrete is to receive an applied finish, orsurface impregnation, release agents shall becompatible with that particular process.

Surface Finishes for Concrete

4 (i) (05/01) Formed Surfaces - Classes of Finish

Formwork as described in sub-Clause 1710.2shall be capable of producing the followingfinishes where required in the Works:




Class F1. No extra requirement.

Class F2. The irregularities in the finish shallbe no greater than those obtained from theuse of wrought thicknessed square edgedboards arranged in a uniform pattern. Thefinish is intended to be left as struck butimperfections such as fins and surfacediscolouration shall be made good.

Class F3. The resulting finish shall besmooth and of uniform texture andappearance. The formwork lining shall leaveno stain on the concrete and shall be sojoined and fixed to its backing that it impartsno blemishes. It shall be of the same typeand obtained from only one sourcethroughout any one structure. The Contractorshall make good any imperfections in thefinish. Internal ties and embedded metalparts shall not be used.

Class F4. The requirements for Class F4 areas for Class F3 except that internal ties andembedded metal parts shall be permitted.The ties shall be positioned only in rebatesor in other positions as described inAppendix 17/3.

Class F5. The resulting finish shall besmooth and of uniform texture. Anyblemishes and imperfections, such asdiscolouration and fins, shall be made good.Provision for the embedment of metal partsin the Permanent Works on a regularspacing, shall be allowed.

Other classes. The finishes shall comply withthe specific requirements described inAppendix 17/3.

Permanently exposed concrete surfaces to allClasses of finish other than F1 shall beprotected from rust marks and stains of allkinds.

Unless otherwise described inAppendix 17/3, all formwork joints for allclasses of finish other than F1 shall form aregular pattern with horizontal and verticallines continuous throughout each structureand all construction joints shall coincidewith these horizontal or vertical lines.

(ii) Unformed Surfaces - Classes of Finish

Class U1 finish. The concrete shall belevelled and screeded to produce a uniformsurface to the profile shown on theDrawings. No further work shall be applied

to the surface unless it is used as a first stagefor another class of finish.

Class U2 finish. After the concrete hashardened sufficiently, the Class U1 finishshall be floated by hand or machinesufficiently only to produce a uniformsurface free from screed marks.

Class U3 finish. When the moisture hasdisappeared and the concrete has hardenedsufficiently to prevent laitance from beingworked to the surface, a Class U1 finishshall be steel-trowelled under firm pressureto produce a dense, smooth uniform surfacefree from trowel marks.

Class U4 finish. The concrete shall belevelled and screeded to produce a uniformsurface. When the concrete has sufficientlyhardened and the bleed water evaporated thesurface shall be trowelled to produce a harddense surface free from screed marks andexposed aggregate. Finally the surface shallbe lightly textured with a wooden float orequivalent.

Alternatively the concrete shall be levelled,screeded and floated to produce a uniformsurface and immediately before thewaterproofing operation this surface shallreceive surface preparation by water jettingor grit blasting to provide a lightly texturedfinish.

The finished surface shall not deviate fromthe required profile by more than 10 mmover a 3 m gauge length or have any abruptirregularities more than 3 mm.

Class U5 finish. The concrete shall belevelled and screeded to produce a uniformfinish. When the concrete has sufficientlyhardened to prevent laitance being worked tothe surface it shall be floated to produce asurface free from screed marks and exposedaggregate. Finally the surface shall betextured to suit the requirements of theparticular waterproofing and surfacingsystem. The accuracy of the finished surfaceshall be such that it does not deviate fromthe required profile by more than 5 mm overa 3 m gauge length or have any abruptirregularities.

Other classes. The finishes shall comply withthe specific requirements described inAppendix 17/3.




1709 (05/01) Concrete - Surface Impregnation

General

1 Impregnation shall be applied to those surfacesdescribed in Appendix 17/2 in accordance with themanufacturer’s instructions unless otherwise directedby Contract Documents or agreed by the OverseeingOrganisation. The works shall in addition, be carriedout in accordance with Health and Safety requirements,COSHH requirements and Waste Disposal Authorityrequirements.

Material

2 (i) The material for impregnation shall bemonomeric alkyl (isobutyl)-trialkoxy-silanewith a minimum active content of 92%delivered to the Site in sealed containers.

(ii) The refractive index of the material shallcomply with the value stated in themanufacturer’s product specification, withina limit of 0.003 units. The refractive indexshall be checked as follows:(a) Collect samples of the material from a

newly opened container and from thespraying nozzle.

(b) Measure the refractive index of threesamples from both the container andspray nozzle using a portablerefractometer.

(c) Measure the temperature of the samples(portable refractometers havetemperature measuring capability).

(d) Correct the refractive indexmeasurements to the temperature statedin the manufacturer’s productspecification.

(e) If the temperature corrected measuredvalue of the refractive index exceeds themanufacturer’s specified value by morethan 0.003 units then a laboratory checkshall be undertaken to confirmcompliance.

(iii) The Contractor shall obtain with eachdelivery a certificate that the material in thatdelivery complies with sub-Clause 2(i) ofthis Clause. No material shall be used in theworks until the Certificate of Compliancehas been accepted by the OverseeingOrganisation.

(iv) The material shall be stored in a securefacility that has a dry frost-free environmentprotected from direct heat.

(v) The containers shall remain sealed until theircontents are required for use. The contents ofany opened container shall be used within48 hours or else disposed of safely, inaccordance with sub-Clause 7 of this Clause.

(vi) Materials offering a performance in respectof the protection of concrete and long termdurability equivalent to that of monomericalkyl (isobutyl)-trialkoxy-silane will beaccepted. The assessment of the durability ofan alternative surface applied hydrophobicpore lining impregnating material will bebased on the provision of evidence that ithas, in practice, provided an effective waterrepellent but vapour-permeable layer at theconcrete surface for a period of not less than15 years after application.

Spraying Equipment

3 (i) A power driven continuously circulatingpumped system operating at a low nozzlepressure shall be used to apply the materialin such a way as to avoid atomisation. Watershall be prevented from entering any part ofthe equipment.

(ii) A pressure gauge shall be installed betweenthe trigger valve and spray lance to enablethe pressure to be monitored.

(iii) A ‘kill’ switch shall be provided so that thepumping system may be stoppedimmediately should this be required.

Protective Measures

4 (i) Use and handling of the silane material shallbe in strict accordance with themanufacturer’s recommendations, and in fullcompliance with all current Health andSafety legislation. The Contractor shallensure that only fully trained operativesundertake impregnation operations, andwhere necessary carry out trials to verifyprocedures.

(ii) Measures shall be taken to ensure that noimpregnation material enters into anydrainage system or watercourse. TheContractor shall obtain all necessary writtenpermissions and licences from theappropriate authorities, prior to any silaneoperations above or adjacent to anywatercourse.

(iii) Measures shall be taken to ensure that noimpregnation material comes into contactwith any humans, animals, vegetation or




vehicular traffic by providing suitable andadequate protection and traffic management.The Contractor shall obtain approval fromthe Overseeing Organisation and all otherauthorities’ licenses, agreements andpermissions associated with traffic safety,management and protective measures inadvance of the commencement ofimpregnation operations.

(iv) Elastomeric bearings, painted steel surfaces,exposed bituminous materials, and jointsealants adjacent to structural elements to beimpregnated shall be masked off or coveredbefore and during impregnation operations.

(v) In the case of spillage, action shallimmediately be taken to limit the extent ofthe spillage and the Overseeing Organisationand other relevant authorities shall beinformed at once.

(vi) After completion of impregnationoperations, all contaminated protectivesheeting and materials used for masking orcovering, shall be disposed of in accordancewith sub-clause 7 of this clause.

Surface Condition

5 (i) Areas to be treated shall be protected fromadverse effects of the weather and shall besurface dry for a minimum of 24 hoursbefore application commences. Artificialdrying of surfaces shall not be permitted

(ii) Surfaces shall be free from loose ordeleterious matter and residues of curingmembranes, release agents graffiti andgraffiti removal agents. The Contractor shallensure that any harmful residual effects fromthe application of curing membranes are notpresent before impregnation commences.Existing structures shall be hand brushedwith a stiff bristle brush to remove surfacedeposits. Where deleterious surface depositscannot be removed using a stiff bristle brushthey shall be removed by light grit blasting.

(iii) Water jetting or steam cleaning shall not ingeneral be used as a means of surfacepreparation.

Application

6 (i) The Contractor shall submit a methodstatement to the Overseeing Organisationand shall obtain the OverseeingOrganisation’s written approval beforecommencing impregnation operations.

(ii) Impregnation of the face of a structuralelement shall be carried out in a singlecontinuous operation for each application.

(iii) (05/04) Impregnation shall be carried out notless than 7 days after the concrete has beenplaced, or 3 days after concrete repairs havebeen completed on a structural element.Particular attention is drawn to compliancewith sub-Clauses 5(i) & (ii) of this Clause.

(iv) The material shall be applied by continuousspray technique giving saturation flooding,working from the lowest level upwards. Twoapplications shall be made each at acoverage of 300 ml/m² with an intervalbetween each of at least six hours.

(v) Impregnation shall not be carried out in thefollowing conditions:

(a) when the shade temperature is below5°C;

(b) when the temperature of the concretesurface is greater than 25°C;

(c) When the wind speed is in excess of8 km/hr unless the working area is fullyencapsulated.

(vi) Members shall be protected from rain andspray during application and for at least sixhours after completion.

Disposal

7 Disposal of impregnation material, anycontaminated materials and protective sheeting ormasking, shall be in strict accordance with therequirements of the Waste Disposal Authority. Whilston site, all such materials must be retained in a safe andsecure facility. The Contractor shall obtain all necessarycertificates of approval for the disposal of the materials.

Testing and Monitoring

8 (05/04) Where required in the Contract, theContractor shall carry out impregnation on trial panels2m x 2m or equivalent area, one on each of a verticaland horizontal surface. The Contractor shall thendemonstrate on these panels, that the proposed methodof working will meet the appropriate requirements ofthis Clause.




1710 Concrete - Construction General

Construction Joints

1 The position of construction joints shall be asshown on the Drawings and at additional positionsdetermined by the Contractor in accordance with therequirements of Appendix 17/4. When concrete isplaced in vertical members, walls, columns and the like,the lifts of concrete shall finish level or, in slopingmembers, at right angles to the axis of the members,and the joint lines shall match features of the finishedwork, if possible, or be formed by grout checks.Kickers shall be constructed integrally with the lift ofconcrete below.

Concreting shall be carried out continuously up toconstruction joints.

Construction joints shall be prepared in either of thefollowing ways:

(i) When the concrete is self-supporting but stillsufficiently green, the formwork shall beremoved, as necessary to expose theconstruction joint, subject to therequirements of sub-Clause 5 of this Clause.The concrete surface shall be sprayed with afine spray of water or brushed with a stiffbrush, just sufficiently to remove the outermortar skin and expose the larger aggregatewithout disturbing it. Alternatively wherethis preparation proves impracticable thehardened surface skin and laitance shall beremoved by grit blasting or a needle gun.Hardened surfaces shall not be hacked.

(ii) By the use of proprietary steel open-meshpermanent formwork.

Retarding agents shall not be used unless permitted inAppendix 17/4.

The joint surface shall be clean and damp but free ofstanding water immediately before any fresh concrete isplaced against it.

Formwork

2 (i) (05/01) Design and construction. Theformwork shall be sufficiently rigid and tightto prevent loss of grout or mortar from theconcrete at all stages and for the appropriatemethod of placing and compacting.

The formwork shall be so arranged as to bereadily dismantled and removed from thecast concrete without shock, disturbance ordamage. Where necessary, the formworkshall be so arranged that the soffit form,

properly supported on props only, can beretained in position for such period as maybe required by maturing conditions asdescribed in sub-Clause 1710.4(ii). If thecomponent is to be prestressed whilst stillresting on the soffit form, provision shall bemade to allow for elastic deformation andany variation in weight distribution.

Where it is intended to re-use formwork itshall be thoroughly cleaned and made good.

Internal metal ties which require to bewithdrawn through hardened concrete shallnot be used where either face is permanentlyexposed. Where internal ties are left in, theyshall be provided with a mortar cover of atleast 50mm. The pocket shall be scabbledand dampened immediately prior to mortarfilling.

(ii) Cleaning and treatment of forms. The facesof the forms in contact with the concreteshall be clean and treated with a suitablerelease agent, where applicable as describedin sub-Clause 1708.3.

Immediately before concreting, all formsshall be thoroughly cleaned out. The sourceof any compressed air used for the clearingof foreign matter from formwork shall befree from oil and other contaminant.

(iii) Projecting reinforcement and fixing devices.Where holes are needed in forms toaccommodate projecting reinforcement orfixing devices, care shall be taken to preventloss of grout when concreting or damagewhen striking forms.

(iv) Permanent formwork shall comply withAppendix 17/4.

Transporting, Placing and Compacting

3 (05/05) Concrete shall be so transported and placedthat contamination, segregation or loss of theconstituent materials does not occur.

Concrete, when deposited, shall have a temperature ofnot less than 5°C and not more than 30°C. Freshconcrete shall not be placed against in situ concrete thathas been in position for more than 30 minutes unless aconstruction joint is formed as described insub-Clause 1 of this Clause.

Concrete shall not be pumped or discharged throughaluminium alloy conduits.

No concrete shall be placed in flowing water.Underwater concrete shall be placed in position bytremies or by pipelines.




Concreting operations shall not displace reinforcement,tendon ducts, tendon anchorages or formwork, ordamage the faces of formwork.

Concrete shall be thoroughly compacted by vibrationduring the operation of placing, and thoroughly workedaround the reinforcement, tendons or duct formers,around embedded fixtures and into corners of theformwork to form a solid mass free from voids. Whenvibrators are used to compact the concrete, vibrationshall be applied continuously during the placing of eachbatch of concrete until the expulsion of air haspractically ceased and in a manner that does notpromote segregation of the ingredients.

It must be noted that self-compacting concrete (SCC) isnot permitted under this Specification, howeverreference shall be made to sub-Clause NG 1710.3.

Particular care shall be taken when concreting bridgedecks of substantial thickness to avoid layering ofconcrete, and the whole thickness shall be placed in onepass. In deck slabs where void formers are used,adequate means to prevent flotation shall be employedand care taken to ensure adequate compaction of theconcrete placed beneath the void formers.

A sufficient number of vibrators in serviceablecondition shall be on site to ensure that spare equipmentis always available in the event of breakdowns.

Vibration shall not be applied by way of thereinforcement. Where vibrators of the immersion typeare used, contact with reinforcement and inserts shall beavoided as far as is practicable.

Concrete shall not be subjected to disturbance between4 hours and 24 hours after compaction except that re-compaction of the upper layers of deep lifts to preventor anneal settlement cracking may be carried out.Whenever vibration has to be applied externally, thedesign of formwork and disposition of vibrators shallensure efficient compaction and the avoidance ofsurface blemishes.

There shall be no excess water on the top surface oncompletion of compaction.

Striking of Formwork

4 (i) (05/01) General. Formwork shall be removedin a manner not to damage the concrete, andat times to suit the requirements for itscuring and to prevent restraint that may arisefrom elastic shortening, shrinkage or creep.

(ii) (05/04) Striking period. Where the concretecompressive strength is confirmed by testson concrete cubes stored under conditionsthat simulate the field conditions, formworksupporting concrete in bending may bestruck when the cube strength is 10 N/mm²or three times the stress to which it will besubjected, whichever is the greater.

For ordinary structural concrete made withPortland cement (CEM I) or sulfate-resistingPortland cement (SRPC) of strength class42.5 or above, in the absence of controlcubes the period before striking shall be inaccordance with the minimum periods givenin Table 17/2.

TABLE 17/2: (05/05) Minimum Period Before Striking Formwork (CEM I or SRPC Concrete)

Minimum Period Before Striking

Surface temperature of concrete:

16°C 7°C t°C (any temperaturebetween 0°C and 25oC)

Vertical formwork to columns, 12 hours 18 hours 300 hourswalls and large beams t + 10

Soffit formwork to slabs 4 days 6 days 100 dayst + 10

Props to slabs 10 days 15 days 250 dayst + 10

Soffit formwork to Beams 9 days 14 days 230 dayst + 10

Props to beams 14 days 21 days 360 dayst + 10

Where surface temperatures of concrete fall outside or are likely to fall outside the above temperature ranges agreement shall be reachedbetween the Contractor and Overseeing Organisation on appropriate striking times.




Curing of Concrete

5 (i) (05/04) Curing methods. Immediately aftercompaction and thereafter for the curingtime, except where elevated temperaturecuring is used, concrete shall be protectedagainst harmful effects of weather, includingrain, rapid temperature changes, frost, andfrom drying out. The method of curing shallprovide a suitable environment for theconcrete to mature and prevent harmful lossof moisture.

The curing time shall be the number of daysgiven in Table 17/3 unless the averagesurface temperature of the concrete duringthe required number of days falls below10°C, in which case the period of curingshall be extended until the maturity of theconcrete reaches the value given in the table.

The Contractor shall keep records of allcuring liquids, compounds and membranesand their subsequent removal from the areasscheduled in Appendix 17/2. Where theContractor proposes to use a curing liquid,compound or membrane on surfaces onwhich a waterproofing system is to be laid, itshall be completely removable.

Where the Contractor proposes the use of acuring liquid, compound or membrane onsurfaces scheduled in Appendix 17/2, it shallbe of a film type that fully degrades byexposure to ultra-violet light without leavingany residue that is detrimental to the surfaceimpregnation of the concrete.

TABLE 17/3: (05/04) Minimum Periods of Normal Curing for Different Types of Cement

Conditions under which Number of days (where the average Equivalent maturity (degree hours)concrete is maturing surface temperature of the concrete calculated as the age of the concrete in

exceeds 10°C during the whole period) hours multiplied by the number of degreesCelsius by which the average surfacetemperature of the concrete exceeds -10°C

Other* SRPC PC Other* SRPC PC

1. Hot weather or drying winds 7 4 3 3500 2000 1500

2. Conditions not covered by 1 4 3 2 2000 1500 1000

NOTE. Other* includes all permitted cements except PC and SRPC.(05/02) PC = Portland cement (CEM I).SRPC = Sulfate-resisting Portland cement.

(ii) (05/02) Accelerated curing. Elevated-temperature curing as described below maybe used only with Portland cement (CEM I)or sulfate-resisting Portland cement.

(a) The formwork may be generally heatedto no more than 20°C prior to theplacing of concrete.

(b) Once placing is complete the concreteshall be left for 4 hours withoutadditional heating. The concretetemperature can then be raised at amaximum rate of 10°C per ½hour.

(c) The concrete temperature shall at notime exceed 70°C.

(d) The rate of subsequent cooling shall notexceed the rate of heating.

(e) Cubes shall be manufactured and curedunder identical conditions to those towhich the concrete is subjected.

The use of accelerated curing methods for concretecontaining other types of cement or any admixture shallnot be used.

Cold Weather Work

6 When concrete is placed at air temperatures below2°C, the following requirements shall be met:

(i) The aggregates and water used in the mixshall be free from snow, ice and frost.

(ii) The surface temperature of the concrete atthe time of placing shall be at least 5°C andshall not exceed 30°C.




(iii) The surface temperature of the concrete shallbe maintained at not less than 5°C until theconcrete reaches a strength of 5 N/mm² asdetermined by tests on cubes that were curedunder identical conditions to the structuralconcrete.

(iv) Before placing concrete, the formwork,reinforcement, prestressing steel and anysurface with which the fresh concrete will bein contact shall be free from snow, ice andfrost.

(v) Cement shall not be allowed to come intocontact with water at a temperature greaterthan 60°C.

Hot Weather Work

7 During hot weather the Contractor shall ensure thatthe constituent materials of the concrete are sufficientlycool to prevent the concrete from stiffening in theinterval between its discharge from the mixer andcompaction in its final position.

Cement shall not be allowed to come into contact withwater at a temperature greater than 60°C.

Precast Concrete Construction

8 (i) (05/01) Manufacture off the Site. TheContractor shall give reasonable notice to theOverseeing Organisation in advance of thedate of commencement of manufacture andcasting of each type of member.

A copy of all 28-day cube test resultsrelating to the work shall be made available.

For all prestressed members, the Contractorshall obtain, not more than 7 days after thetransfer of stress, a certificate showing theforce and extension in the tendons after theywere anchored, the strength and age of testcubes cast as described in sub-Clause1724.4(iv) and the minimum age in hours ofthe concrete at the time the stress wasapplied to the member.

For all prestressed pretensioned members thelength, cross-section dimensions andstraightness of precast concrete shall bemeasured at 28 ± 2 days after casting. Unlessotherwise stated, and notwithstanding therequirements of (iv) below, the allowabledimensional variations shall not exceed thefollowing:

Length VariationUp to 3 m ± 6 mm3 to 4.5 m ± 9 mm4.5 to 6 m ± 12 mmAdditional for every subsequent 6 m ± 6 mm

Cross section (each direction)Up to 500 mm ± 6 mm500 to 750 mm ± 9 mmAdditional for every subsequent ± 3 mm250 mm

Straightness or bow (deviation from intended line)Up to 3 m ± 6 mm3 to 6 m ± 9 mm6 to 12 m ± 12 mmAdditional for every subsequent 6 m ± 6 mm

The above allowable dimensional variationshave not been taken into account in the barschedules (Clause 1713 refers).

Where tests are to be carried out, nomembers to which the tests relate shall bedispatched to the Site until the tests havebeen satisfactorily completed.

All members shall be indelibly marked toshow the member mark as shown on theDrawings, the production line on which theywere manufactured, the date on which theconcrete was cast and, if they are ofsymmetrical section, the face that will beuppermost when the member is in its correctposition in the Works. The markings shall beso located that they are not exposed to viewwhen the member is in its permanentposition.

Unless otherwise specified the vibrated topsurface of precast concrete members whichwill subsequently receive in situ concreteshall be further prepared by one of thefollowing methods as shown on theDrawings:

Class 1 surface preparation,

The surface finish shall be in accordancewith sub-Clause 1 of this Clause.

Class 2 surface preparation,

The hardened surface shall be jetted with airor water to remove laitance and all loosematerial and no further roughening shall thenbe carried out (rough as cast).

(ii) Storage. When members are stored, theyshall be firmly supported only at the pointsdescribed in Appendix 17/4. The




accumulation of trapped water anddeleterious matter in the units shall beprevented. Care shall be taken to avoid ruststaining and efflorescence.

When a stack is several units high, packingsshall be vertically above each other toprevent additional bending stresses in anyunit. Where disfigurement would bedetrimental, packing pieces shall notdiscolour or otherwise permanently damagethe units.

(iii) Handling and transport. Members shall belifted or supported only at points describedin Appendix 17/4 and shall be handled andplaced without impact.

(iv) Assembly and erection. In a composite slabbridge where precast beams are laid side byside with minimal gaps to form a deck:

(a) the difference in soffit level betweenadjacent units before the in situ concreteis placed shall nowhere exceed 5 mmfor units up to 5 m in length or 10 mmfor longer units;

(b) the width of the deck soffit shall bewithin + 25 mm of that shown on theDrawings;

(c) in adjacent spans, the continuity of lineof the outside beams shall bemaintained;

(d) the width of the gap between individualbeams shall not exceed twice thenominal gap shown on the Drawings;

(e) the alignment of transverse holes shallpermit the reinforcement or prestressingtendons to be placed without distortion.

The in situ concrete in composite slabbridges shall be placed in such a sequencethat the advancing edge of the freshlydeposited concrete over the full width of thedeck, between longitudinal constructionjoints, is approximately parallel to the decksupports. Precast beams shall be preventedfrom moving laterally during the placing ofthe in situ concrete.

The method of assembly and erection shallcomply with any particular requirements inAppendix 17/4.

(v) Forming structural connections. Thecomposition and water/cement ratio of the insitu concrete or mortar used in anyconnection and in the packing of joints shall

be in accordance with the assemblyinstructions.

Levelling devices shall only be released orremoved when the structural connection iscomplete and has achieved sufficientstrength.

(vi) Protection. At all stages of construction,precast concrete units and other concreteassociated therewith shall be properlyprotected to prevent damage to permanentlyexposed concrete surfaces, especially arrisesand decorative features.

1711 (05/01) Concrete - Grouting and DuctSystems for Post-tensioned Tendons

Planning, Trials and Basic Requirements

1 (11/03) Site operations, including duct installation,stressing and grouting, shall be carried out byorganisations certificated by CARES in accordancewith the requirements of the CARES Scheme for theSupply and Installation of Post-tensioning Systems inConcrete Structures, or an equivalent scheme.

Grouts for protection of prestressing tendons shall be asrequired in Appendix 17/6 and defined insub-Clause 1711.2.

The Contractor shall undertake full-scale trials of thegrout mix and of the grouting operations as required inthe Contract for duct installation, testing, concreting,grouting and any other associated requirements inaccordance with the details described in Appendix 17/6.The trials are required to demonstrate that the groutingmethods and procedures proposed by the Contractorshall ensure that grout fills the ducts and surrounds theprestressing steel.

The Contractor shall submit for acceptance of theOverseeing Organisation, a detailed method statement,at least 4 weeks prior to use in any trials or in theWorks, covering proposed materials, ducts, anchorageand vent arrangements, personnel, equipment, groutingprocedures and quality control.

Where full scale trials are required, these shall becommenced at least 56 days before the plannedcommencement of fixing ducts for prestressing for thepermanent works unless specified otherwise inAppendix 17/6. The trials shall incorporate all relevantdetails of ducts, vents, duct supports, prestressinganchorages and couplers, prestressing strands, groutinlets and outlets. The tendons shall be sufficientlytensioned such that the strands within the duct take up arepresentative alignment. All systems, methods and




materials are to be those proposed for the permanentworks and shall have been submitted to the OverseeingOrganisation as part of the detailed method statementrequired.

After three days the Contractor shall carefully cut orcore the trial section to expose cross sections andlongitudinal sections of the duct, anchorages and anyother locations where required, or as further directed bythe Overseeing Organisation, to demonstrate that theduct is satisfactorily grouted. A report shall be preparedby the Contractor giving full details of the trial, testingresults and photographs of the exposed sections.

Grouting of the ducts shall be shown to leave no voidwhich has either a dimension greater than 5% of theduct diameter measured in the radial direction of theduct or greater than 200 mm measured in thelongitudinal direction of the duct (or appropriatedimension, in the case of oval ducts, anchorages etc) orwhich poses a risk to the protective system. Thelocation of any voids with respect to grout vents andtheir adequate grouting and subsequent sealing, and thedisposition of the steel tendons within the body of thegrout shall be reported in writing by the Contractor tothe Overseeing Organisation within 24 days.

Prestressing for the permanent works shall not bepermitted without the prior written acceptance of theOverseeing Organisation to grouting procedures andformal acceptance of the results of the grouting trial.

The Contractor shall carry out a materials suitabilityassessment in accordance with sub-Clause 1711.2.

Grout Materials

2 (11/03) The properties of the grout, made with thematerials, and using the plant and personnel proposedfor use on site, shall be assessed for suitability for theintended purpose. This assessment shall be carried outsufficiently in advance of grouting operations to enableadjustments to be made in use of materials or plant orpersonnel.

Grouts shall comply with the requirements insub-Clause 1711.8. The materials’ assessment shallconsist of the preparation of the grout, made with thematerials, and using the plant and personnel proposedfor use on site, and the testing of it in accordance withsub-Clause 1711.9. The preparation shall be carried outunder representative conditions of temperature expectedon site. If grouting operations are likely to coverdifferent seasons, the assessment shall be carried out forthe expected range of temperatures.

No departures from the sources of the materials andprocedures approved as a result of satisfactory trialswill be permitted without the written approval of theOverseeing Organisation.

Grouts shall consist only of Portland cement (CEM I)complying with BS EN 197-1 Class 42.5N, admixturescomplying with sub-Clause 1711.10 and watercomplying with BS EN 1008. Where proprietaryprebagged grout is used it shall be mixed in accordancewith the manufacturer’s instructions.

Grouts shall not contain a chloride ion content of morethan 0.1% by mass of the cement.

Duct Systems

3 (11/03) The system of ducts, duct connectors,grouting connections, vents, vent connections, drains,transitions to anchorages and caps for anchors shallform a complete encapsulation for the tendons which isresistant to the ingress of air and water. Ducts shall beof proven corrosion resistant durable material. Ductingwhich may degrade or corrode during the expected lifeof the structure shall not be permitted. The system shallbe fully compatible with the prestressing anchorages,couplers and other details. Where ducts are non-conductive, metal parts of anchorages shall beelectrically bonded to the adjacent reinforcement ateach end of the tendon and electrical continuity of thestructure over the length of the tendon shall beconfirmed by testing.

The following air pressure tests shall be carried out onsite unless specified otherwise in Appendix 17/6.

Duct Assembly Verification Tests

Each complete duct system including vents, anchorages,anchorage caps, and where appropriate couplers andtheir connections, shall be air-pressure tested beforeconcreting. Testing to a pressure of 0.01N/mm2 unlessotherwise specified in Appendix 17/6, shall demonstratethat the system is undamaged and has been correctlyassembled. The testing shall demonstrate that a loss ofpressure no greater than 10% occurs after 5 minutes,unless specified otherwise in Appendix 17/6.

The minimum manufactured wall thickness of ductingfor internal tendons shall be 2 mm. The duct rigidity andtype and spacing of fixings and supports shall be suchas to maintain line, position and cross section shapeduring concreting. Local deformation of the duct atsupports shall be avoided.

For external tendons the minimum wall thickness shallbe 4 mm for durability, or such thicker wall as requiredto withstand grouting pressures of the particular ductconfiguration.

The Contractor shall provide evidence of testing todemonstrate the following requirements:

(i) Wall thickness of ducts for tendons aftertensioning of the tendons shall be not less




than 1.5mm unless specified otherwise inAppendix 17/6.

(ii) (11/03) For internal tendons the duct shalltransmit full bond strength from the tendonsto the surrounding concrete over a length nogreater than 50-100 duct diameters or othersuch requirement as given in Appendix 17/6.

(iii) (11/03) The duct system shall comply, as aminimum, with the International Federationfor Structural Concrete (fib)recommendations (Technical Report,Bulletin No. 7) for ‘Corrugated plastic ductsfor internal bonded post-tensioning’, andwith other requirements of this Clause.

Vents providing an air passage of at least 15 mminternal diameter shall be provided at the anchoragesand in the troughs and crests and beyond eachintermediate crest in the direction of flow of the groutat the point where the duct is one half diameter lowerthan the crest, (but no further than 1m from the crest),unless otherwise described in Appendix 17/6. Themaximum spacing of vents shall be 15m unlessspecified otherwise in Appendix 17/6.

The vent diameter and spacing may be varied in full-scale trials demonstrating the suitability of alternatives.The vents shall be rigidly connected to the ducts, andshall be capable of being closed and re-opened. Holesin the ducts shall be at least the internal diameter of thevents and shall be formed before pressure testing.

For external tendons the arrangement and detailing ofthe vents at positions within deflectors/diaphragmsshall be proven by detailed testing.

Vents on each duct shall be identified by labelling andshall be protected against damage at all times.

Vents at high points shall extend to a minimum of500 mm above the highest point on the duct profileunless described otherwise in Appendix 17/6.

Grouting Equipment

4 (11/03) Grouting equipment shall consist of a mixer,a storage reservoir and a pump with all the necessaryconnection hoses, valves, measuring devices for water,dry materials, admixtures and testing equipment.

The mixing equipment shall be capable of producing agrout of homogeneous consistency and shall be capableof providing a continuous supply to the injectionequipment. The capacity of the equipment shall be suchthat each duct can be filled and vented withoutinterruption and at the required rate of injection.

The injection equipment shall be capable of continuousoperation and shall include a system for recirculatingthe grout when grouting is not in progress.

The equipment shall provide a constant deliverypressure; it shall have two pressure gauges and apressure relief valve to prevent pressures exceeding1 N/mm2. All piping to the grout pump shall have asfew bends, valves and changes in diameter as possible,and shall incorporate a sampling Tee with a locking-offvalve.

The equipment shall be capable of maintaining pressureon completely grouted ducts and shall be fitted with avalve that can be locked off without loss of pressure inthe duct.

During the grouting operation the Contractor shallprovide adequate flushing-out plant to facilitatecomplete removal of the grout in the event of abreakdown of the grouting equipment or otherdisruption before the grouting operation has beencompleted. The Contractor shall demonstrate that thisequipment is in full working order.

All equipment shall be kept free from build-up ofadhering materials.

(11/03) Batching and Mixing of Grouts

5 (11/03) All materials shall be batched by massexcept the mixing water and liquid admixtures whichmay be batched by mass or by volume. Baggedmaterials shall be weighed before use, unless clearlyweight marked with stated tolerance. The accuracy ofbatching shall be or have been (in case of pre-baggedmaterials):

± 2% for dry materials, cement and admixtures

± 1% for mixing water

of the quantities specified. The total amount of mixingwater shall include the water content of liquidadmixtures.

Depending upon environmental or material influence(eg temperature, configuration of the tendon andproperties of the materials used), the water/cement ratioshall be kept as low as possible having regard to therequired plastic properties of the grout. Actual water/cement ratios shall be recorded.

The material shall be mixed to produce a homogeneousgrout and kept in slow continuous agitation untilpumped into the duct. Unless manufacturers specifyotherwise, water shall be added to the mixer first,followed by the dry materials which may be added as awhole or in part in sequence until the total quantitiesare added. The minimum mixing time determined fromgrouting trials shall be adhered to.

The temperature of freshly mixed grout shall bebetween 5oC and 30oC. The maximum temperature maybe increased provided trials demonstrate that the groutmeets the requirements of sub-Clause 1711.8.




Injecting Grout

6 (11/03) A check shall be made to ensure that theducts, vents, inlets and outlets are capable of acceptinginjection of the grout. This check shall be achieved byblowing through the system with dry, oil-free air andtesting each vent in turn.

Any water in the ducts shall be removed beforegrouting operations commence.

Grouting of the ducts shall be carried out within 28days of installation of the tendon or as soon as ispracticable thereafter, in which case additionalmeasures shall be taken to avoid corrosion of theprestressing steel. The Overseeing Organisation’swritten agreement to commence grouting operationsshall be obtained. Injection shall be continuous and therate of injection slow enough to avoid segregation ofthe grout.

Grout shall only be injected from one end of the duct.

The method of injecting grout shall ensure filling of theducts and that the tendons are surrounded by grout.Grout shall be allowed to flow from each vent and theremote end of the duct until its fluidity is visuallyequivalent to that of the grout being injected. In theevent of disagreement, testing may be carried out inaccordance with sub-Clause 1711.8.

Following this, a further 5 litres of grout at each vent,or such other requirement of Appendix 17/6, shall bevented into a clean receptacle and then discarded. Theopening shall be firmly closed. All vents shall be closedin a similar manner one after another in the direction ofthe flow except that at intermediate crests the ventsimmediately downstream shall be closed before theirassociated crest vent.

The injection tubes shall then be sealed off underpressure with a pressure of 0.5 N/mm2 being maintainedfor at least one minute. Grout vents at high points shallbe reopened immediately after 1 minute, while the groutis still fluid. Any escape of air, water or grout shall berecorded and reported immediately to the OverseeingOrganisation. A further pumping of grout shall then becarried out to expel bleed water – and/or entrapped air.This shall be carried out with the vents open one at atime sequentially in the direction of grouting with afurther 5 litres being released at each vent. In the eventof disagreement over the quality of the vented grout,testing shall be undertaken immediately by theContractor.

The injection tubes shall then be sealed off underpressure, with a pressure of 0.5 N/mm2 beingmaintained for at least one minute.

The filled ducts shall not be subjected to shock orvibration for at least 24 hours from the time of grouting.

When the grout has set, the grout vents shall betemporarily reopened. If voids are apparent oninspecting vents at end caps, the OverseeingOrganisation may require all or some of the end caps tobe removed to demonstrate that they are satisfactorilyfilled with grout. End caps which have been removedshall then be replaced and permanently sealed againstingress of contaminants, such sealing to be proved tothe Overseeing Organisation.

If the method of demonstrating filling of the anchoragecaps involves their removal, a photographic record shallbe made by the Contractor. The record shall clearlyidentify the individual anchorages, and shall beincluded in the report to the Overseeing Organisation.

If, in the opinion of the Overseeing Organisation, thereis doubt that the ducts or any part of the system are notsatisfactorily filled with grout, the OverseeingOrganisation may require investigations to be carriedout.

The Contractor shall keep full records of grouting foreach duct in accordance with the certification schemerequirements for the installation of post-tensioningsystems. Copies of these records shall be supplied to theOverseeing Organisation within 24 hours of completinggrouting to each duct.

On completion of grouting, grout vents shall bepositively sealed and waterproofed by a means separatefrom the concrete waterproofing.

Grouting During Cold Weather

7 (11/03) When the ambient temperature is expected tofall below 5°C, accurate records shall be kept by theContractor of the maximum and minimum airtemperatures, and the temperatures of the structuralelements adjacent to the ducts to be grouted. Nomaterials containing frost or ice shall be used, and theducts and equipment shall be completely free of frostand ice.

Grout shall not be placed when the temperature of thestructural elements adjacent to the ducts is below 4°C,or is likely to fall below 4°C during the following48 hours, unless the element is heated so as to maintainthe temperature of the placed grout above 5°C for atleast 48 hours.

Methods of heating shall be to the acceptance of theOverseeing Organisation.

Ducts shall not be warmed with steam.




Properties of Grout

8 (05/04) The following criteria shall apply:

FluidityWhen tested by the method specified insub-Clause 1711.9, the fluidity of the grout shallmeet the criteria given in Table 17/4. Additionally,the fluidity (flow cone passage time) at outletsshall not vary from that of the injected grout bymore than 20%.

TABLE 17/4: (05/04) Test Requirements for Fluidityof Grout

Test Method Cone

Fluidity immediately <25 safter mixing (see note)

Fluidity at the end of the <25 sinjection period subject (see note)to a minimum of 30 minutesafter mixing*

Fluidity at duct outlet >10 s

* Mixing time shall be measured from the time when all of thematerials are in the mixer. For pre-bagged grout the minimum timeshall be 90 minutes.

NOTE: For grouts prepared in some mixers which have a highshear mixing action, the upper limits given in Table 17/4 may beincreased to 50 s. The mixer and these limits shall be subject tothe acceptance of the Overseeing Organisation.

BleedingWhen tested by the method referred to insub-Clause 1711.9 the bleeding for grout shall beless than 1% of the initial volume of the grout andthe average of 4 successive results shall be lessthan 0.3%. Testing shall be carried out at 24 hours.

Volume ChangeThe volume change assessed may be either anincrease or decrease. When tested in accordancewith the method referred to in sub-Clause 1711.9the volume change of grout shall be within therange - 0% to + 5%.

Strength(05/06) The compressive strength of 100 mm cubesmade of the grout shall exceed 27 N/mm2 at 7 days.Cubes shall be made, cured and tested inaccordance with BS EN 12390-1 andBS EN 12390-3.

Sieve TestThe grout shall contain no lumps. This shall beverified by testing as referred to insub-Clause 1711.9.

Sedimentation TestWhen tested by the method referred to in sub-Clause 1711.9 the grout shall not exhibit variationin density from top to bottom of a single testsample in excess of 5%.

Testing of Grout

9 (05/04) General. Suitability and acceptance tests forthe properties of grout shall be determined inaccordance with the Concrete Society Technical Report47 “Durable Bonded Post-Tensioned Concrete Bridges”2nd edition. The testing requirements are summarisedin Table 17/5.

TABLE 17/5: (05/04) Minimum Test Requirementsfor Grout

Suitability Testing

Fluidity Sampled immediately after mixing,one test.After estimated time to grout duct orminimum of 90 mins from initialmixing.Two tests averaged in both cases.

Bleed Each sampled immediately afterVolume change mixing, 3 tests averaged.SedimentationStrength

Acceptance Testing

Fluidity Sampled immediately after mixing,one test from mixer. After flowthrough duct, one test from eachanchorage outlet.On completion, one test from themixer.

Bleed One tests per day or one per 1.5 m3

Volume Change of grout unless otherwise agreed byStrength the Overseeing Organisation.

Sedimentation One test per day for site batechedgrout, or one test per pre-baggedsupplied batch (by manufacturer’sreference number); subject to aminimum of one test per continuousgrouting operation.




Admixtures

10 (05/05) The following criteria shall apply:

GeneralAdmixtures shall be used where required toachieve a low water/cement ratio and impart goodfluidity, minimum bleed and volume stability orexpansion to the grout to comply withsub-Clause 1711.8. For site batched groutadmixtures shall be added on site during the mixingprocess and used in accordance with themanufacturer’s recommendations. For pre-baggedgrout the admixtures shall form a pre-blendedcomponent.

TypesAdmixtures are divided into two types, expandingand non-expanding and they may be used to obtainthe required grout performance. Admixtures usedin combination shall be checked for compatibilityby the Contractor, and reported to the OverseeingOrganisation for acceptance.

Chemical CompositionAdmixtures shall not contain substances inquantities that will adversely affect the grout orcause the grout to promote corrosion of theprestressing steel by rusting, pitting, stresscorrosion or hydrogen embrittlement.

Material requirementsThe admixture shall not segregate and shall beuniform in colour. The composition shall notchange and the supplier shall operate a qualitysystem complying with BS EN ISO 9001. Thequality system shall be certified by a third partyaccredited by an appropriate organisation inaccordance with sub-Clauses 105.3 and 105.4.

Where appropriate, admixtures shall comply withBS EN 934-4. Other admixtures shall be permittedprovided they satisfy Clause 8 of BS EN 934-2 andfull account is taken of their effects on the finishedproduct and their fitness for purpose. Data on theirsuitability, including previous experience with suchmaterials, shall be made available and records ofthe details and performance of such materials shallbe maintained.

It must be noted that additional information beyondthat required by Clause 8 of BS EN 934-2 must beprovided by the manufacturer for admixturesbearing CE marking (see ZA.2.2 and ZA.3 ofBS EN 934-2).

DosageThe optimum dosage of any admixture shall bedetermined by trial mixes with the cement to beused in the grout. This dosage shall be expressed aspercent by mass of the cement. It shall be withinthe range recommended by the supplier and shallnot exceed 5% by mass of the cement. The methodof measuring dosage and checking weights of pre-packed dry materials shall comply withsub-Clause 1711.5 or as otherwise agreed with theOverseeing Organisation.

1712 (05/01) Reinforcement - Materials

(05/02) Hot Rolled and Cold Worked Carbon SteelBars

1 (05/06) All hot rolled and cold worked steel barsspecified shall conform to BS EN 10080 and BS 4449(Grade B500B or B500C) and shall be cut and bent inaccord ance with BS 8666. The bars shall be obtainedfrom a firm holding a valid CARES (or fully equivalentscheme) certificate of approval.

2 (05/06) Hot rolled and cold worked carbon steel barsshall conform to BS EN 10080 and BS 4449 except thatno bar shall contain a flash weld.

(05/06) Steel Wire

3 (05/06) Steel wire shall only be used in precastconcrete products and shall conform to BS EN 10080and BS 4482 (Ribbed, Grade 500). Steel wire shall havea minimum nominal diameter of 8 mm and shall beobtained from a firm holding a valid CARES (or fullyequivalent scheme) certificate of approval for theproduction and supply of steel wire.

Steel Fabric

4 (05/06) Steel fabric reinforcement shall conform toBS EN 10080 and BS 4483 (Grade B500A, B500B orB500C) and shall be cut and bent in accordance withBS 8666. Steel fabric reinforcement shall have aminimum nominal bar size of 6 mm (8 mm for GradeB500A) and shall be obtained from a firm holding avalid CARES (or fully equivalent scheme) certificate ofapproval for the production and supply of steel fabricreinforcement. Steel fabric reinforcement shall bedelivered to site in flat mats or pre-bent.

(05/02) Stainless Steel Reinforcement

5 (05/06) All stainless steel reinforcement shallconform to BS 6744 and shall be cut and bent inaccordance with BS 8666 and shall be obtained fromcompanies holding valid CARES (or fully equivalent




scheme) certificates of approval for the production andsupply of stainless steel reinforcement.

6 (05/06) Stainless steel reinforcement shall be ribbedGrade 500 conforming to BS 6744.

Bond Strength

7 (05/06) For hot rolled and cold worked carbon steelbars, and for steel fabric reinforcement, the bondproperty requirements of BS 4449 shall be compliedwith based on the surface geometry requirements of thatstandard. For steel wire, the bond property requirementsof BS 4482 shall be complied with based on the surfacegeometry requirements of that standard.

1713 (05/02) Carbon Steel Reinforcement andStainless Steel Reinforcement - Bar ScheduleDimensions - Cutting and Bending

1 (05/06) The bar schedules are based on thedimensions of the concrete and the nominal cover to thereinforcement shown on the Drawings. Thereinforcement shall be cut and bent within thetolerances given in BS 8666 but this shall not relievethe Contractor of his responsibility for the correct fit ofthe reinforcement and the achievement of the requiredcover as described in Clause 1714.

Bending of reinforcement at temperatures below 5°C orin excess of 100°C shall not be carried out.

Re-bending of carbon steel bars and fabricreinforcement on site shall not to be permitted.

Re-bending of stainless steel reinforcement bars on siteshall not be permitted.

Site storage of reinforcement shall ensure that it is clearof the ground and covered with a waterproof sheeting orfixed cover, in order to reduce contamination andexcess corrosion prior to placement.

1714 Reinforcement - Fixing

1 (05/05) Reinforcement shall be secured againstdisplacement. Unless specified otherwise, the actualconcrete achieved cover shall be not less than therequired minimum cover derived from the exposureclass Tables in BS 8500-1, and including any allowancefor longer durability required under clause A5 ofBS 8500-1. The maximum achieved cover shall not bemore than the nominal cover as defined in BS 8500-1,including the stated fixing tolerance ∆c.Bars in inner layers shall be located as shown on theDrawings; they shall be in close contact with the bars ofthe outer layer, unless otherwise indicated. Welding of

carbon steel reinforcing bars for fixing purposes shallbe in accordance with Clause 1717.

Welding of stainless steel reinforcement bars shall notbe permitted.

Cover blocks shall be of comparable strength, durabilityand appearance to the surrounding concrete. They shallmatch the mix proportions of the adjacent material sofar as is practicable. They shall ensure that thereinforcement is correctly positioned and shall be assmall as possible consistent with their purpose, anddesigned so that they will not overturn or be displacedwhen the concrete is placed. Reinforcement spacers andchairs shall be produced and fixed in accordance withthe Concrete Society report CS 101.

Wire cast in the block for the purpose of tying it to thereinforcement shall be as described below.

Spacer blocks (categorised as heavy in the ConcreteSociety Report CS101) shall be factory produced. Siteproduced concrete or mortar spacers shall not be used.

Projecting ends of ties or clips shall not encroach intothe concrete cover. Tying wires shall be 1.2 mmdiameter stainless steel wire throughout the structureexcepting any locations as described in Appendix 17/4where 1.6 mm soft annealed iron wire may be used.Stainless steel tying wire shall be used when tyingstainless steel reinforcement.

The Contractor shall provide access and carry out acover measurement survey of all reinforced concretesurfaces within the 24-hour period following theremoval of formwork. The cover measurement surveyshall be carried out on a 500 mm grid over the wholestructure in general accordance with BA 35(DMRB 3.3).

1715 Reinforcement - Surface Condition

1 (05/01) Immediately before concrete is placedaround it, reinforcement shall be free from mud, oil,paint, retarder, release agent, loose rust, loose millscale, snow, ice, grease or any other substance that canbe shown to have an adverse chemical effect on thesteel or concrete, or to reduce the bond between thesteel and the concrete.

1716 (05/01) Reinforcement - Laps and Joints

1 Laps and joints shall be made only where shown onthe Drawings, except in the case where additional lapsor splice bars are required and the OverseeingOrganisation’s approval has been obtained.




2 Where reinforcing bars are required to be coupledthe coupling system shall have a current British Boardof Agrément Roads and Bridges Certificate or CARESCertificate of Product Assessment and shall be sourcedfrom a firm holding relevant valid CARES (or fullyequivalent scheme) certificate of approval. Couplersshall comply with cover requirements ofsub-Clause 1714.1.

1717 Reinforcement - Welding

General

1 (05/02) Welded reinforcement, other than steelfabric reinforcement, shall not be incorporated in thePermanent Works unless permitted in Appendix 17/4.When required, the Contractor shall demonstrate that ateach location the fatigue life, durability and otherproperties of the member are not adversely affected bythe proposal.

Site welding of stainless steel reinforcement bars shallnot be permitted.

(05/02) Flash Butt Welding for Carbon Steel

2 (05/01) Flash butt welding shall only be carried outwith an appropriate combination of flashing, heating,upsetting and annealing and subject to thedemonstration of the satisfactory performance of trialjoints. Only those machines that automatically controlthis cycle of operations shall be used.

(05/02) Manual Metal-arc Welding for Carbon Steel

3 (05/01) Metal-arc welding shall be carried out inaccordance with BS 7123 and the recommendations ofthe reinforcement manufacturer, subject to thedemonstration of the satisfactory performance of trialjoints.

(05/02) Other Methods of Welding for Carbon Steel

4 (05/01) Other methods of welding may be usedsubject to the demonstration of the satisfactoryperformance of trial joints.

Strength of Structural Welded Joints

5 (05/06) The strength of all structural welded jointsshall be assessed following tests on trial joints toestablish the minimum specified mechanical propertiesof the joint. Tests shall be carried out by an independenttesting body accredited in accordance withsub-Clauses 105.3 and 105.4.

1718 Prestressing Tendons - Materials

Steel Wire

1 (05/01) Steel wire shall comply with BS 5896.

Cold Worked High Tensile Alloy Bar

2 Cold worked high tensile alloy steel bars forprestressed concrete shall comply with BS 4486.

Stress-relieved Seven-wire Strand

3 (05/01) Stress-relieved seven-wire strand shallcomply with BS 5896 or have properties that are notinferior.

Sampling and Testing

4 (05/01) When it is proposed to use super strandcomplying with BS 5896 : Table 6, or other than thelowest strength 3, 4, 5, 6 or 7 mm diameter wirescomplying with BS 5896 Tables 4 or 5 the followingshall apply:

(i) A sample shall be taken from each reel ofmaterial proposed for use in the Works.

(ii) A reel shall only be accepted if both thebreaking load and the 0.1% proof load of thesample exceeds the specified characteristicloads given in Tables 4 or 6. In the case ofTable 5 this requirement shall apply to thebreaking load and the load at 1% elongation.

5 (05/04) Where scheduled in Appendix 1/5, theContractor shall arrange for samples of the steelintended for use in the Permanent Works to be tested ata testing laboratory appropriately accredited by anappropriate organisation in accordance withsub-Clauses 105.3 and 105.4.

1719 Prestressing Tendons - Handling andStorage

1 Care shall be taken to avoid mechanicallydamaging, work-hardening or heating prestressingtendons while handling. All prestressing tendons shallbe stored clear of the ground and protected from theweather, from splashes from any other materials, andfrom splashes from the cutting operation of an oxy-acetylene torch, or arc-welding processes in the vicinity.

In no circumstances shall prestressing tendons aftermanufacture be subjected to any welding operation, orheat treatment or metallic coating such as galvanizing.This does not preclude cutting as described inClause 1722.




1720 Prestressing Tendons - SurfaceCondition

1 (05/01) Prestressing tendons and internal andexternal surfaces of sheaths or ducts shall be clean andfree from pitting at the time of incorporation in thework. Slight surface rusting is acceptable.

1721 Prestressing Tendons - Straightness

Wire

1 Low relaxation and normal relaxation wire shall bein coils of sufficiently large diameter to ensure that thewire pays off straight, except that in cases wherestraight as-drawn wire is not essential, wire in small-diameter coils (corresponding to the diameter of theblocks in the drawing machine) may be used.

Strand

2 Prestressing strand, however manufactured, shallbe in coils of sufficiently large diameter to ensure thatthe strand pays off straight.

Bars

3 (05/01) Prestressing bars as delivered shall bestraight. Any small adjustments for straightness that arenecessary on Site shall be made by hand. Bars bent inthe threaded portion shall be rejected. Any straighteningof bars shall be carried out cold but at a temperature ofnot less than 5°C. Any necessary warming shall be bymeans of steam or hot water.

1722 Prestressing Tendons - Cutting

1 All cutting of wire, strand or bar shall be carriedout using either:

(i) a high-speed abrasive cutting wheel, frictionsaw or equivalent mechanical method at notless than one diameter from the anchor; or

(ii) an oxy-acetylene cutting flame, using excessoxygen to ensure a cutting rather than amelting action, not less than 75 mm from theanchor. The temperature of the tendonadjacent to the anchor shall not be greaterthan 200°C. Care shall be taken that neitherthe flame nor splashes come into contactwith the anchorages or tendons.

1723 Prestressing Tendons - Positioning ofTendons, Sheaths and Duct Formers

1 Tendons, sheaths and duct formers shall beaccurately located and maintained in position bothvertically and horizontally as shown on the Drawings.Unless otherwise described in Appendix 17/4 thetolerance in the location of the centre line of sheath orduct shall be ± 5 mm.

Where tendons are described in the Contract asdebonded from the concrete they shall be covered withsuitable sleeves. The ends of the sleeves shall be tapedto the tendon to prevent the ingress of grout.

Joints in sheaths shall be securely taped to preventpenetration of the duct by concrete or laitance, and endsof ducts shall be sealed and protected after the stressingand grouting operations. Joints in adjacent sheaths shallbe spaced at least 300 mm apart.

1724 Prestressing Tendons - Tensioning

General

1 All wires, strands or bars stressed in one operationshall be taken, where possible, from the same parcel.Each cable shall be tagged with its number from whichthe coil numbers of the steel used can be identified.Cables shall not be kinked or twisted. Individual wiresand strands for which extensions are to be measuredshall be readily identifiable at each end of the member.No strand that has become unravelled shall be used.

Tensioning Apparatus

2 The tensioning apparatus shall meet the followinggeneral requirements:

(i) The means of attachment of the tendon to thejack or tensioning device shall be safe andsecure.

(ii) Where two or more wires or strands arestressed simultaneously, they shall beapproximately of equal length betweenanchorage points at the datum of load andextension measurement. The degree ofvariation shall be small compared with theexpected extension.

(iii) The tensioning apparatus shall be such that acontrolled total force is imposed graduallyand no dangerous secondary stresses areinduced in the tendons, anchorage orconcrete.




(iv) The force in the tendons during tensioningshall be measured by direct-reading loadcells or obtained indirectly from gaugesfitted in the hydraulic system to determinethe pressure in the jacks. Facilities shall beprovided for the measurement of theextension of the tendon and of anymovement of the tendon in the grippingdevices. The load measuring device shall becalibrated to an accuracy within ± 2% andchecked at frequent intervals.

Elongation of the tendon shall be measuredto an accuracy within 2% or 2 mm,whichever is the lesser.

(v) The tensioning equipment shall be calibratedbefore the tensioning operation andsubsequently at frequent intervals.

Pretensioning

3 Where pretensioning methods are used, the tensionshall be fully maintained by some positive meansduring the period between tensioning and transfer. Thetransfer of stress shall take place slowly to minimizeshock.

(i) Straight tendons. In the long-line method ofpretensioning, sufficient locator plates shallbe distributed throughout the length of thebed to ensure that the wires or strands aremaintained in their proper position duringconcreting. Where a number of units aremade in line, they shall be free to slide in thedirection of their length and thus permittransfer of the prestressing force to theconcrete along the whole line.

In the individual mould system, the mouldsshall be sufficiently rigid to provide thereaction to the prestressing force withoutdistortion.

(ii) (05/04) Deflected tendons. Where possible,the mechanisms for holding down or holdingup tendons shall ensure that the part incontact with the tendon is free to move in theline of the tendon so that frictional losses arenullified. If, however, a system is used thatdevelops a frictional force, this force shall bedetermined by test and due allowance made.

For single tendons the deflector in contactwith the tendon shall have a radius of notless than 5 times the tendon diameter forwire or 10 times the tendon diameter forstrand, and the total angle of deflection shallnot exceed 15°.

The transfer of the prestressing force to theconcrete shall be effected in conjunctionwith the release of hold-down and hold-upforces.

Unless otherwise described inAppendix 17/4, concrete shall not bestressed until it has reached at least the ageat which 2 test cubes taken from it attain thespecified transfer strength. The test cubesshall be made and tested as described inBS EN 12390-2 and BS EN 12390-3respectively. They shall be cured in similarconditions to the concrete to which theyrelate. The Contractor shall cast and testsufficient cubes to demonstrate that therequired strength of the concrete at transferhas been reached.

Post-tensioning

4 (i) (05/01) Arrangement of tendons. Wherewires, strands or bars in a tendon are notstressed simultaneously, the use of spacersshall be in accordance with therecommendations of the systemmanufacturer.

(ii) (05/06) Anchorages. Anchorages shall betested in accordance with BS EN 13391.

For each anchorage system used in theWorks, the characteristic value for anchorageefficiency shall be not less than 90%.

Proprietary anchorages shall be handled andused strictly in accordance with themanufacturer’s instructions andrecommendations.

(iii) Deflected tendons. The deflector in contactwith the tendon shall have a radius of notless than 50 times the diameter of the tendon,and the total angle of deflection shall notexceed 15°.

(iv) (05/04) Tensioning procedure. Beforetensioning, the Contractor shall demonstratethat all tendons are free to move in the ductsunless the geometry of the ducts makes thisimpracticable. Tensioning shall be carriedout in such a manner that the stress in thetendons increases at a gradual and steadyrate. Tensioning shall not be carried out at atemperature below 0°C.

Unless otherwise described inAppendix 17/4, concrete shall not bestressed until it has reached at least the ageat which 2 test cubes taken from it attain the



22FAmendment - May 2006

specified transfer strength. The test cubesshall be made and tested as described inBS EN 12390-2 and BS EN 12390-3respectively. They shall be cured in similarconditions to the concrete to which theyrelate. The Contractor shall cast and testsufficient cubes to demonstrate that therequired strength of the concrete at transferhas been reached.

The Contractor shall ensure that thosecarrying out the stressing are provided withparticulars of the required tendon loads,order of stressing and extensions. Allowanceshall be made during stressing for thefriction in the jack and in the anchorage,although the former is not necessary whenusing load cells, and for draw-in of thetendon during anchoring.

Stressing shall continue until the requiredextension and tendon load are reached.

The extension shall allow for any draw-in ofthe tendon occurring at a non-jacking end,but measurement shall not commence untilany slack in the tendon has been taken up.

Immediately after anchoring, the forces inthe prestressing tendons shall not exceed70% of their characteristic strength. Duringstressing the value may exceed 70% of theircharacteristic strength but shall not exceed80%.

After the tendons have been anchored, theforce exerted by the tensioning apparatusshall be decreased gradually and steadily soas to avoid shock to the tendon or theanchorage. Full records shall be kept of alltensioning operations, including themeasured extensions, pressure-gauge orload-cell readings, and the amount of draw-in at each anchorage. When requested copiesof these records shall be provided within24 hours of each tensioning operation.

Tendons shall not be cut within 3 days oftheir being grouted.

1725 Prestressing Tendons - Protection andBond

1 The prestressing tendons shall be protected in theirpermanent positions from both mechanical damage andcorrosion as described in Appendix 17/4.

1726 Stainless Steel Dowels - Materials

1 (05/02) Dowels shall be made from SteelDesignation 1.4429 or 1.4436 and Grade 200 or 500steel bars complying with BS 6744.

1727 Inspection and Testing of Structures andComponents

General

1 Inspection and testing of structures andcomponents shall be carried out as described inAppendix 17/4.