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TIVOLI CARPARK SITE DEVELOPMENT, 218-242 LITTLE COLLINS STREET, MELBOURNE CONTRACT NUMBER 59/3/8228A CONCRETE IN SITU

CONCRETE IN SITU

NATSPEC 1 22 October, 2003


CONCRETE IN SITU

1 GENERAL 1.1 CROSS REFERENCES General Conform to the Preliminaries. Conform to the Environmental Management section of the Invitation to Tender document. Related worksections Conform to associated worksections as follows: - Concrete finishes. - Concrete formwork. - Concrete reinforcement.

1.2 STANDARDS General Concrete: To AS 1379. Concrete structures for retaining liquids: To AS 3735. Materials and construction: To AS 3600.

1.3 INTERPRETATION Definitions Assessment: - Production: An assessment procedure for concrete specified by strength grade, carried out by the supplier

and based on the statistical assessment of standard compressive strength tests on concrete, specified by compressive strength and produced by a specific supplying plant.

- Project: An assessment procedure for concrete specified by strength grade, specified at the customer’s option, which provides additional test data for the statistical assessment of concrete supplied to a specific project.

Concrete class: - Normal: Concrete which is specified primarily by a standard compressive strength grade and otherwise in

accordance with AS 1379 clause 1.6.3. - Special: Concrete which is specified to have certain properties or characteristics different from, or

additional to, those of normal-class concrete and otherwise in accordance with AS 1379 clause 1.6.4. Batch: A quantity of concrete containing a fixed amount of ingredients and producing a discrete operation. Early age: Strength requirement at an age less than 28 days. Joint: - Construction: A joint provided to suit construction sequence with reinforcement continuous across the joint. - Contraction: An unreinforced joint with a bond-breaking coating separating the concrete joint surfaces. - Control: A weakened plane contraction joint created by forming a groove, extending at least one quarter the

depth of the section, either by using a grooving tool, by sawing, or by inserting a premoulded strip. - Expansion: An unreinforced joint with the joint surfaces separated by a compressible filler. - Isolation : A joint without keying, dowelling, or reinforcement, which imposes no restraint on movement. Sample: A portion of the material used in the works, or to take such a sample. Specimen: A portion of a sample which is submitted for testing. Weather: - Cold: Surrounding outdoor shade temperature < 10°C. - Hot: Surrounding outdoor shade temperature > 32°C.

2 QUALITY 2.1 INSPECTION Hold points > Witness points Give sufficient notice so that inspection may be made of the following: - Base or subgrade before covering.



- Commencement of concrete placing. - Completed formwork, and reinforcement, cores, fixings and embedded items fixed in place. - Membrane or film underlay installed on the base. - Surfaces or elements to be concealed in the final work before covering.

2.2 CONCRETE TESTS Concrete Assessment The assessment of concrete shall be made by project assessment procedures. Concrete testing Dissemination of production information: If concrete is manufactured off site, register the project in accordance with AS 1379 clause 6.4.3. Concrete testing methods Sampling, identification and testing: Sample the concrete on site, at the point of discharge from the agitator to AS 1012 and the Concrete tests schedule. Test authority: Concrete supplier or NATA registered laboratory. Control tests General: Determine transfer strength and early strength using site cured specimens in conformance with the Control tests schedule. Acceptance criteria: - Average strength of all samples must exceed the required value. - Strength of any one specimen must be at least 0.85 of the required value. Embedded pressure pipes Leak tests: Before embedment, leak test those pipes which will contain liquid or vapour at a pressure > 10 kPa. Performance tests Standard: To AS 1379. Drying shrinkage: Test 3 specimens of each type of concrete every 3 months or every 3000 m3 placed concrete. Base assessments on the average of the 3 specimens test results. Conduct 2 sets of tests on trial mixes. Frequency: Sample, test and assess the concrete for conformance with the Sampling frequency table and the Concrete tests schedule. For each property test at least two specimens from each sample. Slump: Test at least one sample from each batch before placing concrete from that batch in the work. Slump test shall coincide with each compressive strength test. The slump of all loads shall be visually checked by a trained operator. Strength grade/Characteristic compressive strength: Spread the site sampling evenly throughout the pour. For concrete in columns and bearing walls. Samples for N class concrete shall comprise 3 specimens to be tested at ages 1 x7 days and 2 x 28 days. Samples for S class concrete shall comprise 4 specimens to be tested at 1 x 7 days, 1 x 28 days and 2 x 56 days. - Specimen size: 200 x 100 mm diameter but, if aggregate size exceeds 20 mm, 300 x 150 mm diameter. Sampling frequency table

Minimum number of samples Number of batches for each type and grade of concrete per day Columns and loadbearing

wall elements per batch Other elements per day

1 1 1 2-5 1 2 6-10 1 3 11-20 1 4 each additional 10 1 1 additional Test records Records and reports: To AS 1012.

2.3 SAMPLE PANELS General Supply sample panels to AS 3610 and the Sample panels schedule for the application specified. Manufacture Cast the panels using the formwork, concrete, compaction equipment, form release agents, curing and formwork removal methods which are to be used in the final work.



Storage Maintain the panels on site undamaged and protected from the weather, as samples for future evaluation of completed work.

2.4 COLOURED CONCRETE General Using the same mix and method to be used in the works, supply sample blocks of concrete to be coloured with mineral oxides. - Number: 4. - Size (nominal): 300 x 300 x 50 mm.

2.5 SUBMISSIONS Design Loading: Submit calculations to justify the adequacy of the structure to sustain any construction loads and procedures. Execution proposals General: Submit proposals for mixing, placing, finishing and curing concrete including the following: - Addition of water at the site. - Changes to the plastic concrete mix. - Curing and protection methods. - Curing period for low-pressure steam curing, if proposed. - Cutting or displacing reinforcement, or cutting hardened concrete. - Handling, placing, compaction and finishing methods and equipment, including pumping. - High early strength cement. - Placing under water. - Sequence and times for concrete pours, and construction joint locations and relocations. - Site storage, mixing and transport methods and equipment, if applicable. - Target strength, slump and proposed mix for each type and grade of concrete. - Temperature control methods. Sawn joints: Submit proposed methods, timing and sequence of sawing joints. Materials General: Submit details of proposed sources of materials and type-test reports to verify conformance with the Material tests schedule. Concrete mixes: Submit details requested in the Concrete Review Document. Refer to Appendix B for approval, prior to use. Curing compounds: If it is proposed to use a liquid membrane-forming curing compound submit the following information: - Certified test results for water retention to AS 3799 Appendix B. - Efficiency index. - Evidence of compatibility with concrete, and with applied finishes, if any. - Evidence that an acceptable final surface colour will be obtained. - Methods of obtaining the required adhesion for toppings and render. Foamed concrete: Submit details, including aggregate grading and mix proportions. Ready mixed supply Delivery docket: For each batch, submit a docket listing the following information: - For special class performance concrete, specified performance and type of cement binder. - For special class prescription concrete, details of mix, additives, and type of cement binder. - Method of placement and climate conditions during pour. - Name of concrete delivery supervisor. - Project assessment carried out each day. - Serial numbers of identification certificates of each batch. - The amount of water, if any, added at the site. - The concrete element or part of the works for which the concrete was ordered, and where it was placed. - The total amount of water added at the plant and the maximum amount permitted to be added at the site.



Shop drawings Cores, fixings and embedded items: If the locations of these items are not shown or are shown diagrammatically, submit shop drawings showing the proposed locations, clearances and cover. Indicate proposed repositioning of reinforcement. Subcontractors Submit names and contact details of proposed ready-mixed concrete suppliers, and alternative source of supply in the event of breakdown of ready mixed or site mixed supply. Tests Dissemination of production information: Submit copies of the reports. Embedded pressure pipes: Submit the results of leak tests. Material tests: Before supplying concrete submit test certificates based on samples from the most recent production or from stockpiles for the project, for the materials and properties listed in the Material tests schedule. Submit additional certificates at the scheduled frequency during the course of the works. Sampling and testing of specimens: Submit records providing the full history of sampling and testing. Submit test certificates, and retain results in tabular form on site.

3 EXECUTION 3.1 POLYMERIC FILM UNDERLAY General For termite protection and basement tanking requirements refer to ‘Earthworks’ section. Under internal slabs on ground including integral ground beams and footings, provide a vapour barrier or, in areas prone to rising damp or salt attack, a damp-proofing membrane. Standard Vapour barriers and damp-proofing membranes: To AS 2870. Installation Lay over the base, lap joints at least 200 mm and seal the laps and penetrations with waterproof adhesive tape. Face the laps away from the direction of concrete pour. Take the underlay up vertical faces as far as the damp proof course where applicable, and fix at the top by tape sealing. Locate vertical laps only on vertical or inclined surfaces. Patch or seal punctures or tears before pouring concrete. Base preparation According to base type, as follows: - Concrete working base: Remove projections above the plane surface, and loose material. - Graded stone base: Blind with sufficient sand to create a smooth surface free from hard projections. Wet the

sand just before laying the underlay.

3.2 CONCRETE MATERIALS General Concrete and its constituent materials shall comply with the current relevant codes. The design of concrete mixtures shall satisfy the Primary Objectives and address the Ecologically Sustainable Design (ESD) Objectives. Primary Objectives The Primary Objectives to be satisfied in the selection, combination and use of concrete materials are: - achievement of specified concrete strengths - achievement of specified or implied durability requirements - strict compliance with the specified shrinkage limitations through:

. selection of appropriate sound aggregates having proven low shrinkage characteristics

. strict control of quality and cleanliness of all aggregates during production, supply and use, to minimise the content of deleterious fine materials

. appropriate combination of materials to achieve minimum water demand - achievement of appropriate workability and consistency to permit placement by traditional and pumping

methods. Ecologically Sustainable Design (ESD) Objectives The ESD Objectives of concrete mix designs are:- - to minimise embodied energy (i.e. energy utilised in the production of all constituents) - to minimise the content of ingredients which create greenhouse gasses in their manufacture - to maximise the use of reclaimed, recycled, waste or by-product materials - to minimise the use of prime quarry material - to minimise water use NATSPEC 5 22 October, 2003


The Principal has made a preliminary review of most concrete elements of the building and identified a number of opportunities for achieving the ESD Objectives, refer to Appendix A. The Contractor shall consider all elements of the structure individually and use concrete mix designs that take into account the specified structural and architectural requirements, workability and placement needs and the construction loading history. The Contractor shall submit all Concrete Mix Designs to the Principal for approval and shall demonstrate that the above ESD Objectives have been maximised whilst achieving the Primary Objectives. Submissions shall be supported with prototype samples and test data. Aggregate: To be unsegregated and uncontaminated. Cementitious materials: To be dry and uncontaminated and shall be supplied from a single source. Bagged cement Shall not be permitted. Chemical admixtures Contents: Free of chlorides, fluorides and nitrates.

3.3 CONCRETE General Provide concrete in conformance with: - The structural drawings and Architect’s finishes requirements. Concrete performance Drying shrinkage (maximum including tolerances): 0.65 microstrain for concrete up to and including strength grade 32; 0.7 microstrain for higher strength grades, unless noted, otherwise noted otherwise in Appendix A. Placement: Mix must work readily into corners and angles, and around reinforcement, without segregation or excess free water on the surface, producing sound concrete, with minimal plastic settlement and shrinkage cracking. Elapsed delivery time Elapsed time between the wetting of the mix and the discharge of the mix at the site must be as short as possible, and must conform to the Elapsed delivery time table. Do not discharge below 10°C or above 32°C. Elapsed delivery time table Concrete temperature at time of discharge (°C)

Maximum elapsed time (hours)

10 – 24 1.50 24 – 27 1.50 27 – 30 1.00 30 – 32 0.75 Ready mixed supply Addition of water: Do not add water at the site after starting discharge. Method: Use the batch production process. Deliver in agitator trucks. Transport: Mode must prevent segregation, loss of material and contamination, and must not adversely affect placing or compaction. Site mixed supply Emergencies: Do not mix by hand. Plant: Mix concrete in a plant located on the construction site.

3.4 CORES, FIXINGS AND EMBEDDED ITEMS Adjoining elements For adjoining elements to be fixed to or supported on the concrete, provide for the required fixings. Provide for temporary support of adjoining elements during construction of the concrete. Protection General: Grease threads. Cover and protect embedded items against damage. Compatibility: Ensure inserts, fixings and embedded items are compatible with each other, with the reinforcement and with the concrete mix to be used. Corrosion: Galvanize and chromate passivate inserts, anchor bolts and embedded fixings. Structural integrity Fix cores and embedded items to prevent movement during concrete placing. In locating cores, fixings and embedded items, do not cut or displace reinforcement, or cut or core hardened concrete. Ensure that embedded pipes and conduits do not adversely affect structural integrity.



Tolerances Maximum deviation from correct positions: - Anchor bolt groups for structural steel: To AS 4100. - Cores and embedded items generally: ± 10 mm. - Fixings including anchor bolts: ± 3 mm. Isolation: Isolate fixings so that water cannot track from fixings to reinforcement.

3.5 CONCRETE WORKING BASE Finish Membrane support: Wood float finish or equivalent. Material N15 concrete. Lay over the base or subgrade and screed to the required level. Surface tolerance ± 5 mm from the correct plane, ± 5 mm from a 2 m straight edge. Thickness Minimum 50 mm.

3.6 PLACING AND COMPACTION Compaction General: Remove air bubbles and fully compact the mix. Methods: Use immersion and screed vibrators accompanied by hand methods as appropriate. Vibrators: Do not allow vibrators to come into contact with partially hardened concrete, or reinforcement embedded in it. Do not use vibrators to move concrete along the forms. Avoid over-vibration that may cause segregation. Horizontal movement Use suitable conveyors, clean chutes, troughs or pipes. Do not use water to facilitate the movement. Placing General: Use placing methods which minimise plastic settlement and shrinkage cracking. Avoid segregation. Avoid loss of materials. Between construction joints, maintain a plastic concrete edge. Construction joints: Thoroughly roughen hard concrete joint surfaces. Remove loose or soft material, foreign matter and laitance. Dampen joint surface using clean water and coat with neat cement slurry. Layers: Place concrete in layers ≤ 300 mm thick, such that each succeeding layer is compacted before previous layer has taken initial set. Placing slabs and pavements: Place concrete uniformly over the width of the slab so that the face is generally vertical and normal to the direction of placing. Placing records Keep on site and make available for inspection a log book recording each placement of concrete, including the following: - Date. - Specified grade and source of concrete. - Slump measurements. - The portion of work. - Volume placed. Rain Do not expose concrete to rain before it has set, including during mixing, transport or placing. Sequence of pours Minimise shrinkage effect by pouring the sections of the work between construction joints in a sequence such that there will be suitable time delays between adjacent pours. Time delay between pours Conform to the Minimum time delay schedule. Vertical movement In vertical elements, limit the free fall of concrete to 1500 mm per 100 mm element thickness, up to a maximum free fall of 3000 mm, using enclosed chutes or access hatches in forms. As far as practicable keep chutes vertical and full of concrete during placement, with ends immersed in the placed concrete.

3.7 PLACING IN COLD WEATHER General Concrete: Maintain the temperature of the freshly mixed concrete within the limits shown in the Cold weather placing table. “Outdoor” air temperature applies to the air temperature at the time of mixing and to the predicted or likely air temperature at any time during the next 48 hours.



Formwork and reinforcement: Before and during placing maintain temperature at > 5°C. Admixtures Do not use calcium chloride, salts, chemicals or other material in the mix to lower the freezing point of the concrete. Cold weather placing table

Temperature of concrete Outdoor air temperature

Minimum Maximum

≥ 5°C 10°C 32°C

< 5°C 18°C 32°C

Frozen materials Do not allow frozen materials or materials containing ice to enter the mixer, and keep free of frost and ice any forms, materials, and equipment coming in contact with the concrete. Heating General: Heat the concrete materials, other than cement, to the minimum temperature necessary to ensure that the temperature of the placed concrete is within the limits specified. Maximum temperature of water: 60°C when it is placed in the mixer. High early strength cement Provide in severe weather conditions to enable the concrete to develop sufficient strength to permit formwork removal within the specified time. Do not provide as a substitute for the heating of materials or for adequate protection of placed concrete against low temperatures. Do not provide high alumina cement.

3.8 PLACING IN HOT WEATHER Handling Prevent premature stiffening of the fresh mix and reduce water absorption and evaporation losses. Mix, transport, place and compact the concrete as rapidly as possible. Hot weather placing table Concrete element Temperature limit

Normal concrete in footings, beams, columns, walls and slabs

35°C

Concrete in mass concrete sections ≥ 1 m in each dimension or concrete of strength 40 MPa or greater, in sections exceeding 600 mm in thickness

27°C

Mixing Surrounding outdoor shade temperature > 38°C: Do not mix concrete. Placing Formwork and reinforcement: Before and during placing maintain at ≤ 32°C. Concrete: When being placed in the forms, the temperature of the concrete must not exceed the criteria in the Hot weather placing table. Temperature control methods Select one or more of the following methods of maintaining the specified temperature of the placed concrete: - Cool the concrete using liquid nitrogen injection before placing. - Cover the container in which the concrete is transported to the forms. - Spray the coarse aggregate using cold water. - Use chilled mixing water.

3.9 PLACING UNDER WATER General Condition: Do not place under water if placing in the dry is practicable by pumping or other means of dewatering. Minimum cement content for the mix: Increase by 25%. Method If required, submit proposals.



3.10 CURING General Curing period: Cure continuously from initial set for at least 7 days, under ambient conditions, so that the average compressive strength of the concrete at the completion of curing is not less than 50 percent of the design strength. - Special class concrete containing increased supplementary cementitious material shall be effectively cured

for an extended period, to ensure that required properties are achieved. Protection: Protect fresh concrete, during the curing period, from premature drying and from excessively hot or cold temperatures. Protect fresh concrete from physical and thermal shock, from traffic likely to damage the surface, and from rain. If temperature of surrounding air is > 35°C, protect from wind and sun until the concrete can be covered. Maintain at a reasonably constant temperature with minimum moisture loss, during the curing period. Prevent rapid drying out at the end of the curing period. Cold weather curing Prevent plastic concrete from freezing, but do not use salt or chemicals. Maintain concrete temperature between 10 - 20°C for curing period. Curing compounds Standard: To AS 3799. Unless noted otherwise the specified method of curing shall be the spray application of an approved curing compound not less than 90% moisture retention characteristics as tested in accordance with the testing provisions of AS 3799-1990. The Contractor shall submit technical details of its preferred curing compound supply for approval by the Principal. PVA type compounds will not be approved. Application: Provide a uniform continuous flexible coating without visible breaks or pinholes, which remains unbroken at least seven days after application. Curing compounds shall be spray applied in accordance with the Manufacturer’s instructions and the Contactor shall apply all relevant safety precautions. The curing compound shall not be used until the Contractor has satisfied the Principal that the compound will not adversely affect the adhesion of any subsequent finish that may be applied to the concrete. Substrates: Do not use wax-based or chlorinated rubber-based curing compounds on surfaces forming substrates to concrete toppings and cement-based render. Hot weather curing Do not use curing compounds. Select a method as follows: - If the temperature exceeds 25°C or if not protected against drying winds, protect the concrete using a fog

spray application of aliphatic alcohol evaporation retardant. - Immediately cover the concrete using an impervious membrane, or hessian kept wet, until curing begins. - Pond or continuously sprinkle with water. Visually important surfaces Produce uniform colour on adjacent surfaces.

3.11 PROTECTION Loading Notice: Give notice before loading the concrete structure. Protection: Protect the concrete from damage due to load overstresses, heavy shocks and excessive vibrations, particularly during the curing period. Do not place construction loads on self-supporting structures which will overstress the structures. Surface protection Protect finished and exposed aggregate concrete surfaces from damage.

3.12 CONSTRUCTION JOINTS Location Do not relocate or eliminate construction joints, or make construction joints not shown on the drawings. If emergency construction joints are made necessary by unforeseen interruptions to the concrete pour, submit a report on the action taken. Finish at construction joints Butt join the surfaces of adjoining pours. In visually important surfaces make the joint straight and true, and free from impermissible blemishes relevant to its surface finish class. Joint preparation Roughen and clean the hardened concrete joint surface, remove loose or soft material, free water, foreign matter and laitance. Dampen the surface just before placing the fresh concrete.

3.13 EXPANSION JOINTS Joint filling Joint filling: Fill with jointing materials. Finish visible jointing material neatly flush with adjoining surfaces.



Preparation: Before filling, dry and clean the joint surfaces, and prime. Watertightness: Apply the jointing material so that joints subject to ingress of water are made watertight. Jointing materials Type: Provide jointing materials compatible when used together and non-staining to concrete in visible locations. Bond breaking: Provide back-up materials for sealants, including backing rods, which do not adhere to the sealant. They may be faced with a non-adhering material. Foamed materials (in compressible fillers): Closed-cell or impregnated types which do not absorb water.

3.14 SCHEDULES Concrete tests schedule Property Test method Test/sampling frequency

Air content To AS 1012.4 One test each 750m3 Bleeding To AS 1012.6 Per AS Characteristic compressive strength

To AS 1012.9 Project Assessment per AS3600

Density of hardened concrete

To AS 1012.12.1 or AS 1012.12.2

On all 7 and 28 day compressive strength specimens

Density of plastic concrete To AS 1012.5 Per AS Drying shrinkage To AS 1012.13 Not less than 3 prisms every

750m3 Early age strength To AS 1012.9 Refer to drawings Indirect tensile strength To AS 1012.10 Refer to drawings Modulus of rupture (flexural strength)

To AS 1012.11 Refer to drawings

Slump To AS 1012.3.1 Visual check each load and actual test with every compressive strength test

Material tests schedule Material Test method Test frequency

Admixtures (each type used)

To AS 1478.1 Per AS

Coarse aggregate Dense and lightweight: - LA value To AS 1141.23 Every 2500 m3 - Particle density and water

absorption To AS 1141.6.1 Every 1000 m3

- Particle size analysis To AS 1141.11 and AS 1141.12

Every 1000 m3

- Soundness To AS 1141.24 Per AS Fine aggregate: - Friable particles To AS 1141.32 Per AS - Light particles To AS 1141.31 Each 5000 m3 - Organic impurities To AS 1141.34 Every 1500 m3 - Particle size analysis To AS 1141.11 and

AS 1141.12 Every 1000 m3

- Particle density and water absorption

To AS 1141.5 Every 2500 m3

- Soundness To AS 1141.24 Per AS - Sugar To AS 1141.35 Every 5000 m3 Fly ash To AS 3582.1 Per AS Ground slag To AS 3582.2 Portland and blended cement (each type used)

To AS 3972



Sample panels schedule Application Incorporated features Panel size

3.15 APPENDICES Appendix A Matrix showing ecologically sustainable design initiatives in concrete mix design. Appendix B Concrete Review Document.


APPENDIX A Matrix Showing Ecologically Sustainable Design Initiatives in Concrete Mix Design

Element Mix Designation

Comment / Risk Strength (MPa)

specified at

Age

Drying Shrinkage at 56 days (µm)

Opportunities for consideration to minimise GP content, increase recycled and waste product input and reduce embodied energy of production

Soldier Piles S32

˚25MPa required for stressing anchors, either later age stressing or compromise cement replacement Setting times can be extended

56 days

800

˚30-50% supplementary cementitious ˚Larger max size aggregate ˚Recycled aggregates ˚Crusher Fines

Sprayed Concrete stabilisation of batters

S32

˚Normal Shotcrete properties required (‘stickiness’, rebound etc) ˚Excessive GP substitution may adversely affect properties

28ays

800

˚Crusher fines ˚20-30% supplementary cementitious ˚Silica Fume as cement replacement ˚Recycled aggregate ˚Crusher Fines

Sprayed Concrete infill between Soldier piles

S32

˚Normal Shotcrete properties required (‘stickiness’, rebound etc) ˚Excessive GP substitution may adversely affect properties

28 days

800

˚Crusher fines ˚20-30% supplementary cementitious ˚Silica Fume as cement replacement ˚Recycled aggregate ˚Crusher Fines

Footings S40 ˚Setting times can be extended 56 days 800


Columns in Basement

S70 S80

˚Setting times can be extended, ˚Enhance curing by delaying formwork stripping

56 days 650


NATSPEC Appendix A Page 1 of 5 22 October, 2003

Walls below Level 1

S60

˚Setting times can be extended, consider leaving forms in place or alternate methods of curing. Need to coordinate curing methods with applied finishes.

56 days 800


Slab on ground B2

S32

˚Durable abrasion resistant surface required ˚Normal setting characteristics required, excessive GP substitution can cause dusting and high abrasion rates ˚Chaplin Abrasion testing to conform to BS8204 and Concrete Society TR34 (AR 3)

28 days 800

˚Limit supplementary cementitious in consideration of abrasion requirements ˚Larger max size aggregate ˚Recycled aggregates ˚Crusher Fines

Blinding S15 56 days NA


B3 slab on ground S32

˚Normal setting characteristics required excess GP replacement may contribute to extended set and finishing difficulties

56 days 800


Suspended Floors B1 (Mezzanine) And B2

N32 ˚Normal setting characteristics required excess GP replacement may contribute to extended set and finishing difficulties

28 days 650

˚maximum 20% supplementary cementitious permissible ˚Larger max size aggregate ˚Recycled aggregates ˚Crusher Fines

Ground Floor N32 ˚Normal setting characteristics required excess GP replacement may contribute to extended set and finishing difficulties

28 days 650



Columns above Ground Floor S70

S50 S40

˚Setting times can be extended ˚Use Cardboard forms for circular columns ˚Consider leaving forms in place longer to enhance curing

56 days 650


Walls above Level 1 S40

˚Setting times can be extended, consider leaving forms in place or alternate methods of curing Need to coordinate curing method with applied finishes

56 days 800


Level 1 slab

(1st office level)

N32

˚Normal setting characteristics required - excess GP replacement may contribute to extended set and finishing difficulties

28 days 650


Stabilised backfill Liquifill or equivalent

˚circa 1.5 MPa NA NA

˚+50% supplementary cementitious ˚Crusher Fines ˚Recycled aggregates

Packing Sand ˚Crusher fines or other recycled aggregate with

sufficient Plasticity index.

L2-L9 Typical floor deck over precast panel, including beam

N32

˚Surface Finish not critical ˚Normal setting characteristics required ˚65mm slab thickness over crown of precast will limit aggregate size

28 days 650

˚up to 30% supplementary cementitious ˚Recycled aggregates ˚Crusher Fines


Roof Slab N32

˚ Normal setting characteristics required ˚65mm slab thickness over crown of precast will limit aggregate size

28 days 650

˚up to 30% supplementary cementitious ˚Recycled aggregates ˚Crusher Fines

Precast

to Elevations

N40

˚Some ‘white’ some ‘charcoal’, discussions with colour providers may offer opportunities for GGBFS ˚ Class 1 off form finish required ˚Demoulding / Lifting strengths will require steam curing or additional GP or delayed stripping, early age strength to be confirmed by Pre-cast panel Construction Code of Practice, certificate of compliance

28 days

650

˚supplementary cementitious, dependant on colour and early age requirements ˚Larger max size aggregate ˚Recycled aggregates ˚Crusher Fines

Precast

Curved Soffit Floor panels

N40

˚ Brightonlight off form to Architect’s specified finish class. ˚32 MPa required for Demoulding / lifting, may require steam curing, additional GP or delayed Demoulding / stripping of forms, confirmation by Pre-cast panel Construction Code of Practice, certificate of compliance Min 40MPa required for transport and on site construction. Normal setting characteristics required

28 days

650

˚supplementary cementitious, dependant on colour and early age requirements ˚Larger max size aggregate ˚Recycled aggregates ˚Crusher Fines


Comments on general impact of ESD initiatives:

Initiative

Critical Features

Increase maximum nominal aggregate size (mm)

Placing and pumping, general workability needs to be understood. Availability of suppliers, some will not be able to stock Overall reduction in binder content Curing to code / specification requirements.

Substitution of Aggregates with recycled aggregates

Not recommended in High Strength May increase Drying Shrinkage May increase water demand Additional attention to Proper curing is imperative

Substitution of natural sand with Crusher fines

May increase Drying Shrinkage May increase water demand As percentage increases, but readily available. Additional attention to Proper curing is imperative

Replacement of GP cement with supplementary (GGBFS or Flyash)

Reduction in early age strength development Increased requirement for diligent curing Potential for delayed setting times (more critical in elements requiring trowelled finish) Good long term strength development with continuous curing Additional attention to Proper curing is imperative


CH-2 Council House Redevelopment

Correspondence Ref: CONCRETE REVIEW.DOC

CCOONNCCRREETTEE RREEVVIIEEWW

Contract Number 59/3/8228A Concrete Insitu Specification Appendix B Concrete Review Document

MAIN CONTRACTOR: ……. PTY LTD

PROJECT NAME: CH2

TIVOLI CARPARK SITE REDEVELOPMENT

PROJECT LOCATION: 218 – 242 LITTLE COLLINS STREET, MELBOURNE

COMMENCEMENT DATE FOR CONSTRUCTION: XXX 2004

Data to be submitted by Concrete Supplier prior to concrete supply commencement

SUBMIT TO: MR XXX XXX

CITY OF MELBOURNE

REQUIRED DATE:

ANCON Leading Practical Concrete Technology

CH2 – Tivoli Carpark Development 14 October 2003

CONCRETE REVIEW

OOBBJJEECCTTIIVVEESS OOFF TTHHEE CCOONNCCRREETTEE RREEVVIIEEWW

Successful construction with concrete

Ensure that all possible Ecologically Sustainable Design Objective (ESD*) opportunities are addressed

Successful supply of Premixed Concrete

No delays, problems or disputes

Provide a tool to measure the ESD qualities of the concrete used in the project General

Concrete and its constituent materials shall comply with the current relevant codes. The design of concrete mixtures shall satisfy the Primary Objectives and address the Ecologically Sustainable Design (ESD) Objectives. Primary Objectives The Primary Objectives to be satisfied in the selection, combination and use of concrete materials are: - achievement of specified concrete strengths - achievement of specified or implied durability requirements - strict compliance with the specified shrinkage limitations through:

. selection of appropriate sound aggregates having proven low shrinkage characteristics

. strict control of quality and cleanliness of all aggregates during production, supply and use, to minimise the content of deleterious fine materials

. appropriate combination of materials to achieve minimum water demand - the achievement of appropriate workability and consistency to permit placement by traditional and

pumping methods.

*Ecologically Sustainable Design (ESD) Objectives of concrete mix designs are:-

• to minimise embodied energy (i.e. energy utilised in the production of all constituents) • to minimise the content of ingredients which create greenhouse gasses in their manufacture

• to maximise the use of reclaimed, recycled, waste or by-product materials • to minimise the use of prime quarry material

• to minimise water use

The Builder shall consider all elements of the structure individually and make concrete mix designs that take into account the specified structural and architectural requirements, workability and placement needs and the construction loading history.

ANCON: Leading Practical Concrete Technology


The Builder shall submit all Concrete Mix Designs to the Principal for approval and shall demonstrate that the above ESD objectives have been maximised whilst achieving the primary objectives. Submissions shall be supported with prototype samples and test data. Quality Assurance The attainment of QA certification does not necessarily ensure that the concrete supplied will be of adequate quality, user friendly, fit for purpose, or meets specification.

There may be a gap between the QA processes and satisfactory construction with Premixed Concrete.

There are numerous matters that are not necessarily dealt with by codes and specifications, particularly in relation to the use of environmental initiatives.

This Concrete Review has been prepared to enable a review of the Premixed Concrete Supplier’s:

Proposed supply

Methods and extent to which the ESD Objectives have been incorporated

Status of operation

Historical performance



Introduction

This information is required to be submitted by the Concrete Supplier to the principal where possible at least 28 days in advance of the first pour. The information will be reviewed by the principals’ technical consultants, ANCON Beton Pty Ltd.

The quality and timeliness of the information will assist in cooperative resolution of any matters of concern to both the Contractor and the Concrete Supplier.

Where required the concrete supplier is to submit the information in hard copy..

Concrete Supplier Details

General Details

Name of Company ______________________________________________________________

Address ______________________________________________________________

Phone ______________________________________________________________

Fax ______________________________________________________________

Personal Contact Name ______________________________________________________________

Mobile ______________________________________________________________

Email ______________________________________________________________

Concrete Supply – Main Plant

Plant Manager Name _______________________________________________________

Phone _______________________________________________________

Fax _______________________________________________________

Mobile _______________________________________________________

Email _______________________________________________________

Plant Address _______________________________________________________

Plant Phone _______________________________________________________

Plant Fax _______________________________________________________

Plant Email _______________________________________________________

Approximate delivery time - plant to site _____________________________________________________



Concrete Supply – Back Up Plant (if applicable)

Please provide details as above if applicable

Technical Laboratory / QC Details

Name of Laboratory ______________________________________________________________

Address ______________________________________________________________

Phone ______________________________________________________________

Fax ______________________________________________________________

Person in Charge Name ______________________________________________________________

Cementitious Material

Please attach the last two compliance or dispatch certificates as well as the last full months basic QC test data from the suppliers of all proposed GP cements, Flyash and Blast Furnace Slag materials.

Coarse Aggregate

Sources and Nominated Grading and Limits for Mix Design and Supply Target

Mix Design Grading and Tolerances (Tick Box for Sizes Proposed)

20mm 14mm Other please state

Sieve Aperture size (mm)

Grading % Passing

Tolerance %

Grading % Passing

Tolerance %

Grading % Passing

Tolerance %

37.0

26.5

19.0 13.2 9.5 6.7

4.75 2.36

75 µm

Source Name Source Location

Note here if recycled or

waste material



Historical Grading Test Results of Proposed materials

Sieve aperture size (mm)

20mm - % Passing

Last Monthly Average

3rd Last Test 2nd Last Test Last Test

26.5 19.0 13.2 9.5 6.7 4.75 2.36

75 µm Number of

Samples

Sieve aperture

size (mm) 14mm - % Passing



26.5 19.0 13.2 9.5 6.7 4.75 2.36

75 µm Number of

Samples

Sieve aperture

size (mm) Other please state - % Passing



37.5 26.5 19.0 13.2 9.5 6.7 4.75 2.36

75 µm Number of

Samples

Other Aggregate Test Data

Flakiness Test Results

As appropriate give the date and results of the last two tests on each size.



20mm 14mm Other Date Result Date Result Date Result

Particle Density and Absorption


20mm

Result Date Particle Density (SSD) Absorption %

14mm


Other please state


Loss Angeles Value



Sodium Sulphate Loss





Unsound and Marginal Stone Content


20mm Result Date

Unsound Marginal

14mm Result Date

Unsound Marginal

Other Result Date

Unsound Marginal

Weak and Light Particles

As appropriate give the data and results of the last two tests on each size.

20mm Result Date

Weak Particles Light Particles

14mm

Date Result



Weak Particles Light Particles

Other

Result Date Weak Particles Light Particles

Impurities

Refer Clause 14 of AS2758.1.

Attach test certificates for the last test.

Fine Aggregate

Source and Nominate Gradings and Limits

Mix Design Grading and Tolerances (Tick Box for Sizes Proposed)

Natural Sand 1 Natural Sand 2 Quarry/Crusher Sand

Sieve Aperture size (mm)

Grading % Passing

Tolerance %

Grading % Passing

Tolerance %

Grading % Passing

Tolerance %

6.70 4.75 2.36 1.18

0.600 0.300 0.150 0.075

Source Name Source Location

Fine Aggregate Name

Historical Grading Test Results of Proposed Materials


Sand 1 - % Passing



Last Monthly

Average 3rd Last Test 2nd Last Test Last Test

6.70

4.75

2.36

1.18

0.600

0.300

0.150

0.075


Sand 2 - % Passing



6.70

4.75

2.36

1.18

0.600

0.300

0.150

0.075


Quarry Sand - % Passing



6.70

4.75

2.36

1.18

0.600

0.300

0.150

0.075

Other Test Data

Particle Density and Absorption




Sand 1 Result Date

Particle Density (SSD) Absorption %

Sand 2 Result Date


Quarry Sand Result Date


Sodium Sulphate Loss


Sand 1 Sand 2 Quarry Sand Date Result Date Result Date Result

Impurities

Refer Clause 14 of AS2758.1.

Attach test certificates for the last test.

Additionally attach the last two Test Certificates for Organic Impurities.

Alkali Aggregate Data

Attach relevant information on the proposed materials.

Admixtures

Attach AS 1478 Compliance Test Data on admixtures proposed.

Attach uniformity batch test data for last two batches purchased by concrete supplier.



Water

Attach last two test certificates for recycled water if it is used at the plant.

Concrete Plant Main Supply Plant

Ground Storage Stockpiles

Nominate stockpiles and materials and tonnes maximum storage.

Material Stockpile Size (Tonnes)

Ground Storage Bins

Nominate bins and maximum capacity.

Material Bin Capacity (Tonnes)

Overhead Storage Bins

Nominate bins and maximum capacity.

Material Bin Capacity (Tonnes)

Cementitious Silo’s

Nominate silo’s and maximum capacity.

Material Silo Capacity (Tonnes)



Silica Fume if Applicable

Is silica fume used in degradable bags? Yes / No

If yes, are the bags … 10Kg / 20Kg

Batching Capacity

What is the batch size or capacity in cubic metres for individual batching? ______/m3

What is the rated maximum capacity in cubic metres per hour of plant? ______/m3

Batching Plant

Is the plant dry batch or wet batch? Dry / Wet

What is the make and model of the batch plant?

Slump Stand

Does the plant have one? Yes / No

If yes, does it have an operating calibrated water meter? Yes / No

If yes, does the water pressure inject water to the cab end of the mixer? Yes / No

Batching System

Is it … Manual / Computerised

If computerised, what is the computer batch system name?

Moisture Content Measurement and Control

Give Details

____________________________________________________________________________________________

____________________________________________________________________________________________

Weighing Scales and Flow Meter Calibration

At what intervals are these carried out? __________ months

Attach calibration check for all:

Aggregate scales



Cementitious scales

Admixtures

Water meters

QA Procedure and Method Statement

Does the plant have a complete ISO 9002 system and documentation? Yes / No

If yes, is it readily available? Yes / No

If yes to either of above, is it used and followed? Yes / No

If truck drivers are responsible for slump, do they have Method Statements for slumping and delivery? Yes / No / Not Responsible

Contamination of Aggregates

Does this plant have problems with materials contamination which could be considered as:

Regular contamination Yes / No

Minor contamination Yes / No

No contamination Yes / No

Note: In the answer to the above questions please consider both stockpiles, ground storage bins and overhead bins.

Does the plant procedures include regular inspection of stockpiles, ground storage and overhead storage to check for contamination or spillage? Yes/No

If yes, please state the frequency of visual inspection by the presence of a plant person (not video monitor). __________ frequency

Are there labels on:

Stockpiles? Yes / No

Ground Storage Bins? Yes / No

Overhead Bins? Yes / No

Cementitious Silos

Does the plant have any split silos? Yes / No

Do the plant silos have interconnecting breather pipes between them? Yes / No

Are there clearly identified labels on cementitious silo induction pipes? Yes / No

Are there protective caps and locks on cementitious silo induction pipes? Yes / No

Further details_____________________________________________________________________



The concrete mix proposed

Main Supply Plant

Give details of mixes and mix grades proposed for supply.

Mix Mix 1 Mix 2 Mix 3 Mix 4 Mix 5 Mix Code Strength MPa 28 days Strength MPa at later age nominate days

Max. Aggregate Size mm Shrinkage strain at 56days Mix Type (pump or non) Total Cementitious Content GP Cement Flyash Blast Furnace Slag Silica Fume or Other W:C Ratio Admixtures mls/m3 Admix 1 Admix 2 Batch Proportions (Kg/m3 SSD) Aggregate 1 Aggregate 2 Aggregate 3 Aggregate 4 Aggregate 5 Total Free Water (Kg/m3) Air Content % (Nominal)

Note: Please clearly state ESD materials proposed for use in the table above.

If for any given mix it is likely that the supplier will vary the mix proportions to maintain strength and workability at the required level, then briefly detail here:-

Back Up Supply Plant (if applicable)

If mixes will differ from the main supply plant, they should be attached using the table 11.1 above.



Admixtures

Does the concrete supplier have a correlation table to correlate setting time v’s dosage rate at the ambient temperature range expected during supply? Yes / No

If yes, please attach a copy.

If no, the supplier should explain below what procedure they expect to follow.

____________________________________________________________________________________________

____________________________________________________________________________________________

Historical Concrete Test Data 12.1 Historical Data

The concrete supplier will provide the contractor or its technical consultant copies of data listed below. It is realised that this data may not be exactly and readily available particularly when materials and mixes have been specifically designed to incorporate ESD initiatives. In that instance test data should be submitted as close as practically possible to that request.

Provide information on mixes proposed for supply and in particular supply information on the mixes that are most likely to be supplied for the major part of the project.

Concrete compression test results in summary and statistical form for the past 3 months for Grade for mixes that will be supplied for the majority of the project.

Supply shrinkage test data for the past 12 months as available for any of the proposed mixes.

Air content of the proposed mixes as tested over the past 12 months.

If any of this information is not available, then supply similar information on other frequently supplied mixes.

12.2 prototype test Data

Where insufficient historical data is available requiring prototype mixes to be developed and tested, provide information on mixes proposed for supply.

Concrete compression test results in summary and statistical form for Grade of mixes that will be supplied for the majority of the project.

Concrete strength gain versus age

Supply shrinkage test data for any of the proposed mixes.

Air content of the proposed mixes.



Concrete Truck Mixers

Main Supply Plant

Capacity

Please list truck mixer fleet numbers for trucks normally operating from this plant.

Supply Capacity

What is the normal supply capacity in cubic metres per hour for these truck mixers? __________/m3

Uniformity Verification

Do all truck mixers comply with requirements of Concrete Review of AS 1379? Yes / No

Does the supplier have documentation to confirm this? Yes / No

Please provide more information as necessary.

____________________________________________________________________________________________

____________________________________________________________________________________________

Back up Plant (if applicable)

Information is required as for 13.1.3 above

THe COncrete Supplier

Specification for Project

Does the concrete supplier have a copy?

Does the supplier have a copy of the Concrete Yes / No

If yes, does the supplier understand the requirements? Yes / No

Is the supplier confident of meeting the requirements? Yes / No

Other comments _________________________________________________________________

__________________________________________________________________________________




Project Needs (Fitness for Purpose)

Does the supplier understand the scope of the job and the project needs, for example:

ESD requirements of this project Yes / No / NA

Pumping Yes / No / NA

Bleeding Yes / No / NA

Setting Yes / No / NA

Workability Yes / No / NA

Spraying Yes / No / NA

Early strength Yes / No / NA

Inspection and Test Plans

Does the supplier have these for:

Raw materials Yes / No

Plant Yes / No

Testing Yes / No

Concrete Yes / No

Other comments _________________________________________________________________

__________________________________________________________________________________

Does the supplier comply with Inspection and Test Plan if they have one? Yes / No / NA

Mix Design

Does the Premixed Supplier have a documented process or system? Yes / No

Comments _________________________________________________________________

__________________________________________________________________________________

Additional Information

Please detail any additional relevant information and comments.

____________________________________________________________________________________________

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