r53 concrete (for general use), mortar and grout · iso 9002 replaced by iso 9001 : 10 ....

ROADS AND MARITIME SERVICES (RMS)

QA SPECIFICATION R53

CONCRETE (FOR GENERAL USE), MORTAR AND GROUT

NOTICE

This document is a Roads and Maritime Services QA Specification. It has been developed for use with roadworks and bridgeworks contracts let by Roads and Maritime Services or by local councils in NSW. It is not suitable for any other purpose and must not be used for any other purpose or in any other context.

Copyright in this document belongs to Roads and Maritime Services.

REVISION REGISTER

Ed/Rev Number

Clause Number Description of Revision Authorised

By Date

Ed 1/Rev 0 First issued GM, RNIC (W Ho)

02.07.97

Ed 1/Rev 1 1.2 RTA 3211, HB79 and ASTM C295 added GM, RNIC 15.05.03

1.2, 4 AS/NZS 4671 replaces AS 1302, 1303 and 1304. AS/NZS 4680 replaces AS 1650

1.4.1 HOLD POINT amended, reference to QA scheme deleted

2.2 Requirements for grout added

2.3 Conformance to RTA 3211 added

2.4 Altered to reflect changed requirements of AS 2758.1

2.4.1 Changed aggregate requirements

3.3 Provisions for repair included

4 Requirements for lapped splices altered Bar grades changed to conform to new Standard

6.1 Provisions for mortar and grout added. Clause title changed

6.2 Wording of sprayed concrete altered

Annexure R53/1

Alkali aggregate reaction documentation included

Annexure R53/2

Notes 1 and 2 changed. New Note 3 included

Annexure R53/3

Frequency of concrete sampling was changed to min.2 pairs.

Ed 1/Rev 2 Fonts changed. GM, RNIC 07.08.03

Edition 2 / Revision 2 ROADS AND MARITIME SERVICES June 2013

Ed/Rev Number

Clause Number Description of Revision Authorised

By Date

Ed 2/Rev 0 Various Text revised to direct imperative style ”Superintendent” replaced by “Principal” “Shall” replaced by “must” References updated Reformatting and minor editing

GM, RNIC 31.10.05

Foreword New clause after the Table of Contents

1.2 New clause, references transferred to Annexure R53/M

1.4 ISO 9002 replaced by ISO 9001

10 Transferred to Annexure R53/B

R53/1, R53/2, R53/3, R53/4

Renumbered R53/D, R53/E, R53/L, R53/C respectively

Ed 2/Rev 1 ”Notice” RTA PO Box and Fax numbers updated GM, IC 13.03.09

2.3 “to AS 3972” deleted

7.4 “Clause 13” changed to “Clause 22”

Annex M Referenced documents updated

Ed 2/Rev 2 Annex E, Note 3

Maximum flyash content for slipformed S32 concrete deleted.

GM, IC 17.06.13

ii

GUIDE NOTES (Not Part of Contract Document)

Using Specification R53

RMS R53 is a QA specification and the use of QA specifications requires the implementation of a quality management system by the Contractor that meets the quality management system requirements specified in RMS Q. To comply with the intention of government policy as well as RMS R53, concrete works undertaken using RMS R53 require adequate surveillance and audit by the Principal.

Edition 1/Revision 0

Edition 1 Revision 0 was a new specification issued to replace clauses in several roadworks specifications and thus provide a unified concrete specification for most road construction purposes except bridgeworks and concrete pavement. RMS R53 was issued in the new style of RMS QA Specifications and in Word 6 format.

Project Managers may find the following guides useful in understanding the requirements of RMS R53 and in making project specific amendments:

SAA HB64: “Guide to Concrete Construction”

SAA HB67: “Concrete Practice on Building Sites”

Where special requirements are to be specified for the concrete used on a project the Project Manager could consider using RMS B80 instead of RMS R53 as the model specification.

Edition 1/Revision 1

The purpose of the new edition is to address the requirements of the 1998 edition of AS 2758.1: “Aggregates and Rock for Engineering Purposes - Concrete Aggregates” and to modify the HOLD POINT in Clause 1.4.1 to clarify the Authority’s intention.

The significant changes in this revision are as follows:

The HOLD POINT in Clause 1.4.1 now makes it clear that the Production Assessment Report required is the most recent available but, where Production Assessment has not been carried out or has been suspended since the most recent Production Assessment Report, test reports are required. The Principal may need to verify that the Production Assessment complies with AS 1379.

A revised edition of AS 2758.1 was issued during 1998. This edition has new clause numbering, contains modified durability requirements for concrete aggregates and new provisions for alkali- aggregate reaction (AAR). Clause 2.4 has accordingly been divided into two sub-clauses and revised as follows:

Clause 2.4.1 recognises the renumbered clauses of the Standard and the revised exposure classifications. The exposure classifications and test methods chosen represent most situations where the concrete is more than 1 km from the coast but Project Managers should review these requirements where more severe conditions apply (e.g. in near coastal areas or where soils are aggressive) and could consider relaxing the Wet Strength and Wet/Dry Strength variation requirements to those for exposure classifications A1 and A2 only for areas over 50 km from the coast. Refer to Appendix A of the Standard for details of the exposure classifications.

Clause 2.4.2 has been inserted to comply with Clause 10.2 of AS 2758.1 regarding the purchaser’s obligation to specify its requirements for dealing with ARR. The requirement for testing may seem onerous, especially in view of the time required for some of the tests, but

iii

Clause 10.2 of AS 2758.1 requires that the supplier provide appropriate documentation and therefore established suppliers should already be in a position to comply. This should certainly be true for suppliers able to meet the requirements for supplying concrete to RMS B80. It is clear that ARR is not relevant for uses such as backfill for fence posts and blinding layers and SAA HB79 makes it clear that the risk of damage due to ARR is low for any structure for which the concrete strength is 25 MPa or less. Where advantage is taken of the low risk for Strength Grades up to and including N25, the Contractor should not be permitted to use higher strength grades in these structures.

An extra sentence has been added to Note 1 in Annexure R53/E. The current edition of AS 1379 includes an increased range of slump values for Normal-class concrete and the Contractor may now be able to use Normal-class instead of Special-class for some uses.

iv

QA SPECIFICATION R53


Copyright – Roads and Maritime Services IC-QA-R53

VERSION FOR: DATE:

Edition 2 / Revision 2 ROADS AND MARITIME SERVICES June 2013

Concrete (for General Use), Mortar and Grout R53

CONTENTS

CLAUSE PAGE

FOREWORD ............................................................................................................................................... II RMS Copyright and Use of this Document ................................................................................... ii Revisions to Previous Version ....................................................................................................... ii Project Specific Changes ............................................................................................................... ii

1 GENERAL ........................................................................................................................................ 1 1.1 Scope .............................................................................................................................. 1 1.2 Structure of the Specification ......................................................................................... 1 1.3 Definitions of Terms ...................................................................................................... 2 1.4 Quality Management System ......................................................................................... 2

2 SUPPLY OF CONCRETE, MORTAR AND GROUT ............................................................................... 3 2.1 Concrete.......................................................................................................................... 3 2.2 Cement Mortar and Grout .............................................................................................. 3 2.3 Cement ............................................................................................................................ 3 2.4 Aggregates ...................................................................................................................... 3 2.5 Admixtures ..................................................................................................................... 4 2.6 Sampling and Testing ..................................................................................................... 4

3 FORMWORK .................................................................................................................................... 4 3.1 General Requirements .................................................................................................... 4 3.2 Surface Finish Requirements ......................................................................................... 5 3.3 Stripping of Formwork ................................................................................................... 5

4 STEEL REINFORCEMENT ................................................................................................................. 5

5 TRANSPORT AND DELIVERY OF CONCRETE ................................................................................... 6

6 PLACING CONCRETE, MORTAR AND GROUT .................................................................................. 6 6.1 Preparation and Inspection ............................................................................................. 6 6.2 Handling and Placing of Concrete.................................................................................. 7 6.3 Temperature and Rain .................................................................................................... 7 6.4 Finish of Unformed Surfaces ......................................................................................... 7 6.5 Prevention of Moisture Loss .......................................................................................... 8 6.6 Construction Joints ......................................................................................................... 8 6.7 Movement Joints ............................................................................................................ 8

7 CURING AND PROTECTION OF CONCRETE ...................................................................................... 8 7.1. General Requirements .................................................................................................... 8 7.2 Moist Curing................................................................................................................... 8 7.3 Curing Compounds ......................................................................................................... 8 7.4 Loads on Structures ........................................................................................................ 9

8 CONCRETE CRACKING .................................................................................................................... 9

9 TOLERANCES .................................................................................................................................. 9

ANNEXURE R53/A – (NOT USED) .......................................................................................................... 10

ANNEXURE R53/B – MEASUREMENT AND PAYMENT ............................................................................ 10

Ed 2 / Rev 2 i

R53 Concrete (for General Use), Mortar and Grout

ANNEXURE R53/C – SCHEDULE OF HOLD POINTS AND WITNESS POINTS ............................................. 10

ANNEXURE R53/D – PLANNING DOCUMENTS ........................................................................................ 11

ANNEXURE R53/E – CONCRETE PARAMETERS ...................................................................................... 12

ANNEXURES R53/F TO R53/K – (NOT USED) ......................................................................................... 13

ANNEXURE R53/L – MINIMUM FREQUENCY OF TESTING ...................................................................... 13

ANNEXURE R53/M – REFERENCED DOCUMENTS................................................................................... 14

LAST PAGE OF THIS DOCUMENT IS .......................................................................................................... 14

FOREWORD

RMS COPYRIGHT AND USE OF THIS DOCUMENT

Copyright in this document belongs to Roads and Maritime Services.

When this document forms part of a contract

This document should be read with all the documents forming the Contract.

When this document does not form part of a contract

This copy is not a controlled document. Observe the Notice that appears on the first page of the copy controlled by RMS. A full copy of the latest version of the document is available on the RMS Internet website: http://www.rms.nsw.gov.au/business-industry/partners-suppliers/specifications/index.html

REVISIONS TO PREVIOUS VERSION

This document has been revised from Specification RMS R53 Edition 2 Revision 1.

All revisions to the previous version (other than minor editorial and project specific changes) are indicated by a vertical line in the margin as shown here, except when it is a new edition and the text has been extensively rewritten.

PROJECT SPECIFIC CHANGES

Any project specific changes are indicated in the following manner:

(a) Text which is additional to the base document and which is included in the Specification is shown in bold italics e.g. Additional Text.

(b) Text which has been deleted from the base document and which is not included in the Specification is shown struck out e.g. Deleted Text.

ii Ed 2 / Rev 2

http://www.rms.nsw.gov.au/business-industry/partners-suppliers/specifications/index.html

(RMS COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)

RMS QA SPECIFICATION R53


1 GENERAL

1.1 SCOPE

This Specification sets out the requirements for the supply, placing and curing of concrete for drainage structures, footings and plinths, kerbs and gutters, safety barriers, paving for cycleways, footways, traffic islands, mowing and other edge strips, medians, driveways and behind kerbs and gutters and any other concrete work not specified elsewhere.

This Specification also includes requirements for the supply and placing of mortar for filling gaps and distributing loads between components, and grout for grout filled revetment mattresses.

When developing procedures, be guided by SAA HB 67.

This Specification covers both unreinforced concrete and concrete reinforced with steel bars, wire, fabric or fibres.

Forming and placing includes fixed formwork, slipforming, extruding and spraying.

1.2 STRUCTURE OF THE SPECIFICATION

This Specification includes a series of annexures that detail additional requirements.

1.2.1 Measurement and Payment

The method of measurement and payment is detailed in Annexure R53/B.

1.2.2 Schedules of HOLD POINTS and WITNESS POINTS

The schedules in Annexure R53/C list the HOLD POINTS and WITNESS POINTS that must be observed. Refer to Specification RMS Q for the definitions of HOLD POINTS and WITNESS POINTS.

1.2.3 Planning Documents

The PROJECT QUALITY PLAN must include each of the documents and requirements shown in Annexure R53/D and must be implemented.

1.2.4 Minimum Frequency of Testing

The Inspection and Test Plan must nominate the proposed testing frequency to verify conformity of the item, which must not be less than the frequency specified in Annexure R53/L. Where a minimum frequency is not specified, nominate an appropriate frequency. Frequency of testing must conform to the requirements of RMS Q.

Ed 2 / Rev 2 1



1.2.5 Referenced Documents

Unless specified otherwise or is specifically supplied by the Principal, the applicable issue of a referenced document, other than an RMS Specification, is the issue current at the date one week before the closing date for tenders, or where no issue is current at that date, the most recent issue.

Standards, specifications and test methods are referred to in abbreviated form (e.g. AS 1234). For convenience, the full titles are given in Annexure R53/M.

1.3 DEFINITIONS OF TERMS

The following definitions apply to terms used in this Specification:

Mortar A mixture of cement, water and sand (fine aggregate), with or without chemical admixtures with a characteristic compressive strength at 28 days of not less than 20 MPa.

Grout A mixture, similar to mortar, but more workable and possibly without any sand or fine aggregate, proportioned to produce a pourable liquid which does not readily segregate into its constituents during pouring or pumping.

Other terms are used as defined in AS 1379, AS 3600, and AS 3610.

1.4 QUALITY MANAGEMENT SYSTEM

Produce concrete by a manufacturing plant operating under a quality management system which satisfies the requirements of AS/NZS ISO 9001.

Suppliers of reinforcement materials and curing compounds must have a quality assurance system in accordance with AS/NZS ISO 9001 which covers the supply of reinforcement material or the supply of curing compounds, as appropriate.

HOLD POINT

Process Held: Initial production of each Strength Grade for the project.

Submission Details: At least 7 days prior to production, a statement signed by you verifying that the concrete, its constituent materials and curing compounds comply with specified requirements. Support the statement with the most recent Production Assessment Report or by test reports where Production Assessment has not been carried out or has been suspended since the most recent Production Assessment Report.

Release of Hold Point: The Principal will consider the submitted documents and may inspect test records prior to authorising the release of the Hold Point.

For concrete subject to production assessment, register the project with the concrete supplier and obtain production assessment information in accordance with AS 1379. For concrete subject to project assessment, produce monthly a Project Assessment Report for each strength grade, in a form similar to a Production Assessment Report.

Forward on request copies of the completed verification checklists, Production and Project Assessment Reports.

2 Ed 2 / Rev 2



2 SUPPLY OF CONCRETE, MORTAR AND GROUT

2.1 CONCRETE

Except where specified otherwise, the manufacture and supply of concrete must be in accordance with AS 1379.

Unless shown otherwise on the Drawings, the parameters for concrete must be as shown in Annexure R53/E.

The mix design of concrete containing steel fibre reinforcement, including the quantity of steel fibre reinforcement, must be in accordance with the fibre manufacturer’s recommendations.

2.2 CEMENT MORTAR AND GROUT

Cement mortar for filling gaps and distributing loads between components must be a mixture of 3 parts sand or fine aggregate to 1 part cement with sufficient water to produce a mix of a consistency suitable for the intended use.

Grout for grout filled revetment mattresses must comply with the parameters specified in Annexure R53/E.

2.3 CEMENT

Cement and fly ash must conform to the requirements of Specification RMS 3211. Cement used in mortar or grout must be Type GP or Type GB.

2.4 AGGREGATES

2.4.1 General

Aggregates used in the manufacture of concrete and mortar must comply with AS 2758.1 and must:

(a) have a maximum water absorption of 2.5% for aggregate as defined in AS 2758.1 Clause 8 7.3 except for slag aggregate which is to have a maximum limit of 6%;

(b) satisfy the fine aggregate durability requirements specified in AS 2758.1 Clause 9.2 for exposure classifications A1, A2 or and B1 as appropriate for the concrete application as defined in Appendix A of the Standard; and

(c) satisfy the Wet Strength and Wet/Dry Strength Variation requirements specified in AS 2758.1 Clause 9.3.2 for exposure classifications A1, A2 or and B1, B2 as appropriate for the concrete use as defined in Appendix A of the standard.

2.4.2 Alkali - Reactive Materials

All aggregate intended for use in concrete to be incorporated into the Works must be assessed and classified for alkali -aggregate reaction and the effects controlled in accordance with SAA HB79.

Submit documentation verifying that the aggregate complies with this requirement, including the results of petrographic examinations undertaken in accordance with ASTM C295 and the results of accelerated tests using the appropriate test method from Section B.3 of SAA HB79 Appendix B.

Ed 2 / Rev 2 3



Note that tests may take six months or more to complete and make due allowance for any testing in your program.

2.5 ADMIXTURES

Do not use air entraining admixtures, unless specified.

Do not use admixtures containing calcium chloride, calcium formate or triethanolamine.

2.6 SAMPLING AND TESTING

2.6.1 General

Project assess all special-class concrete where noted in Annexure R53/E.

2.6.2 Sprayed Concrete

Test the compaction of sprayed concrete when directed by the Principal using 75 mm diameter cores taken from the in-place sprayed concrete. Secure cores in accordance with AS 1012 Part 14 and place them immediately either in a tank of lime saturated water or in an individual plastic bag sealed to prevent water loss. Do not subject cores to temperatures in excess of either ambient temperature or 23ºC, whichever is the higher, and to a temperature less than 10ºC, until delivered to the testing laboratory.

The core specimens must be wet conditioned in accordance with AS 1012.14. Test specimens to determine mass per unit volume at age seven (7) days.

The relative compaction of a core specimen is the ratio, expressed as a percentage, of the mass per unit volume of the core specimen to the average mass per unit volume of the standard cylinders used to determine the seven (7) day compressive strength from the same Lot of concrete. Determine the mass per unit volume of both standard cylinders and cores in accordance with AS 1012.12 Method 2.

Clean and restore all core holes using a concrete having a compressive strength of not less than that of the sprayed concrete and having a maximum nominal aggregate size of 10 mm.

2.6.3 Grout

Sample grout used for grout filled mattresses by injecting the grout into a 3 metre length of mattress. Pressurise the grout to at least 1.4 MPa and, after expulsion of water ceases, sample the grout from a cut in the mattress at the end distant from the pump and mould the grout into cylinders in accordance with AS 1012.8. Test in accordance with AS 1012.9 at the frequency specified in Annexure R53/L.

3 FORMWORK

3.1 GENERAL REQUIREMENTS

The materials, design, fabrication, erection and stripping of formwork, must comply with the relevant requirements of AS 3610 and this Specification. Construct joints in formwork to prevent loss of mortar.

Before placing reinforced concrete in an earth excavation:

4 Ed 2 / Rev 2



(a) place a 50 mm thick layer of unreinforced concrete on the floor of the excavation; and

(b) erect formwork so that fresh concrete is not placed directly against the sides of the excavation,

unless otherwise shown on the Drawings or approved by the Principal.

3.2 SURFACE FINISH REQUIREMENTS

Unless otherwise stated in the Drawings or the Specification, design and construct the formwork to produce concrete with finish of the following classes as defined in AS 3610:

(a) external surfaces Class 3

(b) permanently hidden surfaces Class 4.

Project requirements for surface finish are:

(i) test panels are not required;

(ii) where tie rods will be visible in the completed structure, position them in a uniform pattern;

(iii) the minimum spacing of face steps on external surfaces are 2 m horizontally and 1 m vertically; and

(iv) colour control is not required.

3.3 STRIPPING OF FORMWORK

Do not strip formwork until the minimum times specified in AS 3610 Table 5.4.1 have elapsed from the time of completion of the placing of the concrete and, in addition, the minimum time must not be less than:

(a) 2 days for vertical forms on external surfaces; and

(b) 1 day for vertical forms on permanently hidden surfaces.

Carry out any necessary repairs to formed surfaces immediately after stripping the forms, using a method accepted by the Principal.

4 STEEL REINFORCEMENT Steel reinforcement must comply with AS/NZS 4671 or AS 1311 as appropriate.

Galvanizing, where specified, must be in accordance with AS/NZS 4680.

Steel fibre reinforcement must be of a type recommended by the fibre manufacturer for the intended use.

In areas of steel congestion, do not splice at locations other than those shown on the Drawings.

Ed 2 / Rev 2 5



Unless shown otherwise on the Drawings, the length of lapped splices must be as follows:

(a) Deformed bar, grade 500N: 35 bar diameters

(b) Plain bars and hard-drawn wire: 50 bar diameters

(c) Reinforcing fabric: the two outermost transverse wires of one sheet of fabric must overlap the two outermost transverse wires of the sheet being lapped

(d) 7-wire prestressing strand: 90 strand diameters.

Welding must comply with AS 1554.3.

The minimum cover of any steel bar, wire or fabric reinforcement to the nearest concrete surface is 50 mm unless specified otherwise on the Drawings or in the Specification.

Where a sheet of fabric has been cut so that the outermost wire parallel to an edge of the concrete is more than 20 mm from the end of the transverse wires or the wires are not parallel to the edge, tie a D500N12 bar to the edge of the fabric.

Support reinforcement using either concrete or plastic chairs. Do not use wire chairs with or without plastic tips, bricks or pieces of timber or coarse aggregate to support reinforcement.

5 TRANSPORT AND DELIVERY OF CONCRETE Transport concrete to the site in transit mixers or agitator trucks constructed, maintained and operated to comply with the requirements of AS 1379.

On site, only dispose of excess concrete and wash the drum and other equipment in bunded areas designed, constructed and maintained to ensure that no contaminated water is released.

6 PLACING CONCRETE, MORTAR AND GROUT

6.1 PREPARATION AND INSPECTION

WITNESS POINT

Process Witnessed: Placing of concrete, mortar or grout

Submission Details: Notify the Principal, not less than 24 hours and not more than 3 clear working days prior to the intended time of commencing to place concrete, mortar or grout, when fixing of the formwork and reinforcement in position (if applicable) will be completed and when concrete, mortar or grout will be placed.

6 Ed 2 / Rev 2



HOLD POINT (Where nominated in the relevant specification)

Process Held: Placing of concrete.

Submission Details: As required for the preceding Witness Point.

Release of Hold Point: The Principal may inspect the completed reinforcement and formwork prior to authorising the release of the Hold Point.

Before commencing placement of concrete, remove all dirt, and other foreign matter from the forms.

Gaps which are to be filled with mortar must be free of all dirt and other foreign matter.

Prepare revetment mattresses, which are to be filled with grout, in accordance with the manufacturer’s recommendations.

6.2 HANDLING AND PLACING OF CONCRETE

Place and finish concrete so as to:

(a) limit segregation or loss of materials;

(b) limit premature stiffening;

(c) produce a dense homogeneous product which is monolithic between joints and edges;

(d) expel entrapped air and closely surround all reinforcement and embedments; and

(e) provide the specified thickness and surface finish.

Place sprayed concrete to achieve the minimum relative compaction specified in Annexure R53/E.

6.3 TEMPERATURE AND RAIN

Do not place concrete either during rain or when the air temperature in the shade is below 5°C or above 38°C.

6.4 FINISH OF UNFORMED SURFACES

Finish unformed concrete surfaces:

(a) to achieve the specified:

(i) dimensions and grade;

(ii) cover from the surface to reinforcement and embedments;

(iii) texture of the surface; and

(b) to avoid plastic or drying shrinkage cracks.

Unless otherwise specified or shown on the Drawings, do not finish unformed surfaces with a wood float.

Ed 2 / Rev 2 7



6.5 PREVENTION OF MOISTURE LOSS

Restrict the evaporation of water from the concrete surface and prevent plastic shrinkage cracking.

Where an evaporation retarder is used to restrict the evaporation of water, apply by using a fine uniform spray. Do not to incorporate the evaporation retarder into the surface during any subsequent finishing operations.

Regularly inspect the concrete to monitor the effectiveness of the procedures used to prevent moisture loss.

6.6 CONSTRUCTION JOINTS

Prior to placing adjoining concrete, roughen the surfaces of construction joints to expose coarse aggregate.

Wash clean the roughened surfaces and projecting reinforcement, and remove all excess water and loose material.

6.7 MOVEMENT JOINTS

Construct movement joints as shown on the Drawings and as provided in the relevant Specifications.

7 CURING AND PROTECTION OF CONCRETE

7.1. GENERAL REQUIREMENTS

After initial set has taken place, cure the concrete for at least seven (7) days.

Cure by moist curing or by using curing compounds.

Effectively protect freshly finished surfaces from rain or injury from other causes until hard set has occurred.

When formwork is removed before the required seven (7) day curing period has elapsed, continue curing the exposed surfaces for the remainder of the period.

7.2 MOIST CURING

Immediately after the concrete has taken its initial set, spray all exposed surfaces with water and keep the concrete continually wet for at least seven (7) days. The water used must be free from ingredients harmful to concrete.

7.3 CURING COMPOUNDS

The compound must be:

(a) a hydrocarbon resin compound complying with AS 3799 Type 1-D; or

(b) a wax emulsion complying with AS 3799 Type 1.

8 Ed 2 / Rev 2



Apply the curing compound at the rate specified by the manufacturer, or at the rate of 0.20 litre/m2, whichever is the greater. Apply the curing compound to all exposed surfaces to give a uniform cover. Apply two coats when necessary to ensure complete and uniform coverage. The time between the first and second coat must be in accordance with the manufacturer’s recommendation, or on the basis of a trial application.

Apply curing compound to unformed surfaces immediately after the surface is firm and free of bleed water, and to formed surfaces within 30 minutes of removal of formwork. After stripping, and before applying the curing compound, moisten formed surfaces by light spraying until the surface will not readily absorb more water.

Care must be taken to ensure that the curing compound is thoroughly mixed during application. Where a sprayer is used, it shall incorporate a device for continuous agitation and mixing of the compound in its container during spraying.

Check the application rate by calculating the application rate from the total measured surface area covered and by another method selected to indicate uniformity of cover. For spray application to horizontal surfaces uniformity may be demonstrated by calculating the amount of curing compound falling on felt mats, each approximately 0.25 m2 in area, placed on the concrete surface. On removal of the felt mats, apply curing compound to the area they covered.

Keep equipment and materials for curing on hand at all times during concrete placing and for a minimum of 7 days thereafter.

Take care during application to ensure that curing compound is not deposited on adjacent surfaces and does not drift away from the concrete.

Maintain the curing membrane intact until at least seven (7) days have elapsed after placing the concrete. During this period, repair any damage to the curing membrane by further application of curing compound to the affected areas within 30 minutes of the damage occurring.

7.4 LOADS ON STRUCTURES

In addition to the requirements of Specification RMS G2 Clause 23, no loads, including loads from backfilling, must be placed on a concrete structure until testing shows that the concrete has reached sufficient strength to carry the loads without damage.

8 CONCRETE CRACKING At the completion of the curing period, the concrete must have no cracks of width greater than 0.05 mm, measured at the concrete surface. Where such cracks exist, identify them as nonconformities.

9 TOLERANCES Tolerances for surfaces constructed using fixed forms must comply with the requirements of AS 3610 unless shown otherwise on the Drawings or required by the relevant Specifications.

Tolerances for unformed exposed surfaces and surfaces constructed by slipforming or extrusion must be as shown on the Drawings or as required by the relevant Specifications.

Ed 2 / Rev 2 9



ANNEXURE R53/A – (NOT USED)

ANNEXURE R53/B – MEASUREMENT AND PAYMENT Payment will be made for all costs associated with completing the work detailed in this Specification in accordance with the Pay Items in the relevant Specifications.

Unless specified otherwise, where steel reinforcement is listed as a separate pay item, only one sheet of mesh within the area or one bar within length of each lap or splice will be measured for payment.

Where no specific pay items are provided for a particular item of work, the costs associated with that item of work are deemed to be included in the rates and prices generally for the Work Under the Contract.

Unless specified otherwise, a lump sum price for any of the items will not be accepted.

ANNEXURE R53/C – SCHEDULES OF HOLD POINTS AND WITNESS POINTS

Refer to Clause 1.2.2.

Clause Type Description

1.4.1 Hold Initial production of each concrete strength grade

6.1 Witness Placing concrete

6.1 Hold Inspection of formwork and reinforcement before placing concrete (where nominated in relevant specification)

10 Ed 2 / Rev 2



ANNEXURE R53/D – PLANNING DOCUMENTS Refer to Clause 1.2.3.

The following documents are a summary of documents that must be included in the PROJECT QUALITY PLAN. The requirements of this Specification and others included in the Contract must be reviewed to determine additional documentation requirements.

Clause Description

2.4 Details of testing undertaken and planned to ensure that aggregates do not react with alkalis in the concrete to the extent that may result in excessive expansion.

3, 6 Details of the equipment and methods to be used for placing and finishing concrete, mortar and grout.

6 Actions to be taken to avoid placing or finishing concrete during rain and to protect plastic concrete if rain does occur.

6 Method of ensuring and verifying that concrete is not placed beyond specified air temperatures.

7 Details of the equipment and methods to be used for curing and protecting concrete.

8 Descriptions of the measures which will be taken to restrict the evaporation of water from the concrete surface and to prevent the incidence of plastic shrinkage cracking.

Ed 2 / Rev 2 11



ANNEXURE R53/E – CONCRETE PARAMETERS

Description Strength Grade

Slump (mm)

Max Nom Aggregate Size (mm)

Project Assessment Required?

Other

Concrete safety barrier systems

• Slipformed S32 Note 1 20 Yes Note 3

• Hand placed N32 80 20 No -

Kerb/gutter alongside or on top of flexible pavement or on top of concrete base

• Extruded or slipformed S25 Note 1 10 No -


Kerb/gutter alongside concrete base

• Tied, slipformed S32 Note 1 20 Yes -

• Tied, hand placed N32 80 20 Yes -

• Not tied Same as alongside flexible pavement

Footways, traffic islands, edge strips, medians, cycleways, driveways, and behind kerb and gutter

• Unreinforced N20 80 20 No -

• Reinforced N25 80 20 No -

Open drains

• Sprayed S25 Note 1 10 No Note 2


Backfill for fence posts, and unreinforced concrete on earth floors of excavations

N20 80 20 No -

Drainage structures N25 80 20 No -

Grout for grout-filled revetment mattresses S20 Note 1 5 Yes -

Signpost footings and plinths for lighting columns, telephone pillars and control cabinets

N20 80 20 No -

Notes: 1 Design mixes for slipformed, extruded and sprayed concrete and pumped grout so that the finished product

is at the specified line and level. Normal-class concrete of the same strength may be used where this meets all requirements except where Note 3 applies.

2 Sprayed concrete is to have a minimum cement content of 380 kg/m3 as discharged from the nozzle. The minimum relative compaction of sprayed concrete, tested in accordance with Clause 2.6.1, must be 95.0%.

3 For insitu placement including slipforming, the minimum Portland cement content is 250 kg/m3.

12 Ed 2 / Rev 2



ANNEXURES R53/F TO R53/K – (NOT USED)

ANNEXURE R53/L – MINIMUM FREQUENCY OF TESTING

Clause Characteristic Analysed Test Method Minimum Frequency of Testing

Production Assessment

1.4 As specified in AS 1379

Project Assessment

1.4, 2.6.1 Concrete slump AS 1012.3 For each homogeneously manufactured grade per day, one on each of the first three batches at the start of the day and after a non conforming batch, then one per four batches

1.4, 2.6.1 Concrete compressive strength

AS 1012.9 Sampling, testing and assessment for compliance shall be accordance with Appendix B of AS 1379.

1.4, 2.6.2 Compaction of sprayed concrete

AS 1012.12 Method 2

One pair of test specimens per 50 m3 of concrete, minimum 2 pairs per pour, when required by Principal

2.6.3 Grout compressive strength

AS 1012.9 One pair of test specimens per 20 m3 of grout, minimum 2 pair per pour.

Ed 2 / Rev 2 13



ANNEXURE R53/M – REFERENCED DOCUMENTS Refer to Clause 1.2.5.

RMS Specifications

RMS G2 General Requirements

RMS Q Quality Management System

RMS 3211 Cements, Binders and Fillers

Australian Standards

AS 1012 Methods of testing concrete

AS 1311 Steel tendons for prestressed concrete – 7-wire stress-relieved steel strand for tendons in prestressed concrete

AS 1379 Specification and supply of concrete

AS 1554.3 Structural steel welding – Welding of reinforcing steel

AS 2758.1 Aggregates and rock for engineering purposes – Concrete aggregates

AS 3600 Concrete structures

AS 3610 Formwork for concrete

AS 3799 Liquid membrane-forming curing compounds for concrete

AS/NZS 4671 Steel reinforcing materials

AS/NZS 4680 Hot dipped galvanized (zinc) coatings on fabricated ferrous articles

AS/NZS ISO 9001 Quality management systems – Requirements

Standards Australia Publications

SAA HB67 Concrete Practice on Building Sites

SAA HB79 Alkali Aggregate Reaction. Guidelines on Minimising the Risk of Damage to Structures in Australia

ASTM Standards

C295 Standard Practice for Petrographic Examination of Aggregates for Concrete

14 Ed 2 / Rev 2