Cairo Alexandria Trade Logistics

Development Project

Structure
Specifications

Rev.00, APRIL 2025

 TABLE OF CONTENTS

STRUCTURE

SECTION DESCRIPTION
033000 Cast In Place Concrete.

071613 Polymer Modified Cement Waterproofing.

312000 Earth Moving

Cairo Alexandria Trade Logistics Development Project

april, 2025
 SECTION 033000

CAST-IN-PLACE CONCRETE

PART 1 – GENERAL

1.1 RELATED DOCUMENTS

A. All tests listed in this document according to ASTM Standards are also accepted to
be conducted using equivalent BS/BS EN Standards or Egyptian Code of Practice ECP
203. Frequency of testing materials for quality assurance shall comply with ECP 203 as
minimum requirements.

B. Drawings and general provisions of the Contract, including Conditions of Contract and
Division 1 Specification Sections, apply to this Section.

1.2 SUMMARY

A. This Section specifies cast-in-place concrete, including formwork, reinforcement, concrete

materials, mix design, placement procedures, and finishes for the following:

1. Foundations and piles

2. Retaining walls
3. Slab-on-grade
4. Suspended slabs
5. Walls and cores
6. Building frame members
7. Columns
8. Stairs
9. All reinforced and plain concrete elements.

1.3 DEFINITIONS

A. Cementitious Materials: Portland cement alone or in combination with one or more of

blended hydraulic cement, fly ash and other pozzolans, ground granulated blast-furnace
slag, and silica fume; subject to compliance with requirements of ASTM C150, BS EN
197- 1/2011 or Egyptian Standards 4756-1/2013.

1.4 SUBMITTALS

A. Product Data: For each type of manufactured material and product indicated.

B. Design Mixes: For each concrete mix. Include alternate mix designs when
characteristics of materials, project conditions, weather, test results, or other
circumstances warrant adjustments.

C. Steel Reinforcement Shop Drawings: Details of fabrication, bending, and placement,

prepared according to Egyptian code of practice, "Details and Detailing of Concrete
Reinforcement." Include material, grade, bar schedules, stirrup spacing, and bent bar
diagrams, arrangement, and supports of concrete reinforcement. Include special
reinforcement required for openings through concrete structures.
D. Consultant Formwork Shop Drawings: Prepared by or under the supervision of a qualified
Consultant engineer detailing fabrication, assembly, and support of formwork. Design and

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 1
 engineering of formwork are Contractor's responsibility.

1. Shoring and Reshoring: Indicate proposed schedule and sequence of stripping

formwork, shoring removal, and installing and removing reshoring.

E. Construction joint layout: Indicate proposed construction joints required to construct

the structure.

F. Welding Certificates: Copies of certificates for welding procedures and personnel.

G. Qualification Data: For firms and persons specified in "Quality Assurance" Article to
demonstrate their capabilities and experience. Include lists of completed projects with
project names and addresses, names and addresses of architects/engineers and owners,
and any other information required by Engineer.

H. Material Test Reports: From a qualified testing agency indicating and interpreting test
results for compliance of the following with requirements indicated, based on
comprehensive testing of current materials:

I. Material Certificates: Signed by manufacturers certifying that each of the following items
complies with requirements:

1. Cementitious materials and aggregates.

2. Form materials and form-release agents.
3. Steel reinforcement and reinforcement accessories.
4. Fiber reinforcement.
5. Admixtures.
6. Waterstops.
7. Curing materials.
8. Floor and slab treatments.
9. Bonding agents.
10. Adhesives.
11. Vapor retarders.
12. Epoxy joint filler.
13. Joint-filler strips.
14. Repair materials.

1.5 QUALITY ASSURANCE

A. Consultant Engineer Qualifications: A Consultant engineer who is legally registered and

qualified to practice in jurisdiction where Project is located and who is experienced
in providing engineering services of the kind indicated. Engineering services are defined
as those performed for formwork and shoring and reshoring installations that are similar
to those indicated for this Project in material, design, and extent.

B. Concrete Manufacturer Qualifications: A firm experienced in manufacturing ready-mixed

concrete products complying with ASTM C 94/C94M requirements for production
facilities and equipment.

C. Testing Agency Qualifications: An independent testing agency, acceptable to Engineer and

qualified according to ASTM C 1077 and ASTM E 329 to conduct the testing indicated, as
documented according to ASTM E 548.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 2
 D. Source Limitations: Obtain each type or class of cementitious material of the same brand
from the same manufacturer's plant, each aggregate from one source, and each admixture
from the same manufacturer.

E. Publications and codes: Comply with the provisions of the following:

1. ECP-203 (2017), “Egyptian code for design and construction of concrete

structures”.
2. ACI 301, "Specification for Structural Concrete."
3. ACI 117, "Specifications for Tolerances for Concrete Construction and Materials."

F. Mockups: Before casting concrete that is exposed to view on surfaces of the completed
structure or building, cast a mockup for each exposed element, including slabs if applicable,
to demonstrate typical joints, surface finish, texture, color, tolerances, quality of materials
and standard of workmanship in the completed Work.

1. Build mockups in the location and of the size indicated or, if not indicated, as directed
by Engineer.
2. Notify Engineer seven days in advance of dates and times when mockups will be
constructed.
3. In presence of Engineer, damage parts of exposed surfaces as selected by Engineer,
and demonstrate materials and techniques proposed for repairs to match adjacent
undamaged surfaces
4. Obtain Engineer's approval of mockups before starting cast-in-place concrete
elements exposed to view.
5. If Engineer determines that any mockup does not meet requirements, demolish and
remove from the site and cast another until the mockup is approved.
6. Maintain mockups during construction in an undisturbed condition as a standard for
judging the completed Work.
7. Demolish and remove mockups when directed.
8. Before submitting design mixes, review concrete mix design and examine
procedures for ensuring quality of concrete materials. Require representatives of
each entity directly concerned with cast-in-place concrete to attend, including the
following:

a. Contractor's superintendent.
b. Independent testing agency responsible for concrete design mixes.
c. Ready-mix concrete producer.
d. Concrete subcontractor.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 3
 1.6 DELIVERY, STORAGE, AND HANDLING

A. Deliver, store, and handle steel reinforcement to prevent bending and damage.

B. Waterstops: Store waterstops sunder cover to protect from moisture, sunlight, dirt, oil,
and other contaminants.

PART 2 - PRODUCTS

2.1 FORM-FACING MATERIALS

A. Smooth-Formed Finished Concrete: Form-facing panels that will provide continuous, true,
and smooth concrete surfaces. Furnish in largest practicable sizes to minimize number
of joints.

1. Plywood, metal, or other approved panel materials.

2. Exterior-grade plywood panels, suitable for concrete forms, complying
with DOC PS 1, and as follows:

a. Medium-density overlay, Class 1, or better, mill-release agent treated and

edge sealed.

B. Rough-Formed Finished Concrete: Plywood, lumber, metal, or another approved material.

Provide lumber dressed on at least two edges and one side for tight fit.

C. Forms for Cylindrical Columns, Pedestals, and Supports: Metal, glass-fiber-reinforced

plastic, paper, or fiber tubes that will produce surfaces with gradual or abrupt irregularities
not exceeding specified formwork surface class. Provide units with sufficient wall thickness
to resist plastic concrete loads without detrimental deformation.

D. Pan-Type Forms: Glass-fiber-reinforced plastic or formed steel, stiffened to resist plastic

concrete loads without detrimental deformation.

E. Void Forms: Biodegradable paper surface, treated for moisture resistance, structurally
sufficient to support weight of plastic concrete and other superimposed loads.

F. Chamfer Strips: Wood, metal, PVC, or rubber strips, 20 by 20 mm, unless otherwise
indicated.

G. Form-Release Agent: Commercially formulated form-release agent that will not bond with,
stain, or adversely affect concrete surfaces and will not impair subsequent treatments
of concrete surfaces.

1. Formulate form-release agent with rust inhibitor for steel form-facing materials.

H. Form Ties: Factory-fabricated, removable or snap-off metal or glass-fiber-reinforced plastic

form ties designed to resist lateral pressure of fresh concrete on forms and to prevent
spalling of concrete on removal.

1. Furnish units that will leave no corrodible metal closer than 25 mm to the plane of
the exposed concrete surface.
2. Furnish ties that, when removed, will leave holes not larger than 25 mm in
diameter in concrete surface.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 4
 3. Furnish ties with integral water-barrier plates to walls indicated to receive
damp proofing or waterproofing.

2.2 STEEL REINFORCEMENT

A. Reinforcing Bars: Reinforced bars shall be deformed of grade B500DWR as per Egyptian
Standard Specifications 262-2015. Submit the following to demonstrate compliance with
the specified Standards:

1. Results of tensile tests.

2. 2% proof stress for bars and for steel wires.
3. Yield stress.
4. Percentage elongation and gauge length.
5. Cold bent test and rebend test.
6. Size of effective cross-section.

B. Deformed-Steel Welded Wire Fabric: ASTM A 497/A 497M, flat sheet.

C. Plain-steel Wire: ASTM A82/A82M

D. One test on chemical analysis per each 50 tons from consignments delivered to Site.

E. Reinforcement shall be accurately bent, cut or formed to the dimensions and configuration
shown on Drawings and within the tolerances specified in Egyptian code of practice.
Reinforcement shall be bent cold using pin sizes in accordance with Egyptian code of
practice. Bars may be preheated only if prior approval has been requested and received.
Reinforcement shall not be rebent or straightened without prior approval.

1. Reinforcement having a reduced section, kinks, visible transverse cracks at bends,

or otherwise damaged in any way shall not be used. Galvanized steel shall not be
used for reinforcement.
2. Reinforcement shall not be welded unless specifically shown on Drawings or
permitted as an exception and then only after approval of the welding method
appropriate to the grade of steel and the type of welding rod to be used

F. Only new reinforcing bars shall be furnished. On receipt and at time of installation, steel
shall be free of loose rust, loose mill scale and any deleterious amounts of salts and coatings
that reduce bond.

2.3 REINFORCEMENT ACCESSORIES

A. Bar Supports: Bolsters, chairs, spacers, and other devices for spacing, supporting, and
fastening reinforcing bars and welded wire fabric in place. Manufacture bar supports
according to CRSI's "Manual of Standard Practice" from steel wire, plastic, or precast
concrete or fiber-reinforced concrete of greater compressive strength than concrete, and
as follows:

1. For concrete surfaces exposed to view where legs of wire bar supports contact
forms, use CRSI Class 1 plastic-protected or CRSI Class 2 stainless-steel bar
supports.
2. Joint Dowel Bars: Plain-steel bars, Grade B240D-P as per ECP-203. Cut bars true
to length with ends square and free of burrs.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 5
 B. Mechanical Splices (Couplers) of deformed high yield steel bars are to consist of two
seamless steel sleeves and interconnecting high tensile steel stud with plastic protection
caps for threaded section of sleeve. To be tested and the test to exceed 135% of the specified
yield strength of the bars.

2.4 CONCRETE MATERIALS

A. Portland Cement: Cement shall be low alkali with chemical composition in accordance
with ASTM C 150/C150M type I or Type CEM I 42.5N to BS EN 197-1 standard,
gray and white color, of same type, brand and source for the entire project unless otherwise
approved by the Engineer. Manufacturer’s test certification shall be supplied for each
delivery of cement and shall confirm that the cement complies with the above requirements
and shall be submitted by the Contractor not later than the day of delivery of the cement.
The Engineer shall have the right to call for tests, the cost of which is to be borne by the
Contractor, on each delivery of cement to confirm that the cement meets the following
requirements.

1. Ordinary Portland cement (OPC) conforming to ASTM C 150/C150M, Type I or

Type CEM I 42.5N to BS EN 197-1 standard. Cement meeting the requirements
of rapid hardening Portland cement shall not be used and the heat of hydration
shall not exceed 325 kj/kg when tested in accordance with ASTM C186.
2. Sampling shall be carried out in accordance with EN 196: Part 7.
3. Test cement for fineness by air permeability apparatus in accordance with ASTM
C 204 to meet the requirements of ASTM C 150/C150M.
4. Test cement for soundness, Autoclave expansion in accordance with ASTM
C151/C151M.

B. Silica Fume: Silica fume (SF) used as a cement replacement shall be in accordance with
Type U, specified in ASTM C1240. There shall be a 5% to 10% percent replacement of the
cementitious content. The silica fume shall be obtained from an approved supplier.

1. The approved supplier shall provide documentation to establish the following:

a. That the silica fume complies with ASTM C1240.

b. The silica fume results from the production of silicon or ferro-silicon
alloys containing at least 85 percent silicon.
c. That source of supply shall remain the same for the construction period of
the project.
d. That the supply shall be adequate to meet the anticipated peak requirement.
e. Chemical analyses to give the percentages of the following materials:

1) Si O2 C
2) Ca O Fe2 O3
3) Al2 O3 Na2 O
4) K2 O Mg O
5) SO3
f. Loss on ignition.
g. Percentage of particles greater than 44 mm.
h. Specific surface area and method of test, together with corresponding
particle size.

2. Delivery of silica fume to the concrete batching plant shall be in dry powder

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 6
 form, with a bulk density between 400 and 720 kg/cu. m.
3. Manufacturer's test certification shall be supplied for each delivery of silica fume
and shall confirm that the silica fume complies with the above requirements and
shall be submitted by the Contractor no later than the day of delivery of the silica
fume.
4. The Engineer shall have the right to call for tests, the cost of which are to be
borne by the Contractor, on each delivery of silica fume, if necessary to establish
or confirm that the silica fume meets the above requirements.
5. It should be made clear that structures with micro silica require rigorous curing to
diminish shrinkage and thermal stresses as concrete hardens. To reduce plastic
shrinkages protect fresh concrete from early moisture loss with fogging.

C. Supplementary Cementing materials: Blending of fly ash or slag with Portland cement is
accomplished at mixing plant. Fly ash, slag, or Pozzolanic materials may slow rate of
concrete strengthening and affect color uniformity.

1. Fly ash : ASTM C618, class C or F

2. Ground Granulated Blast-Furnace slag: ASTM C9898, Grade 100.

D. Normal-Weight Aggregates: Aggregates shall be from approved sources and shall conform
to the requirements of Egyptian Standards 1109 or ASTM C 33/C33M or BS EN 12620,
from the same source for entire project, uniformly graded. Petrographic analyses shall be
made in accordance with ASTM C 295. Aggregates for exposed concrete shall not contain
substances that cause spalling. Only aggregates not susceptible to alkali aggregate reaction
shall be used. The Contractor shall supply samples of the materials for approval by the
Engineer and each aggregate source shall be subject to monitoring by the Engineer.

1. Coarse Aggregate: Coarse aggregate size shall be 20 mm nominal and those

retained on a 5mm sieve and shall consist of crushed or uncrushed gravel or crushed
stone and shall be selected, recrushed, finish screened and washed with water
meeting the requirements of Paragraph 2.4.E as necessary to comply with the
following:

Frequency of Test Description Standard Limit

Tests
Initial Los Angeles Abrasion Loss ASTM C 131 20% maximum
(Grading A or B)
Initial Ratio of Los Angeles Abrasion ASTM C 131 0.25% maximum
Loss at 100 & 500 Revolutions Note 6
(100/500 Revolutions Value)
1 per day Clay Lumps and Friable Particles ASTM C 142 1.0% maximum
1 per day Material Finer than 75 Microns ASTM C 117 2.0% maximum
1 per 7 days Water Absorption ASTM C 127 2.0% maximum
1 per month Chlorides as Cl BS EN 1744-5 0.04% maximum
1 per month Sulfates as SO3 BS EN 1744-1 0.4% maximum
1 per 30 days Magnesium Sulfate Soundness ASTM C 88/C 18.0% maximum
Loss (5 cycles) 88M
1 per 3 days Flakiness Index BS EN 933-1 25% maximum
1 per 3 days Elongation Index BS 812 25% maximum
1 per 7 days Specific gravity Minimum 2.6

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 7
 1 per each Moisture Content
batch
1 per 30 day Coal and lignite ASTM Maximum 0.5 %
C123/C123M
1 in 3 days Sieve analysis ASTM C136 As per ASTM C33
requirement
 Additionally, limits specified in Paragraph 2.12.I for the total salt
content of concrete shall not be exceeded.

2. Fine Aggregate: Fine aggregate, those passing a 5mm sieve, shall consist of crushed
gravel, crushed stone or natural sand with rounded or surrounded particles and shall
be washed as necessary to comply with the following:

Frequency of Test Description Standard Limit

Tests
1 per day Clay Lumps and ASTM C 142 3.0% maximum
Friable Particles
1 per day Material Finer than ASTM C 117 maximum 3.0% for
75 Microns natural sand and 5%
for crushed sand with
no plastic fines
1 per 7-days Water Absorption ASTM C 128 2.0% maximum
1 per 3-days Chlorides as Cl BS EN 1744-5 0.06% maximum
1 per 3-days Sulfates as SO3 BS EN 1744-1 0.40% maximum
1 per 7-days Organic Impurities ASTM C 40 Lighter than Standard
1 per day Coal and lignite ASTM C123/C123M Maximum 0.5 %
1 per day Sand equivalent ASTM D2419 Minimum 75 %
1 per 3-days Sieve Analysis ASTM C136 As per ASTM C33
requirement

 Additionally, limits specified in Paragraph 2.12.I for the total salt

content of concrete shall not be exceeded.

3. Certification: Obtain from each proposed source of supply Test Certification to

confirm that the aggregates comply with the above requirements. The following
information shall be provided:

A. Quarry location.
B. Aggregate type.
C. Petrographic analysis report.
D. Grading curve.
E. Shape and surface texture.
F. Flakiness index.
G. 10 percent fines value.
H. Impact test.
I. Shell content.
J. Chloride and sulfate content.
K. Relative density.
L. Water absorption value and moisture content.
M. Silt, clay, and dust content.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 8
 N. Results of reactive silica tests.
O. Organic impurities (fine aggregate only).
P. Sand equivalent

4. Testing:

A. When a source of supply for each aggregate type had been established,
samples of materials delivered to Project site shall be taken for testing in
accordance with BS 812 or ASTM standard as follows:

1) Tests for clay, silt and dust, and sieve analysis shall be carried out
for every 100 tons of fine aggregate and every 100 tons of coarse
aggregate.
2) Chemical analyses shall be carried out on every 200 tons of
aggregate.

B. The Engineer shall have the right to call for additional samples at any time
for testing of aggregates delivered to the Project site or of aggregates at the
source of supply in order to confirm that the aggregates meet the above
requirements.

1. Transportation: During transportation to the Project site, all aggregates shall be

protected from wind-borne contaminants. If these contaminants are present at time
of delivery to the Project site, then the aggregates shall be washed with water
meeting the requirement of Paragraph 2.4.E. Transport vehicles shall be cleaned
of possible contamination due to previous use.
2. Storage: Aggregates shall be stored (under shade) on hard concrete floors or other
approved materials having sufficient slope to ensure adequate drainage of aggregate
before being used for concrete and each size and type shall be stored in separate
heaps without intermixing. Storage shall prevent contamination of the aggregates by
foreign material including windblown dust. Fine and coarse aggregates shall be
separated by permanent substantial partitions. Methods of storing, shading and
cooling aggregates shall be approved by the Engineer.

C. Water: Water used for mixing concrete, ice production, washing and cooling
aggregates, and curing concrete shall be potable water, free from impurities,
oil, acid, salts, alkali, organic matter, and other potentially deleterious
substances complying with ASTM C1602/C1602M and ECP 203
requirements when tested in accordance with ASTM D 512 and ASTM D
516. The chloride content shall not exceed 500ppm.

1. Once a source of satisfactory supply has been established, further tests shall be made
daily with a portable electrical conductivity probe calibrated against the satisfactory
supply. If the conductivity exceeds that of the satisfactory supply, then further
chemical tests shall be performed.
2. The limits specified in Paragraph 2.12.I for the total salt content of the concrete shall
not be exceeded.

2.5 ADMIXTURES

A. General: Admixtures certified by manufacturer to contain no more than 0.1 percent water-
soluble chloride ions by mass of cementitious material and to be compatible with
other admixtures and cementitious materials. Do not use admixtures containing calcium

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 9
 chloride.

B. Air-Entraining Admixture: No air entraining agent shall be used.

C. Water-Reducing Admixture (Plasticizer): ASTM C 494/C 494M, Type A.

D. High-Range, Water-Reducing Admixture (Superplasticizer): ASTM C 494/C 494M,

Type F.

E. Water-Reducing and Accelerating Admixture: ASTM C 494/C 494M, Type E.

F. Water-Reducing and Retarding Admixture: ASTM C 494/C 494M, Type D.

G. Third Generation admixtures, Polycarboxylate Ether, shall be used in concrete containing

silica fume or if self-compacting concrete is required.

2.6 WATERSTOPS

A. Flexible Rubber Waterstops: CE CRD-C 513, for embedding in concrete to prevent passage
of fluids through joints. Factory fabricate corners, intersections, and directional changes.

1. Profile: Flat, dumbbell with center bulb.

B. Self-Expanding Strip Waterstops: Manufactured rectangular or trapezoidal strip, sodium

bentonite or other hydrophylic material for adhesive bonding to concrete.

2.7 VAPOR RETARDERS, CURING COMPONDS AND FINISH

A. Vapor Retarder: ASTM E 1745, Class C, of one of the following materials; or polyethylene
sheet, ASTM D 4397, not less than 0.25 mm thick:

1. Nonwoven, polyester-reinforced, polyethylene coated sheet; 0.25 mm thick.

2. Three-ply, nylon- or polyester-cord-reinforced, laminated, high-density
polyethylene sheet; 0.18 mm thick.

B. Sand Cushion: Clean, manufactured or natural sand.

C. Absorptive Cover: Burlap cloth made from jute or kenaf weighing approximately 0.29
kg/sq. m and complying with AASHTO M182, Class 2.

D. Moisture-Retaining Cover (Impervious Sheeting): One of the following, complying with

ASTM C 171:

1. Waterproof paper.
2. Polyethylene film.
3. Polyethylene-coated burlap.

E. Curing Compound: Curing Compound shall be a non-degradable Pliolite Resin in

accordance with ASTM C 309, Type I, Class B. It shall in addition to curing, act as both a
sealer and primer coat for most subsequent coatings. The Contractor shall obtain
confirmation from the supplier of the curing compound that it is compatible with the final
applied finishes and meets the above requirements.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 10
 F. Evaporation Control: Monomolecular film-forming compound applied to exposed concrete
slab surfaces for temporary protection from rapid moisture loss.

G. Underlayment Compound: Free-flowing, self-leveling, pumpable, cement-based compound

for applications from 25 mm thick to feathered edges. The underlay shall be applied in
passes not thicker than 6 mm at any interval.

H. Colored Wear-Resistant Finish: Packaged dry combination of materials consisting of BS

EN 197-1 Type CEM III/A 42.5Ncement, graded aggregate, coloring pigments, and
plasticizing admixture. Use coloring pigments that are finely ground nonfading mineral
oxides interground with cement. Color shall be as selected by the Engineer from
manufacturers' standards, unless otherwise indicated.

2.8 FLOOR AND SLAB TREATMENTS

A. Slip-Resistive Aggregate Finish: Factory-graded, packaged, rustproof, nonglazing, abrasive

aggregate of fused aluminum-oxide granules or crushed emery with emery aggregate
containing not less than 50 percent aluminum oxide and not less than 25 percent ferric
oxide; unaffected by freezing, moisture, and cleaning materials.

B. Unpigmented Mineral Dry-Shake Floor Hardener: Factory-packaged dry combination of

BS EN 197-1 Type CEM III/A 42.5N cement, graded quartz aggregate, and plasticizing
admixture.

C. Pigmented Mineral Dry-Shake Floor Hardener: Factory-packaged dry combination of BS

EN 197-1 Type CEM III/A 42.5N cement, graded quartz aggregate, coloring pigments, and
plasticizing admixture. Use coloring pigments that are finely ground, nonfading mineral
oxides interground with cement.

1. Colors: As selected by Engineer from manufacturer's full range for

these characteristics.

D. Penetrating Liquid Floor Treatment: Chemically reactive, waterborne solution of inorganic

silicate or siliconate materials and proprietary components; odorless; colorless; that
penetrates, hardens, and densifies concrete surfaces.
2.9 CURING MATERIALS

A. Evaporation Retarder: Waterborne, monomolecular film forming, manufactured

for application to fresh concrete.

B. Absorptive Cover: AASHTO M 182, Class 2, burlap cloth made from jute or
kenaf, weighing approximately 305 g/sq. m when dry.

C. Moisture-Retaining Cover: ASTM C 171, polyethylene film or white burlap-

polyethylene sheet.

D. Water: Potable.

E. Clear, Solvent-Borne, Membrane-Forming Curing Compound: ASTM C 309,

Type 1, Class B.

F. Clear, Waterborne, Membrane-Forming Curing Compound: ASTM C 309, Type

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 11
 1, Class B.

G. Clear, Waterborne, Membrane-Forming Curing Compound: ASTM C 309, Type

1, Class B, 18 to 22 percent solids.

H. Clear, Solvent-Borne, Membrane-Forming Curing and Sealing Compound:

ASTM C 1315, Type 1, Class A.

I. Clear, Waterborne, Membrane-Forming Curing and Sealing Compound: ASTM

C 1315, Type 1, Class A.

2.10 RELATED MATERIALS

A. Joint-Filler Strips: ASTM D 1751, asphalt-saturated cellulosic fiber.

B. Bonding Agent: ASTM C 1059/C 1059M, Type II, non-redispersible, acrylic emulsion or
styrene butadiene.

C. Epoxy-Bonding Adhesive: ASTM C 881/C 881M, two-component epoxy resin, capable

of humid curing and bonding to damp surfaces, of class and grade to suit requirements,
and as follows:

1. Types I and II, non-load bearing, for bonding hardened or freshly mixed concrete
to hardened concrete.
2. Types IV and V, load bearing, for bonding hardened or freshly mixed concrete to
hardened concrete.

D. Reglets: Fabricate reglets of not less than 0.55-mm- thick galvanized steel sheet.
Temporarily fill or cover face opening of reglet to prevent intrusion of concrete or debris.

E. Dovetail Anchor Slots: Hot-dip galvanized steel sheet, not less than 0.85 mm thick, with
bent tab anchors. Temporarily fill or cover face opening of slots to prevent intrusion of
concrete or debris.

2.11 REPAIR MATERIALS

A. Repair Underlayment: Cement-based, polymer-modified, self-leveling product that can be

applied in thicknesses from 3 mm and that can be feathered at edges to match adjacent floor
elevations.

1. Cement Binder: ASTM C 150 or BS EN 197-1 Type CEM III/A 42.5N cement
or hydraulic or blended hydraulic cement as defined in ASTM C 219.
2. Primer: Product of underlayment manufacturer recommended for substrate,
conditions, and application.
3. Aggregate: Well-graded, washed gravel, 3 to 6 mm or coarse sand as recommended
by underlayment manufacturer.
4. Compressive Strength: Not less than 30 MPa at 28 days when tested according to
ASTM C109/C 109M.

B. Repair Topping: cement based, cement-based, polymer-modified, self-leveling product that

can be applied in thicknesses from 6 mm.

1. Cement Binder: ASTM C 150 or BS EN 197-1 Type CEM III/A 42.5Ncement or

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 12
 hydraulic or blended hydraulic cement as defined in ASTM C 219.
2. Primer: Product of topping manufacturer recommended for substrate, conditions,
and application.
3. Aggregate: Well-graded, washed gravel, 3 to 6 mm or coarse sand as recommended
by topping manufacturer.
4. Compressive Strength: Not less than 45 MPa at 28 days when tested according to
ASTM C 109/C 109M.

2.12 CONCRETE MIXES

A. Prepare design mixes for each type and strength of concrete determined by laboratory
trial mix bases, as follows:

1. Proportion normal-weight concrete according to ACI 211.1 and ACI 301.

2. Proportion high strength concrete according to ACI 211.4 and ACI 301.
3. Proportion Self Consolidated Concrete according to ACI 237R and ACI 301.
4. Proportion lightweight structural concrete according to ACI 211.2 and ACI 301.

B. For reinforced structural elements in contract with soil, use cementitious additives, such as
GGBS up to 65% or fly ash up to 35% of the cementitious weight, in combination with
Microsilica 5% to 10% of the cementitious weight to ensure “Very Low” permeable
concrete.

C. Use a qualified independent testing agency acceptable to the Engineer for preparing and
reporting proposed mix designs for the laboratory trial mix basis.

1. Do not use the same testing agency for field quality control.

D. Submit written reports to the Engineer of each proposed mix for each class of concrete at
least 15 days prior to start of Work. Do not begin concrete production until proposed mix
designs have been reviewed and approved by the Engineer.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 13
 E. Design mixes to provide normal-weight concrete with the following properties unless
otherwise indicated on Drawings:

1. Slab-on-grade as indicated in the drawings: Proportion normal-weight concrete mix

as follows:

a. Cubic Compressive Strength: 30 MPa (28 Days)

b. Maximum water-cementitious materials ratio: 0.45
c. Minimum cementitious materials content: 350 kg/m3.
d. Maximum Slump without admixture: 100 mm.
e. Maximum Slump for Concrete Containing High-Range Water-Reducing
Admixture: 200 mm (+/- 20 mm) on site after admixture is added to concrete
with 50- to 100-mm slump.

2. Structural plain concrete: Proportion normal-weight concrete mix as follows:

a. Cubic Compressive Strength: 20 MPa (28 Days)

b. Maximum water-cementitious materials ratio: 0.45
c. Minimum cementitious materials content: 300 kg/m3.
d. Maximum Slump without admixture: 100 mm.
e. Maximum Slump for Concrete Containing High-Range Water-Reducing
Admixture: 200 mm (+/- 20 mm) on site after admixture is added to concrete
with 50- to 100-mm slump.

3. For reinforced concrete elements as indicated in the drawings, Proportion normal-

weight concrete mix as follows:

a. Cubic Compressive Strength: 35 MPa (28 Days)

b. Maximum water-cementitious materials ratio: 0.45
c. Minimum cementitious materials content: 370 kg/m3.
d. Maximum Slump without admixture: 100 mm.
e. Maximum Slump for Concrete Containing High-Range Water-Reducing
Admixture: 200 mm (+/- 20 mm) on site after admixture is added to concrete
with 50- to 100-mm slump.
f. Cementitious additives, such as GGBS up to 65% or fly ash up to 35% of the
cementitious weight, in combination with Microsilica 5% to 10% of the
cementitious weight, shall be used in reinforced sub-structural concrete
elements, to achieve the specified permeability test requirements for “Very
Low” permeable concrete.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 14
 F. All concrete below ground shall have protective coating as specified in Paragraphs 3.17.

G. Water-Cement Ratio: The free water-cement ratio shall not exceed 0.45 except for blinding
concrete where water-cement ratio can be limited to 0.6. Where cementitious additives are
used, the water-cement ratio shall be the water content divided by the cement plus
cementitious content. The water-cement ratio shall be continuously checked at the mixer
with due allowance made for water contained in the aggregates. Under no circumstance
shall water be added between the mixer and the place of concrete placement. The Engineer
may require that the water-cement ratio be checked during tests performed on fresh concrete
samples taken at the time of placement as specified in Paragraph 3.20.

H. Slump Limits: The slump of concrete mixes shall be such that the concrete can be
transported, placed into the forms, and compacted without segregation in accordance with
Paragraph 3.9. If no superplasticizer is required, the slump at time of placement shall be 50-
75 mm as measured in accordance with ASTM C 143/C143M. In accordance with
Paragraph 3.9, the concrete shall at all times exhibit a mobility that enables this placement
to be affected with the minimum amount of difficulty.

I. Total Salt Content:

1. Chlorides: The total chloride content (sum of both acid soluble and water soluble
chlorides) of the concrete from all sources, expressed as chloride ion, shall not
exceed 0.3 percent by weight of dry cement, inclusive of cementitious additives,
when tested in accordance with BS 1881 and ECP 203 requirements.
2. Sulfates: The total sulfate content of the concrete from all sources, expressed as SO3,
when tested in accordance with BS 1881 and ECP203 requirements, shall not exceed
4 percent by weight of dry cement, inclusive of cementitious additives.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 15
 J. Initial Setting Time:

1. The initial setting time shall be not less than one hour after the production concrete
is discharged into the form. With a maximum time between mixing and placing
concrete of one hour, the total time between mixing and initial set shall be a
minimum of 2 hours. There shall be a maximum setting time of 6 hours.
2. When trial mixes are made to determine the workability of the concrete, the initial
setting time of the cement paste shall be determined using the method defined in
ASTM C 191 but at the maximum allowable temperature and with same proportions
of pozzolan and retarding superplasticizer as specified in this Specification.

K. Test Mixes - Structural Grade Concrete: When the proposed workability, proportions of
aggregates and superplasticizer, and strength for each grade of concrete have been
established, test concrete shall be produced for approval by the Engineer. The following
shall be performed for each grade of concrete:

1. Six separate test mixes shall be made and cured in accordance with ASTM C
192/C192M and tested in accordance with ASTM C 39/C39M.
2. The 36 cylinders for each grade of concrete shall be tested for compressive strength
at 28 days and the mean strength and standard deviation established for each grade.
3. The test mixes shall be accepted provided that:

a. The mix proportions and workability are in accordance with this

Specification.
b. The standard deviation for each grade is 3.5 MPa or less, in accordance with
ACI 318.
c. The mean strength for structural concrete exceeds the specified design
strength by the limits specified in ACI 318 standard.

L. Test Mixes - Blinding or Mudmat Concrete:

1. Concrete for blinding or mudmat shall be a designed mix with the specified design
strength. The trial mix proportions shall be left to the discretion of the Contractor.
Once they have been chosen, three separate test mixes shall be made with
those proportions and three 150 mm test cylinders shall be made from each mix for
testing at 28 days. The trial mix proportions and water/cement ratio shall be
approved if the average strength of the nine cylinders is not less than 15 N/sq. mm.
2. No production test shall be made for this grade of concrete but the Engineer will
monitor the mix proportions and water/cement ratio.

M. Adjustment to Concrete Mixes: Mix design adjustments may be requested when

characteristics of materials, job conditions, weather, test results, or other circumstances
warrant. Laboratory test data for revised mix design and strength results shall be
submitted to and approved by the Engineer before using in the Work.

N. Absorption Test: The absorption of the hardened concrete from the trial mixes for structural
grades shall be tested as a measure of the concrete’s ability to resist the ingress of aggressive
salts. No absorption tests shall be required for blinding or mudmat concrete. Absorption
tests shall be in accordance with modified BS 1881: Part 122 as follows:

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 16
 1. After trial mixes have been accepted, three 150 mm cylinders shall be cast from each
grade of concrete and immersed in water at 20 deg. C (68 deg. F) for 7 days.
2. At the end of the curing period, 75 mm diameter core specimens shall be cut along
the longitudinal axis of each cylinder to a depth of 75 mm.
3. The specimens shall be dried in an oven at 105 deg. C (221 deg. F) for 72 hours.
4. The specimens shall be cooled in a dry airtight vessel for 24 hours, weighed, and
then immediately immersed in a tank containing water at 20 deg. C (68 deg.F) with
the longitudinal axis of the cores horizontal, and with 25 mm depth of water over the
specimens.
5. The specimens shall be immersed for 24 hours, then removed, shaken, surface dried,
and reweighed. The water absorption shall be calculated as the increase in mass
resulting from immersion, expressed as a percentage of the dry mass.
6. If the cores lengths differ from 75 mm, a correction factor (graph given in BS 1881)
shall be applied.

O. Permeability Tests:

The concrete shall be of the “Low” to "Very Low" permeability level i.e. High
durability satisfying the below permeability requirement

1. BS EN 12390-8 Depth of Penetration shall be carried out as a measure of

water permeability on concrete before the mix design or manufacturing method are
approved. The tests shall be carried out in accordance with BS EN 12390-8 at age
28 days and the maximum value of penetration shall not exceed the following limits:

In-situ construction: Less than 20 mm.

Substructure concrete and Precast units: Less than 15 mm.

Use ISAT (initial Surface Absorption Test) during construction, as in-situ testing of
structures and will form one of the basic criteria for rejecting/accepting precast
concrete elements.

2. The chloride permeability of the concrete shall be determined using cores taken from
the concrete samples, in accordance with AASHTO T277 "Rapid Determination of
the Chloride Permeability of Concrete". The following limits shall not be exceeded:

units In-situ construction: 3000 Coulombs for superstructure

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 17
 3. The chloride permeability of the concrete shall be determined using cores taken from
the prototype samples, in accordance with NT build 492 "Chloride Migration
coefficient". The following limits shall not be exceeded at 28-days:

In-situ Construction- Substructure Concrete: 3.0 x 10-12 m2/s

4. The concrete will be deemed to comply with the permeability requirements of this
specification if all test results comply with the limits indicated in paragraphs 1, 2
and 3.

5. If any of the BS EN, chloride migration and the rapid chloride permeability test
results of unprotected surfaces of a sample failed to meet the above requirements,
then all the concrete work represented by such sample shall be deemed not to comply
with the permeability requirements.

6. If, in the opinion of the Engineer, the concrete that has failed to meet the
permeability requirements of this Specification is likely to cause durability
problems, three cores shall be cut from the area represented by failed samples for
additional BS EN, chloride migration and rapid chloride permeability testing. The
actual location shall be decided by the Engineer.

P. Test Construction:

1. Test Foundation: A test foundation footing and plinth shall be cast on grade to
the details provided by the Engineer in accordance with specified requirements. This
shall be performed before any permanent works are constructed. The concrete shall
be cured for the period required in Paragraph 3.13, after which an epoxy coating
shall be applied to that part of the plinth which would normally be above ground
and a bitumen coating applied to the remainder of the plinth and the footing, all in
accordance with Paragraph 3.17.
2. Test Floor Slab: A 3 m by 4 m test area of 150 mm thick floor slab constructed of
above ground reinforced concrete in accordance with this Specification shall be cast
on grade and given a Class U4 finish as specified in Paragraph 3.11.D. The concrete
shall be cured for the period specified in Paragraph 3.13.

2.13 FABRICATING REINFORCEMENT

A. Fabricate steel reinforcement according to CRSI's "Manual of Standard Practice."

2.14 CONCRETE MIXING

A. General: Concrete production shall be in accordance with Egyptian code of practice. A

checklist for concrete production shall be produced, such as that used by the NRMCA or
approved equal.

1. Batching of materials shall be by weight. All weighing equipment shall be calibrated

and documentation shall be provided to establish that the accuracy is continuously
maintained in accordance with the requirements of ACI 304. Batching scale
accuracy shall be in accordance with the Concrete Plant Standards of the Concrete
Plant Manufacturers Bureau, or approved equal.

2. Furnish the necessary equipment and establish accurate procedures for determining
the quantities of free moisture in the aggregates. Moisture determinations shall be

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 18
 made daily and whenever there is an apparent change in the moisture content. The
moisture content shall be recorded. The moisture of aggregates shall be utilized in
adjusting the weight of aggregate added to the mix. The water added to the mix shall
be similarly adjusted.

B. Job-Site Mixing: All concrete mixed on Project site shall be in a batch mixer of approved
size and design complying with ACI 304 and producing a uniform distribution of the
materials throughout the mixed concrete in accordance with ASTM C 94/C94M uniformity
test. The contents of the drum shall be completely discharged before re-charging. After all
the materials are in the mixer, mixing shall continue until the whole of the materials are
uniformly distributed and the mass is of uniform color and consistency. In the case of
concrete that contains silica fume with a density between 400-650 kg/cu. m, the mixing
time shall be 50 percent greater than the requirement for concrete without silica fume.

1. Whenever mixing is to be suspended for half an hour or longer, the drum of the
mixer shall be thoroughly washed out with clean water. Provide a competent operator
who shall be in continuous control of the mixer. No retempering of concrete,
which has partially hardened, by the addition of cement, aggregate, or water shall be
allowed.

2. Provide batch ticket for each batch discharged and used in the Work, indicating
Project identification name and number, date, mix type, mix time, quantity, and
amount of water introduced.

C. Ready-Mixed Concrete:

1. Ready-Mixed concrete shall comply with the requirements of ASTM C 94/C94M

or BS EN 206-1 and as follows:

a. Concrete shall be centrally mixed off site and transported in an agitator

truck. Truck mixing shall not be permitted.
b. The plant and trucks shall be certified as meeting the requirements of
the NRMCA Check List, or approved equal.
c. Details and information regarding the supplier proposed by the contractor
shall be submitted to the Engineer for approval.
d. The sewer of ready mixed concrete shall not subsequently be charged
without further approval of the Engineer.

2. When air temperature is between 30 deg.C (82 deg.F) and 32 deg.C (90 deg.
F), delivery time from the time water is added to the mix until it is placed in its
final position in the form shall not exceed 60 minutes. When air temperature is 35
deg.C, delivery time shall not exceed 2.5 hours (by using additives).

3. Before discharging concrete at the point of delivery, provide the Engineer with
a delivery ticket for each batch of concrete containing the following information
as a minimum:

a. Name or number of off-site concrete depot.

b. Serial number for ticket.
c. Date.
d. Time of dispatch.
e. Truck number.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 19
 f. Name of Supplier.
g. Grade or mix description of concrete.
h. Type of cement.
i. Cement content.
j. Water/cement ratio.
k. Nominal maximum size of aggregate.
l. Source of aggregate, maximum size, weight of fine and coarse aggregate.
m. Type or name of admixture, if included.
n. Quantity of concrete in cubic meters.
o. Certifying that chlorides and sulfate contents are within specified limits
and stating their values.
p. Amount of concrete in cubic meter.

2.15 PEARING PADS

A. Provide one of the following bearing pads :

1. Elastomeric Pads: AASHTO M 251, plain, vulcanized, 100 percent polychloroprene

(neoprene) elastomer, molded to size or cut from a molded sheet, type A durometer,
hardness of 50 to 70, ASTM D2240 minimum tensile strength
15.5 MPa,
ASTM D 412.
2. Frictionless Pads: PTFE, glass-fiber reinforced, bonded to stainless- or mild-steel
plate, or random-oriented-fiber-reinforced elastomeric pads; of type required for in-
service stress.
3. High-Density Plastic: Multimonomer, nonleaching, plastic strip.
4. Laminated Elastomeric Pads: An elastomeric pad reinforced with steel plates.

PART 3 – EXECUTION

3.1 FORMWORK

A. Design, erect, shore, brace, and maintain formwork, according to ACI 301, to support
vertical, lateral, static, and dynamic loads, and construction loads that might be applied,
until concrete structure can support such loads.

B. Construct formwork so concrete members and structures are of size, shape, alignment,
elevation, and position indicated, within tolerance limits of ECP 203 Chapter 9.

C. Limit concrete surface irregularities, designated by ACI 347R as abrupt or gradual, as

follows:

1. Class A, 4 mm.
2. Class B, 6 mm.
3. Class C, 10 mm.
4. Class D, 25 mm.

D. Construct forms tight enough to prevent loss of concrete mortar.

E. Fabricate forms for easy removal without hammering or prying against concrete surfaces.
Provide crush or wrecking plates where stripping may damage cast concrete surfaces.
Provide top forms for inclined surfaces steeper than 1.5 horizontal to 1 vertical. Kerf wood
inserts for forming keyways, reglets, recesses, and the like, for easy removal.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 20
 1. Do not use rust-stained steel form-facing material.

F. Set edge forms, bulkheads, and intermediate screed strips for slabs to achieve required
elevations and slopes in finished concrete surfaces. Provide and secure units to support
screed strips; use strike-off templates or compacting-type screeds.

G. Provide temporary openings for cleanouts and inspection ports where interior area of
formwork is inaccessible. Close openings with panels tightly fitted to forms and securely
braced to prevent loss of concrete mortar. Locate temporary openings in forms at
inconspicuous locations.

H. Chamfer exterior corners and edges of concrete receiving applied

waterproofing membranes.

I. Do not chamfer corners or edges of concrete unless otherwise indicated.

J. Form openings, chases, offsets, sinkages, keyways, reglets, blocking, screeds, and
bulkheads required in the Work. Determine sizes and locations from trades providing such
items.

K. Clean forms and adjacent surfaces to receive concrete. Remove chips, wood, sawdust, dirt,
and other debris just before placing concrete.

L. Retighten forms and bracing before placing concrete, as required, to prevent mortar leaks
and maintain proper alignment.

M. Coat contact surfaces of forms with form-release agent, according to manufacturer's written
instructions, before placing reinforcement.

3.2 EMBEDDED ITEMS

A. Place and secure anchorage devices and other embedded items required for adjoining work
that is attached to or supported by cast-in-place concrete. Use Setting Drawings, templates,
diagrams, instructions, and directions furnished with items to be embedded.

1. Install anchor bolts, accurately located, to elevations required.

2. Install reglets to receive top edge of foundation sheet waterproofing and to receive
through-wall flashings in outer face of concrete frame at exterior walls, where
flashing is shown at lintels, shelf angles, and other conditions.
3. Install dovetail anchor slots in concrete structures as indicated.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 21
 3.3 REMOVING AND REUSING FORMS

A. General: Formwork, for sides of beams, walls, columns, and similar parts of the Work, that
does not support weight of concrete may be removed after cumulatively curing at not
less than 10 deg C for 24 hours after placing concrete provided concrete is hard enough to
not be damaged by form-removal operations and provided curing and protection
operations are maintained.

B. Leave formwork, for beam soffits, joists, slabs, and other structural elements, that supports
weight of concrete in place until concrete has achieved the following:

1. 28-day design compressive strength.

2. Determine compressive strength of in-place concrete by testing representative
field- or laboratory-cured test specimens according to ECP 203.
3. Remove forms only if shores have been arranged to permit removal of forms
without loosening or disturbing shores.

C. Clean and repair surfaces of forms to be reused in the Work. Split, frayed, delaminated, or
otherwise damaged form-facing material will not be acceptable for exposed surfaces. Apply
new form-release agent.

D. When forms are reused, clean surfaces, remove fins and laitance, and tighten to close joints.
Align and secure joints to avoid offsets. Do not use patched forms for exposed concrete
surfaces unless approved by Engineer.

3.4 SHORES AND RESHORES

A. Comply with ACI 318M, ACI 301, and recommendations in ACI 347R for design,
installation, and removal of shoring and reshoring.

B. In multistory construction, extend shoring or reshoring over a sufficient number of stories

to distribute loads in such a manner that no floor or member will be excessively loaded or
will induce tensile stress in concrete members without sufficient steel reinforcement.

C. Plan sequence of removal of shores and reshore to avoid damage to concrete. Locate and
provide adequate reshoring to support construction without excessive stress or deflection.

3.5 VAPOR RETARDERS

A. Vapor Retarder: Place, protect, and repair vapor-retarder sheets according to ASTM E 1643
and manufacturer's written instructions.

B. Fine-Graded Granular Material: Cover vapor retarder with fine-graded granular material,
moisten, and compact with mechanical equipment to elevation tolerances of plus 0 mm or
minus 20 mm.

C. Granular Fill: Cover vapor retarder with granular fill, moisten, and compact with
mechanical equipment to elevation tolerances of plus 0 mm or minus 20 mm.

1. Place and compact a 15-mm- thick layer of fine-graded granular material over
granular fill.

3.6 STEEL REINFORCEMENT

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 22
 A. General: Comply with CRSI's "Manual of Standard Practice" for placing reinforcement.

1. Avoid cutting or puncturing vapor retarder/barrier and waterproofing membranes

during reinforcement placement and concreting operations. Repair damages before
placing concrete.

B. Accurately position, support, and secure reinforcement against displacement. Locate

and support reinforcement with bar supports to maintain minimum concrete cover. Do
not tack weld crossing reinforcing bars.

C. Set wire ties with ends directed into concrete, not toward exposed concrete surfaces.

D. Install welded wire fabric in longest practicable lengths on bar supports spaced to
minimize sagging. Lap edges and ends of adjoining sheets at least one mesh spacing.
Offset laps of adjoining sheet widths to prevent continuous laps in either direction. Lace
overlaps with wire.

E. Shipping and Storage:

1. Reinforcement shall be handled and shipped in a manner to avoid bending or

other damage to the bars. Bars shall be bundled, separated in sizes and clearly marked
by diameter size preferably for one placement, in accordance with the placement
schedule and as follows:

a. Bars for separate buildings or large structures shall not be bundled together.
Bars for small structures may be bundled together but each bar or group of
bars that have the same piece mark shall be tagged and coded.
b. Metal tags or approved equal shall be provided and labeled with legible
markings.
c. All bundles shall be tagged at each end. Tags shall show piece marks
corresponding to the mark numbers on the placement drawings and on the
bar list.
d. Bars shall be bundled in the largest size practical for handling and
shipping.

2. Reinforcement shall be stored 20 cm above ground on platforms, skids or other

approved supports and suitably spaced subject to not being exposed to any kind of
flooding. Contact with the soil shall be avoided. Proper drainage and protection from
the elements shall be provided to minimize corrosion.

F. Clean reinforcement of loose rust and mill scale, earth, ice, and other materials that
reduce or destroy bond with concrete.

G. Accurately position, support, and secure reinforcement against displacement. Locate

and support reinforcement on concrete blocks of a size to give the correct cover to the
reinforcement. Concrete spacer blocks shall be made of the same materials, to the same
specified requirements and have the same inherent properties as the parent material, but
with the exception that the maximum aggregate size shall be appropriate for the
thickness of cover to the reinforcement.

1. Where cathodic protection is utilized, reinforcement shall be isolated from the

electrical grounding system.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 23
 2. Chairs made of reinforcement shall be used to support the top mats of slab
reinforcement and they shall be so dimensioned as to be stable during concreting
operations. The chairs shall themselves be supported on concrete blocks as specified
above.

H. Place reinforcement to maintain minimum coverages as indicated for concrete

protection. Arrange, space, and securely tie bars and bar supports to hold reinforcement
in position during concrete placement operations. Ties at intersections shall be made
with 1.5 mm diameter annealed wire with wire ends directed into concrete, not toward
exposed concrete surfaces.

I. Concrete Cover:

1. Concrete cover has to satisfy the ECP 203 and also comply with Table 2-14 in
ECP 203 to satisfy three hours fire rating for all vertical elements and two hours fire
rating for all horizontal elements.

2. Cover to reinforcement shall be checked before any concrete is cast. The bending of
reinforcement at a cold joint is not permitted. Concrete cover shall be checked with
a cover meter as soon as formwork is removed.

J. All lap splices shall be in accordance with the ECP-203 splice requirements unless
otherwise shown on Drawings. All reinforcement bars shall be developed in accordance
with the Egyptian Code of Practice unless otherwise shown on Drawings. Welded wire
fabric shall be lapped 1.5 mesh plus the extension on the wires unless otherwise shown
on Drawings.

3.7 JOINTS

A. General: Construct joints true to line with faces perpendicular to surface plane of concrete.

B. Construction Joints: Install so strength and appearance of concrete are not impaired, at
locations indicated or as approved by Engineer.

1. Place joints perpendicular to main reinforcement. Continue reinforcement across

construction joints, unless otherwise indicated. Do not continue r e i n f o r c e m e n t
through sides of strip placements of floors and slabs.
2. Form from preformed galvanized steel, plastic keyway-section forms, or bulkhead
forms with keys, unless otherwise indicated. Embed keys at least 40 mm into
concrete.
3. Locate joints for beams, slabs, joists, and girders in the middle third of spans. Offset
joints in girders a minimum distance of twice the beam width from a beam-girder
intersection.
4. Locate horizontal joints in walls and columns at underside of floors, slabs, beams,
and girders and at the top of footings or floor slabs.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 24
 5. Space vertical joints in walls as indicated. Locate joints beside piers integral with
walls, near corners, and in concealed locations where possible.
6. Use a bonding agent at locations where fresh concrete is placed against hardened or
partially hardened concrete surfaces.
7. Use epoxy-bonding adhesive at locations where fresh concrete is placed against
hardened or partially hardened concrete surfaces.

C. Contraction Joints in Slabs-on-Grade: Form weakened-plane contraction joints, sectioning

concrete into areas as indicated. Construct contraction joints for a depth equal to at least
one-fourth of concrete thickness, as follows:

1. Grooved Joints: Form contraction joints after initial floating by grooving and
finishing each edge of joint to a radius of 3 mm repeat grooving of contraction joints
after applying surface finishes. Eliminate groove tool marks on concrete surfaces.
2. Sawed Joints: Form contraction joints with power saws equipped with shatterproof
abrasive or diamond-rimmed blades. Cut 3-mm wide joints into concrete when
cutting action will not tear, abrade, or otherwise damage surface and before concrete
develops random contraction cracks.

D. Isolation Joints in Slabs-on-Grade: After removing formwork, install joint-filler strips at

slab junctions with vertical surfaces, such as column pedestals, foundation walls, grade
beams, and other locations, as indicated.

1. Extend joint-filler strips full width and depth of joint, terminating flush with finished
concrete surface, unless otherwise indicated.
2. Terminate full-width joint-filler strips not less than 12 mm or more than 25 mm
below finished concrete surface where joint sealants, specified in Section 079200
"Joint Sealants," are indicated.
3. Install joint-filler strips in lengths as long as practicable. Where more than one length
is required, lace or clip sections together.

E. Dowel Joints: Install dowel sleeves and dowels or dowel bar and support assemblies at
joints where indicated.

1. Use dowel sleeves or lubricate or asphalt-coat one-half of dowel length to prevent

concrete bonding to one side of joint.

3.8 WATERSTOPS

A. Flexible Waterstops: Install in construction joints as indicated to form a continuous

diaphragm. Install in longest lengths practicable. Support and protect exposed waterstops
during progress of Work. Field-fabricate joints in waterstops according to manufacturer's
written instructions.

B. Self-Expanding Strip Waterstops: Install in construction joints and at other locations

indicated, according to manufacturer's written instructions, bonding or mechanically
fastening and firmly pressing into place. Install in longest lengths practicable.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 25
 3.9 CONCRETE PLACEMENT

A. General: Comply with ECP 203 Chapter 9.

B. Inspection: Before placing concrete, inspect and complete formwork installation,

reinforcing steel, and items to be embedded or cast in. Notify other trades to permit
installation of their work. Concrete shall not be placed until the condition of the
reinforcement, other embedded items, and the formwork has been inspected and approved
by the Engineer.

C. Transportation: Concrete, after being discharged from the mixer, shall be transported as
rapidly as possible to its final position in the Work by agitator trucks, which shall prevent
adulteration, segregation, loss of workability or contamination of the ingredients. The
containers that convey the concrete shall be kept clean and free from hardened or partially
hardened concrete.

1. The addition of water at the point of discharge is prohibited and trucks shall have
the water tank completely disconnected from the drum.
2. The use of chutes, spouts, skips and pumps shall be permitted if approval is obtained.
Under no circumstances shall any aluminum pipe or other conveying equipment
containing aluminum be allowed to contact fresh concrete when it is conveyed to its
point of placement.
3. Method of pouring and pouring sequence shall be submitted by the Contractor to the
Engineer’s approval.

D. Placing Concrete in Forms: Deposit concrete in forms continuously or in horizontal layers

no deeper than 450 mm and in a manner to avoid inclined construction joints. Where
placement consists of several layers, place each layer while the preceding layer is still
plastic to avoid cold joints. If a section cannot be placed continuously, provide construction
joints as specified. Deposit concrete to avoid segregation at its final location.

1. Concrete shall not be dropped into place from a height exceeding 1.5 m nor through
dense reinforcing steel, which could cause segregation of the coarse aggregate.
Structural concreting against open excavation will not be permitted as the concrete
cannot be coated afterwards.
2. When vertical lifts of concrete are interrupted or delayed for more than one hour, the
surface of the unfinished concrete shall be thoroughly cleaned and washed with
cement grout immediately before fresh concrete is added and the first layer of new
concrete placed shall not exceed 150mm depth and particular care shall be taken with
compaction of this new layer to ensure good bond.
3. Method of pouring and pouring sequence shall be submitted by the Contractor to the
Engineer’s approval.
4. Consolidate placed concrete with mechanical vibrating equipment. Use equipment
and procedures for consolidating concrete recommended by ACI 309R.
5. Do not use vibrators to transport concrete inside forms. Insert and withdraw vibrators
vertically at uniformly spaced locations no farther than the visible effectiveness of
the vibrator. Place vibrators to rapidly penetrate placed layer and at least 150 mm
into preceding layer. Do not insert vibrators into lower layers of concrete that have
begun to lose plasticity. At each insertion, limit duration of vibration to time
necessary to consolidate concrete and complete embedment of reinforcement and
other embedded items without causing mix constituents to segregate.

E. Do not add water or admixture to concrete during delivery, at Project site, or during

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 26
 placement.

F. Deposit and consolidate concrete for floors and slabs in a continuous operation, within
limits of construction joints, until placement of a panel or section is complete.

1. Consolidate concrete during placement operations so that concrete is thoroughly

worked around reinforcement and other embedded items and into corners.
2. Maintain reinforcement in position on chairs during concrete placement.
3. Screed slab surfaces with a straightedge and strike off to correct elevations.
4. Slope surfaces uniformly to drains where required.
5. Begin initial floating using bull floats or darbies to form a uniform and open-textured
surface plane, free of humps or hollows, before excess moisture or bleedwater
appears on the surface. Do not further disturb slab surfaces before starting finishing
operations.

G. Compaction and Vibration: Full compaction of the concrete shall be achieved throughout
the entire depth of the layer. It shall be thoroughly worked against the formwork and
around the reinforcement and successive layers shall be thoroughly bonded together. Air
bubbles formed during the mixing and casting shall be expelled particular care shall be
taken where sloping formwork is used.
H. Hot-Weather Placement: When hot weather conditions exist that would impair quality and
strength of concrete, place concrete complying with ACI 305 and as specified.

1. Cool ingredients before mixing to maintain concrete temperature at time of

placement to below 25 deg.C (68 deg. F). Mixing water may be chilled or chopped
ice may be used to control temperature, provided water equivalent of ice is
calculated to total amount of mixing water. Using liquid nitrogen to cool concrete
is the Contractor's option.
2. Concrete temperature shall not exceed 32 deg. C (90 deg.F) and the temperature
differential shall not exceed 25 deg. C (68 deg. F).
3. No concreting operation shall be carried out at ambient temperature of 40 deg. C
(104 deg. F) or more.
4. Cover reinforcing steel with water-soaked burlap if it becomes too hot, so that steel
temperature will not exceed the ambient air temperature immediately before
embedding in concrete.
5. Fog spray forms, reinforcing steel, and subgrade just before placing concrete. Keep
subgrade moisture uniform without puddles or dry areas.
6. Use water-reducing retarding admixture when required by high temperatures, low
humidity, or other adverse placing conditions, as acceptable to the Engineer.
7. Shade mixing plant and trucks, aggregates, water tank, and cement silo.
8. Paint white the mixing plant, trucks, water tank, and cement silo.
9. Insulate the water tank and supply piping.
10. Provide necessary shades over and around the concrete being poured to prevent sun
rays from coming into direct contact with the surface of the concrete and the
formwork for a period of about 7 days (minimum from the time of pouring concrete).
11. Concrete placing shall be completed as quickly as possible to reduce transit time.
12. Curing of exported concrete shall be immediately carried out.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 27
 3.10 FINISHING FORMED SURFACES

A. Rough-Formed Finish: As-cast concrete texture imparted by form-facing material with tie
holes and defective areas repaired and patched. Remove fins and other projections
exceeding ACI 347R limits for class of surface specified.

B. Smooth-Formed Finish: As-cast concrete texture imparted by form-facing material,

arranged in an orderly and symmetrical manner with a minimum of seams. Repair and patch
tie holes and defective areas. Remove fins and other projections exceeding 3 mm in height.

1. Apply to concrete surfaces exposed to public view or to be covered with a coating

or covering material applied directly to concrete, such as waterproofing,
dampproofing, veneer plaster, or painting.

2. Do not apply rubbed finish to smooth-formed finish.

C. Rubbed Finish: Apply the following to smooth-formed finished concrete:

1. Smooth-Rubbed Finish: Not later than one day after form removal, moisten concrete
surfaces and rub with carborundum brick or another abrasive until producing a
uniform color and texture. Do not apply cement grout other than that created by
the rubbing process.

2. Grout-Cleaned Finish: Wet concrete surfaces and apply grout of a consistency of

thick paint to coat surfaces and fill small holes. Mix one part CEM III/A cement to
one and one-half parts fine sand with a 1:1 mixture of bonding admixture and water.
Add white CEM III/A cement in amounts determined by trial patches so color of dry
grout will match adjacent surfaces. Scrub grout into voids and remove excess grout.
When grout whitens, rub surface with clean burlap and keep surface damp by fog
spray for at least 36 hours.

3. Cork-Floated Finish: Wet concrete surfaces and apply a stiff grout. Mix one part
CEM III/A cement and one part fine sand with a 1:1 mixture of bonding agent and
water. Add white CEM III/A cement in amounts determined by trial patches so color
of dry grout will match adjacent surfaces. Compress grout into voids by grinding
surface. In a swirling motion, finish surface with a cork float.

D. Related Unformed Surfaces: At tops of walls, horizontal offsets, and similar unformed
surfaces adjacent to formed surfaces, strike off smooth and finish with a texture matching
adjacent formed surfaces. Continue final surface treatment of formed surfaces uniformly
across adjacent unformed surfaces, unless otherwise indicated.

3.11 FINISHING FLOORS AND SLABS

A. General: Comply with recommendations in ACI 302.1R for screeding, restraightening, and
finishing operations for concrete surfaces. Do not wet concrete surfaces.

B. Scratch Finish: While still plastic, texture concrete surface that has been screeded and bull-
floated or darbied. Use stiff brushes, brooms, or rakes.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 28
 1. Apply scratch finish to surfaces indicated and to surfaces to receive concrete
floor topping or mortar setting beds for ceramic or quarry tile, CEM III/A cement
terrazzo, and other bonded cementitious floor finishes.

C. Float Finish: Consolidate surface with power-driven floats or by hand floating if area is
small or inaccessible to power driven floats. Restraighten, cut down high spots, and fill low
spots. Repeat float passes and restraightening until surface is left with a uniform, smooth,
granular texture.

1. Apply float finish to surfaces indicated, to surfaces to receive trowel finish, and
to floor and slab surfaces to be covered with fluid-applied or sheet waterproofing,
built- up or membrane roofing, or sand-bed terrazzo.

D. Trowel Finish: After applying float finish, apply first trowel finish and consolidate concrete
by hand or power-driven trowel. Continue troweling passes and restraighten until surface
is free of trowel marks and uniform in texture and appearance. Grind smooth any surface
defects that would telegraph through applied coatings or floor coverings.

1. Apply a trowel finish to surfaces indicated and to floor and slab surfaces exposed
to view or to be covered with resilient flooring, carpet, ceramic or quarry tile set over
a cleavage membrane, paint, or another thin film-finish coating system

2. Finish surfaces to the following tolerances, measured within 24 hours according to

ASTM E 1155 for a randomly trafficked floor surface:

a. Specified overall values of flatness, F(F) 35; and levelness, F(L) 25; with
minimum local values of flatness, F(F) 24; and levelness, F(L) 17; for slabs-
on-grade.
b. Specified overall values of flatness, F(F) 30; and levelness, F(L) 20; with
minimum local values of flatness, F(F) 24; and levelness, F(L) 15; for
suspended slabs.

3. Finish and measure surface so gap at any point between concrete surface and an
unleveled freestanding 3-m long straightedge, resting on two high spots and placed
anywhere on the surface, does not exceed the following:

a. 5 mm.

E. Trowel and Fine-Broom Finish: Apply a partial trowel finish, stopping after second
troweling, to surfaces indicated and to surfaces where ceramic or quarry tile is to be installed
by either thickset or thin-set method. Immediately after second troweling, and when
concrete is still plastic, slightly scarify surface with a fine broom.

F. Broom Finish: Apply a broom finish to exterior concrete platforms, steps, and ramps, and
elsewhere as indicated.

1. Immediately after float finishing, slightly roughen trafficked surface by brooming

with fiber-bristle broom perpendicular to main traffic route. Coordinate required
final finish with Engineer before application.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 29
 G. Slip-Resistive Aggregate Finish: Before final floating, apply slip-resistive aggregate finish
where indicated and to concrete stair treads, platforms, and ramps. Apply according to
manufacturer's written instructions and as follows:

1. Uniformly spread 12 kg/10 sq. m of dampened slip-resistive aggregate over surface

in one or two applications. Tamp aggregate flush with surface, but do not force
below surface.

2. After broadcasting and tamping, apply float finish.

3. After curing, lightly work surface with a steel wire brush or an abrasive stone, and
water to expose slip-resistive aggregate.

H. Mineral Dry-Shake Floor Hardener Finish: After initial floating, apply mineral dry-shake
materials to surfaces according to manufacturer's written instructions and as follows:

1. Uniformly apply mineral dry-shake materials at a rate of 49 kg/10 sq. m, unless

greater amount is recommended by manufacturer.

2. Uniformly distribute approximately two-thirds of mineral dry-shake materials over

surface by hand or with mechanical spreader, and embed by power floating. Follow
power floating with a second mineral dry-shake application, uniformly distributing
remainder of material, and embed by power floating.

3. After final floating, apply a trowel finish. Cure concrete with curing compound
recommended by dry-shake material manufacturer and apply immediately after final
finishing.

3.12 MISCELLANEOUS CONCRETE ITEMS

A. Filling In: Fill in holes and openings left in concrete structures, unless otherwise indicated,
after work of other trades is in place. Mix, place, and cure concrete, as specified, to blend
with in-place construction. Provide other miscellaneous concrete filling indicated or
required to complete Work.

B. Curbs: Provide monolithic finish to interior curbs by stripping forms while concrete is still
green and by steel-troweling surfaces to a hard, dense finish with corners, intersections, and
terminations slightly rounded.

C. Equipment Bases and Foundations: Provide machine and equipment bases and foundations
as shown on Drawings. Set anchor bolts for machines and equipment at correct elevations,
complying with diagrams or templates of manufacturer furnishing machines and equipment.

D. Steel Pan Stairs: Provide concrete fill for steel pan stair treads, landings, and associated
items. Cast-in inserts and accessories as shown on Drawings. Screed, tamp, and trowel-
finish concrete surfaces.

E. Tolerance and concrete dimensions for in-situ concrete members shall, under no
circumstances, exceed the permissible ones as indicated in the ACI.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 30
 3.13 CONCRETE PROTECTION AND CURING

A. General: Protect freshly placed concrete from premature drying and excessive cold or
hot temperatures. Comply with Egyptian code requirements

B. Evaporation Retarder: Apply evaporation retarder to unformed concrete surfaces if hot, dry,
or windy conditions cause moisture loss approaching 1 kg/sq. m x h before and during
finishing operations. Apply according to manufacturer's written instructions after placing,
screeding, and bull floating or darbying concrete, but before float finishing.

C. Formed Surfaces: Cure formed concrete surfaces, including underside of beams, supported
slabs, and other similar surfaces. If forms remain during curing period, moist cure after
loosening forms. If removing forms before end of curing period, continue curing by one
or a combination of the following methods:

D. Unformed Surfaces: Begin curing immediately after finishing concrete. Cure unformed
surfaces, including floors and slabs, concrete floor toppings, and other surfaces, by one or
a combination of the following methods:

1. Moisture Curing: Keep surfaces continuously moist for not less than seven days
with the following materials:

a. Water.
b. Continuous water-fog spray.
c. Absorptive cover, water saturated, and kept continuously wet. Cover
concrete surfaces and edges with 300 mm lap over adjacent absorptive
covers.
2. Moisture-Retaining-Cover Curing: Cover concrete surfaces with moisture-retaining
cover for curing concrete, placed in widest practicable width, with sides and ends
lapped at least 300 mm, and sealed by waterproof tape or adhesive. Cure for not
less than seven days. Immediately repair any holes or tears during curing period
using cover material and waterproof tape.

a. Moisture cure or use moisture-retaining covers to cure concrete surfaces

to receive floor coverings.
b. Moisture cure or use moisture-retaining covers to cure concrete surfaces to
receive penetrating liquid floor treatments.
c. Cure concrete surfaces to receive floor coverings with either a moisture-
retaining cover or a curing compound that the manufacturer recommends for
use with floor coverings.

3. Curing Compound: Shall be to the Engineer’s approval applied uniformly in

continuous operation by power spray or roller according to the manufacturer's
written instructions. Recoat areas subjected to heavy rainfall within three hours
after initial application. Maintain continuity of coating and repair damage during
curing period.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 31
 4. Curing and Sealing Compound: Apply uniformly to floors and slabs indicated in a
continuous operation by power spray or roller according to manufacturer's written
instructions. Recoat areas subjected to heavy rainfall within three hours after initial
application. Repeat process 24 hours later and apply a second coat. Maintain
continuity of coating and repair damage during curing period.

E. Curing Methods: Cure concrete by curing compound, by moist curing, by moisture-

retaining cover curing, or by combining these methods, as specified below.

1. Horizontal Surfaces: Horizontal surfaces shall be saturated with water and then
treated with curing compound. Apply curing compound as soon as final finishing
operations are complete (within 2 hours and after surface water sheen has
disappeared). Apply uniformly in continuous operation by power spray or roller
according to manufacturer's directions. Recoat areas subjected to heavy rainfall
within 3 hours after initial application. The surfaces shall then be bonded and
flooded with water or draped with wet burlap together with a perforated soaker
hosepipe, covered with white impervious sheeting held firmly in place along all
edges and kept continuously wet for the duration of the curing period.

2. Vertical Surfaces: Vertical timber formwork shall be draped with wet burlap as soon
as concrete is placed. Vertical surfaces shall be treated with curing compound as
soon as formwork is removed, draped with wet burlap, covered with white
impervious sheeting held firmly in place along all edges and kept continuously wet
for the duration of the curing period. Care shall be taken to avoid drying winds.

3. Impervious Sheeting: Impervious sheeting shall be in accordance with ASTM C 171.

4. Curing Compound: Curing compound shall be white and in accordance with

CE CRD-C300. It shall be a water-based wax emulsion for concrete above grade,
which will not be subsequently coated. Otherwise the curing compound shall be
compatible with the coating. Obtain confirmation from the supplier of the curing
compound that it meets the above requirements.

3.14 LIQUID FLOOR TREATMENTS

A. Penetrating Liquid Floor Treatment: Prepare, apply, and finish penetrating liquid floor
treatment according to manufacturer's written instructions.

1. Remove curing compounds, sealers, oil, dirt, laitance, and other contaminants
and complete surface repairs.
2. Do not apply to concrete that is less than seven days old.
3. Apply liquid until surface is saturated, scrubbing into surface until a gel forms; rewet;
and repeat brooming or scrubbing. Rinse with water; remove excess material until
surface is dry. Apply a second coat in a similar manner if surface is rough or porous.

B. Sealing Coat: Uniformly apply a continuous sealing coat of curing and sealing compound
to hardened concrete by power spray or roller according to manufacturer's written
instructions.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 32
 3.15 JOINT FILLING

A. Prepare, clean, and install joint filler according to manufacturer's written instructions.

1. Defer joint filling until concrete has aged at least six months. Do not fill joints until
construction traffic has permanently ceased.

B. Remove dirt, debris, saw cuttings, curing compounds, and sealers from joints; leave
contact faces of joint clean and dry.

C. Install semirigid epoxy joint filler full depth in saw-cut joints and at least 50 mm deep in
formed joints. Overfill joint and trim joint filler flush with top of joint after hardening.

3.16 CONCRETE SURFACE REPAIRS

A. Concrete exposed by the removal of formwork shall be inspected by the Engineer before
any remedial work, subsequent coating or other treatment that would hinder the proper
inspection of the concrete is carried out. Any concrete not complying with this requirement
shall be liable for rejection.

B. Concrete not meeting the specified requirements shall be removed and rebuilt without delay
unless the Engineer approves that a repair may be satisfactorily effected. This agreement
shall not preclude the subsequent rejection of the repaired work by the Engineer. The
proposed method for removal and replacement of defective work shall be submitted to the
Engineer for approval for each concrete placement before the removal commences.

C. All repairs approved by the Engineer shall be performed by a subcontractor specialized in

the repair of concrete in the Middle East and prepared to guarantee the work. Any repair
method submitted for approval shall produce a result that is as impermeable as the original
concrete. Subsequent tests on the repaired concrete shall be carried out at the discretion of
the Engineer in order to establish the quality of the repair, particularly at the joint between
the original and the repaired concrete.

D. Defective Concrete: Repair and patch defective areas when approved by Engineer. Remove
and replace concrete that cannot be repaired and patched to Engineer's approval.

E. Patching Mortar: Mix dry-pack patching mortar, consisting of one part CEM III/A cement
to two and one-half parts fine aggregate passing a 1.2-mm sieve, using only enough water
for handling and placing.

F. Repairing Formed Surfaces: Surface defects include color and texture irregularities, cracks,
spalls, air bubbles, honeycombs, rock pockets, fins and other projections on the surface,
and stains and other discolorations that cannot be removed by cleaning.

1. Immediately after form removal, cut out honeycombs, rock pockets, and voids more
than 13 mm in any dimension in solid concrete but not less than 25 mm in depth.
Make edges of cuts perpendicular to concrete surface. Clean, dampen with water,
and brush-coat holes and voids with bonding agent. Fill and compact with patching
mortar before bonding agent has dried. Fill form-tie voids with patching mortar
or cone plugs secured in place with bonding agent.
2. Repair defects on surfaces exposed to view by blending white CEM III/A cement
and standard CEM III/A cement so that, when dry, patching mortar will match

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 33
 surrounding color. Patch a test area at inconspicuous locations to verify mixture and
color match before proceeding with patching. Compact mortar in place and strike off
slightly higher than surrounding surface.

3. Repair defects on concealed formed surfaces that affect concrete's durability and
structural performance as determined by Engineer.

G. Repairing Unformed Surfaces: Test unformed surfaces, such as floors and slabs, for finish
and verify surface tolerances specified for each surface. Correct low and high areas. Test
surfaces sloped to drain for trueness of slope and smoothness; use a sloped template.

1. Repair finished surfaces containing defects. Surface defects include spalls, popouts,
honeycombs, rock pockets, crazing and cracks in excess of 0.25 mm wide or
that penetrate to reinforcement or completely through unreinforced sections
regardless of width, and other objectionable conditions.

2. After concrete has cured at least 14 days, correct high areas by grinding.

3. Correct localized low areas during or immediately after completing surface finishing
operations by cutting out low areas and replacing with patching mortar. Finish
repaired areas to blend into adjacent concrete.

4. Correct other low areas scheduled to receive floor coverings with a repair
underlayment. Prepare, mix, and apply repair underlayment and primer according to
manufacturer's written instructions to produce a smooth, uniform, plane, and level
surface. Feather edges to match adjacent floor elevations.

5. Correct other low areas scheduled to remain exposed with a repair topping. Cut out
low areas to ensure a minimum repair topping depth of 6 mm to match adjacent floor
elevations. Prepare, mix, and apply repair topping and primer according to
manufacturer's written instructions to produce a smooth, uniform, plane, and level
surface.

6. Repair defective areas, except random cracks and single holes 25 mm or less
in diameter, by cutting out and replacing with fresh concrete. Remove defective
areas with clean, square cuts and expose steel reinforcement with at least 20 mm
clearance all around. Dampen concrete surfaces in contact with patching concrete
and apply bonding agent. Mix patching concrete of same materials and mix as
original concrete except without coarse aggregate. Place, compact, and finish to
blend with adjacent finished concrete. Cure in same manner as adjacent concrete.

7. Repair random cracks and single holes 25 mm or less in diameter with patching
mortar. Groove top of cracks and cut out holes to sound concrete and clean off dust,
dirt, and loose particles. Dampen cleaned concrete surfaces and apply bonding agent.
Place patching mortar before bonding agent has dried. Compact patching mortar and
finish to match adjacent concrete. Keep patched area continuously moist for at least
72 hours.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 34
 H. Perform structural repairs of concrete, subject to Engineer's approval, using epoxy adhesive
and patching mortar.

I. Repair materials and installation not specified above may be used, subject to Engineer's
approval.

3.17 CONCRETE PROTECTION

A. The following are typical concrete protection and waterproofing requirements except
at basements, tunnels, and other buried structures. General: All concrete shall have
surface holes investigated and filled with a filler compatible with the coating to be applied
(if that coating alone cannot fill the hole) provided that they are small and formed by air
bubbles caught against the formwork. For surface holes having any dimension greater than
10 mm, refer to paragraph 3.16.

B. Blinding or Mudmat Concrete: Unless otherwise shown on Drawings, all foundations shall
be placed on 75 mm thick blinding or mudmat concrete and all slab on grade shall be placed
on 50 mm thick blinding or mudmat. Prior to placing this concrete, the subsoil shall be well
consolidated and free from loose material.

C. Impervious Membrane: Concrete shall be cast onto impervious sheeting complying with
ASTM E 154 laid over the concrete blinding or mudmat. Overlap shall be 150 mm and the
sheeting shall extend 150 mm beyond the edge of all foundations.

D. Surfaces Below Ground Level: Surfaces below ground level shall be coated with 3 coats of
modified bitumen giving a total coating thickness of 1 mm. A square scrape master sample
shall be taken to determine the weight of specified thickness of coating from a 300 mm by
300 mm patch. The weight can then be compared with test samples. With surfaces at grade
coated as specified, the bitumen shall overlap the epoxy coating by 75 mm. Before soil is
backfilled around the foundations, the coated surfaces shall be permanently covered with
impervious sheeting as specified in Paragraph 3.17.C and overlain with protection board,
suitably banded to retain it in position. Overlap of the sheeting shall be 150 mm.

E. Exposed External Surfaces at Ground Level:

1. Exposed external concrete surfaces for a depth of 150 mm below and 300 mm above
ground level, or to the underside of base plates (whichever is lowest), shall be primed
with a low viscosity primer and coated with 2 coats of a light gray colored epoxy
paint with a minimum thickness of 125 microns per coat.

2. Application trials shall be carried out on the chosen coating. Concrete surface
preparation and application shall be in accordance with the manufacturer’s
instructions.

F. Exposed External Surfaces Above Ground Level: General exposed exterior surfaces above
grade shall be coated as specified in Paragraph 3.17.E. The coating shall extend to the
underside of the baseplates; i.e., cover the grout.

G. External Surfaces Exposed to Saline Waters: Exterior surfaces in the sea splash zone or in
the tidal zone, or the interior faces of structures containing saline water, shall be coated as
specified in Paragraph 3.17.E.
3.18 GROUTING

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 35
 A. Preparation: Concrete foundation top shall be cleaned of dirt, laitance, oil and grease.
Anchor bolt boxes and sleeves shall be cleaned of all polystyrene and other deleterious
material. The surface of the concrete shall be thoroughly wetted just prior to grouting
but shall contain no excess water, particularly in the bolt boxes and sleeves.

B. Materials:

1. Type G1: For interior bases protected from weather and saline bearing waters and
not subject to heavy or vibratory loads, grout shall consist of one part CEM III/A
cement to two parts well graded sand by volume. Sand shall comply with Paragraph
2.5.C.2. A retarding superplasticizer may be used if necessary to obtain the correct
fluidity in high ambient temperatures.

2. Type G3: For all other exterior work exposed to potential saline ingress, a proprietary
general purpose non-shrink grout, especially formulated for high temperature work.

C. Placement:

1. The manufacturer’s recommendations shall be followed for proprietary grouts. The

temperature of the grout at time of placement shall not exceed 25 deg.C (77 deg.
F) and the temperature of the elements in contact with the grout shall not
exceed 40 deg.C (104 deg. F) . To obtain the required temperatures, it may be
necessary to do the following:

a. Shield the materials from the direct rays of the sun.

b. Mix materials with flaked ice.
c. Cool base plates with water but ensure that anchor bolt pockets are free
from water.
d. Require certification of plant and trucks to meet requirements of the
NRMCA Check List or approved equal.

2. Grout strength shall not be less than 30 N/sq. mm at 28 days. Document to Engineer
that this strength is being achieved. Grouting shall not proceed until the steel work
or equipment has been leveled and plumbed with the bases being supported in the
meantime by steel packers and shims.

3. Completely fill anchor bolt sleeves with grout before placing grout under base plates.
The gravity grouting method shall be used wherein the flowable self-leveling grout
is poured on one side of a base until it flows out at the opposite side. Packers and
shims used to level bases shall be removed after the grout has set and the resulting
pocket repaired with similar grout.

3.19 WATER-RETAINING CONSTRUCTION

A. General: Water-retaining construction shall comply with this Specification.

B. Joints: Joints shall be designed and constructed in accordance with ACI 504R. Details and
positioning of joints, together with the materials to be used, shall be shown on the
Drawings.
1. Waterstops shall be in accordance with Paragraph 2.6. Jointing of waterstops shall
be made by welding in an approved fashion. Lapping of waterstops at joints and the
use of adhesives for jointing purposes shall not be permitted unless specifically
authorized. Waterstops shall not be perforated or damaged. Concrete shall be

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 36
 carefully placed and compacted to ensure dense impervious concrete, particularly
around the ribs of waterstops. At all joints the concrete shall be placed up to the
centerline of the waterstop. All starters to walls of watertight construction shall
be cast using hung formwork so that the concrete in the starters is placed
simultaneously with the concrete in the slab.

C. Coating: Coat inside faces of structures containing saline waters as specified in Paragraph
3.17.F.

D. Testing: In addition to the testing required in Paragraph 3.20.C, further tests to determine
the water tightness of the structure shall be performed based on the requirements of ACI
350.1-01. Testing shall be performed after completion of the structure, installation of
fittings and accessories, but before the application of internal waterproofing, and before
any backfilling behind the structure's walls has taken place. The following measures
should be considered:

1. All tank penetrations and outlets shall be securely sealed to prevent loss of water
from the tank during the test. Tank penetrations and outlets shall be monitored before
and during the test and shall be repaired from leakage (if any) prior to taking
test measurements.

2. Rate of initial filling of a new tank should not exceed 1.2m/hr (of the tank height).
Tank filling shall be continued until the water surface is at the design maximum
water level or 100 mm below any fixed overflow level, whichever is lower.

3. Test measurements shall be recorded at 24 hr intervals. The test period shall be at

least the theoretical time required to record a drop in the water surface of 10 mm,
which is, according to the acceptance criterion, (2x104/h) days, rounded up, where h
is the water depth in (mm). Test period need not exceed five consecutive days.

4. The change in water volume in the structure shall be calculated and corrected, if
necessary for evaporation, precipitation and temperature. If loss exceeds the required
criterion, the structure shall be considered to have failed the test. The structure shall
also be considered to have failed the test if observed flowing or seeping from the
structure or if moisture can be transferred from exterior surface to a dry hand. The
structure shall not be considered to have failed the acceptance criterion if dampness
or wetness on top of a footing, in the absence of flowing water, is observed.

5. Acceptance criterion and performance of test shall be in accordance with the

requirements of ACI 350.1, standard criterion HST-050, which requires that the drop
in the water surface not exceed 0.05% in 24 hours.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 37
 6. Retesting shall be permitted if the first test fails to satisfy the criterion. A second test
may be performed immediately following the first test, provided that no visible
leakage is exhibited. If the tank fails the second test or if it was not tested
immediately after the first test failure, the tank shall only be retested after probable
areas of leakage have been detected and repaired. Tanks shall be retested until they
meet the required criterion.

3.20 QUALITY CONTROL AND TESTING

A. General:

1. Testing Laboratory:

a. Employ an independent testing agency, approved by the Engineer, to

perform tests and to submit test reports.
b. Be responsible for taking, identifying and delivering to the test laboratory all
test samples called for in this Specification. The testing laboratory shall be
responsible for the testing. Collect all test results and deliver them to the
Engineer in the format and detail as specified.

B. Quality Control - Testing on Fresh Concrete:

1. Compressive Strength Test for Structural Concrete:

a. Sampling, curing and testing shall be performed using the relevant procedures
in ASTM C 31/C31M, ASTM C 39/C39M, and ASTM C 172.

1) Samples for production concrete cylinders shall be taken at the point

of placement at the average rate of one per 50 cu. m of concrete
placed, with a minimum of one sample taken every day that the mix is
used. A sample shall consist of five 150 mm cylinders molded and
stored for laboratory-cured test specimens except when field-cured test
specimens are required. One cylinder is for testing at 7 days after
casting, two for testing at 28 days after casting, one cylinder is for
testing at 90 days after casting, and one reserved for later testing if
required. Concrete samples shall also be obtained for permeability and
absorption testing.

2) If frequency of testing provides fewer than 5 strength tests for a

given class of concrete, conduct testing from at least 5 randomly
selected batches or from each batch if fewer than 5 are used.

3) When total quantity of a given class of concrete is less than 50 cu. m,

the Engineer may waive strength testing if adequate evidence of
satisfactory strength is provided.

4) When strength of field-cured cylinders is less than 85 percent of

companion laboratory-cured cylinders, evaluate current operations and
provide corrective procedures for protecting and curing the in-place
concrete.

b. Permeability Tests:

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 38
 1) All specified absorption and permeability tests included under clause
2.12.N and 2.12.O shall be carried out on representative concrete
cylinder samples, collected from the concrete batches delivered on site,
frequency of testing to be determined by the Engineer on site.

c. Records: Records shall be kept of the mix details and position in the works of
all batches of concrete and of all samples taken for cylinders and other
specimens and of their test results. A copy shall be supplied to the Engineer
within 24 hours after recording/testing. Records shall contain, but not be
limited to, the following information:

1) Date, time, location, and volume of pour.

2) Ambient temperature and humidity.
3) Concrete temperature (at time of placement).
4) Cement type and manufacture.
5) Concrete type and class.
6) Aggregate type and source.
7) Admixture details.
8) Water/cement ratio.
9) Identification of test cylinder.
10) Name of concrete testing service.
11) Date and time of sampling.
12) Method of compaction.
13) Date of testing and results of test.
14) Age of sample in days, weight in grams, density in kg/cu. m.
15) Crushing load in newtons and crushing strength in N/sq. mm.
16) Signatures of person preparing cylinder and of person crushing
cylinder.
17) Results of testing.

d. For the 28-day tests, the concrete will be deemed to comply with the specified
design strength if the average strength determined from all sets of 3
consecutive tests is at least equal to the specified design strength and no
individual strength test falls below the specified design strength by more than
3.5 N/sq. mm. Any concrete not complying with the specified design strength
shall be at risk for removal and replacement at the Contractor’s expense.

e. The 28-day cylinder crushing results shall be grouped consecutively in groups

of 40 and each group shall have a standard deviation less than 3.5 N/sq. mm.
If the standard deviation is greater than or equal to 3.5 N/sq. mm, then
concrete production shall be investigated by the Engineer and further tests on
trial mixes may be required.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 39
 f. Tests shall be carried out at 7 days to establish a relationship between the 7-
day and 28-day strengths. This relationship shall be used to interpret future
test results in order to predict the corresponding 28-day strength. The
Engineer shall be advised without delay of any 7-day test result indicating
that the corresponding 28-day strength will likely fail to meet the specified
strength so that any necessary action can be taken to minimize the effect of
such possible failure.

2. Compressive Strength Test for Blinding or Mudmat Concrete: There shall be no

production tests on blinding or mudmat concrete. The Engineer will require
compressive strength tests if it is believed that the characteristic cylinder strength
is below 11 N/sq. mm. Characteristic strength is defined as that value of the cube
strength below which 5 percent of all possible test results would be expected to
fall. If the tests confirm that the characteristic strength is less than 11 N/sq. mm,
then the Engineer will require revisions to the mix design to ensure that the
concrete meets the specified requirements.

3. Measurement of Concrete Temperature: Temperature measurements shall be in

accordance with ASTM C 1064/C1064M. Concrete temperature shall be
measured 50 mm below the surface prior to and at the point of placement and
recorded on the pour card for each pour. There shall be one test hourly when air
temperature is 4 deg.C (39 deg. F) and below and when air temperature is 27 deg.C
(81 deg. F) and above, and one test for each set of compressive-strength
specimens. Concreting shall stop if the temperature of the concrete does not meet
the requirements of Paragraph 3.9.H.

4. Cement Content and Water/Cement Ratio: Samples of freshly mixed concrete shall
be chosen by the Engineer at least once per month from each structural grade and
determination made of cement content and water/cement ratio in accordance with
BS 1881. If the cement content is less than 90 percent of the requirement in
Paragraph 2.12.E. or the water/cement ratio greater than 110 percent of the
requirement in Paragraph 2.12.G. then there shall be an investigation to establish
the cause and the Engineer may reject the casted concrete for the pour from which
the samples were taken. The Engineer may request an analysis of fresh concrete
from any pour. No analysis of freshly mixed concrete is required for blinding or
mudmat concrete.

5. Salt Content: The total concentrations of sulfates and chlorides in the fine and
coarse aggregates shall be measured at least once a week for all structural grades
of concrete. Tests shall be in accordance with BS EN 1744-1. Concentrations of
each ion shall not exceed the limits specified in Paragraph 2.4.E.1 for coarse
aggregates, 2.4.E.2 for fine aggregates and 2.12.I for the total salt content of
concrete. If these limits are exceeded, the concrete pour from which the samples
were taken shall be rejected and further tests performed on the cast concrete in
accordance with Paragraph 3.20.C to determine the total extent of the problem.
Slump: Slump tests shall be performed in accordance with ASTM C 143/C143M.
There shall be a minimum of one test at the point of discharge for each day's pour
for each type of concrete. Additional tests shall be performed when concrete
consistency appears to have changed

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 40
 C. Quality Control - Testing on Hardened Concrete:

1. General: The Engineer may request samples to be taken and tests carried out on
any hardened structural grade concrete as specified below if he suspects that the
concrete does not meet the specified requirements. If the tests confirm that the
concrete does not meet the requirements of this Specification, then the Engineer
may require the concrete to be removed at the Contractor’s expense. If the tests
confirm that the concrete meets the requirements of this Specification, then the
cost of taking the samples shall not be at the Contractor’s expense.

2. Compressive Strength Tests: The Engineer may request cores to be drilled from a
particular pour. 100 mm diameter cores shall be drilled as requested, in accordance
with ASTM C 42/C42M, and sent for crushing. If the cores from that pour have an
average compressive strength less than 85 percent of the characteristic strength or
any individual core has a compressive strength less than 75 percent of the
characteristic strength, it shall be evidence that the concrete from which it was taken
is not in accordance with the specified requirements.

3. Concrete Cover: The Engineer may check the concrete cover over the reinforcement
with a cover meter. Any indication that the cover is generally less than the
requirements specified in Paragraph 3.6.I shall be checked by limited surface
concrete removal. If it is confirmed that the actual cover is generally less than
specified, then the concrete shall be removed at the Contractor’s expense. In the case
of localized lack of cover and where appearance is not important, a repair shall be
effected by removal of the inadequate cover and the cutting back of concrete for 50
mm behind the reinforcement. Resurfacing of the concrete with the specified cover
shall be carried out as a repair by a specialist subcontractor as specified in Paragraph
3.16.

4. Absorption: A sample of three 75 mm diameter cores, 75 mm long, shall be taken

from hardened concrete if directed by the Engineer and tested in accordance with
Paragraph 2.12.N. Should the absorption of any core exceed by more than 1 percent
the highest approved test result, then the concrete from which it was cut shall be
removed. No absorption test shall be required for blinding or mudmat concrete.

5. Permeability Tests: Sample of three 75 mm diameter cores, 75 mm long, shall be

taken from hardened concrete if directed by the Engineer and tested in accordance
with Paragraph 2.12.O. Should the permeability of any core exceed the highest
approved test result, then the concrete from which it was cut shall be removed. No
permeability test shall be required for blinding or mudmat concrete.

6. Salt Content: Engineer may request samples to be taken from two 20 mm diameter
drillings into the concrete surface, spaced 75 mm apart. Each drilling shall proceed
in 25 mm increments for a total depth of 100 mm and the dust from the 4 samples in
each hole shall be sent for sulfate and chloride content analysis in accordance with
BS 1881 Part 124. Should the tests show that the limits specified in Paragraph 2.12.I
are exceeded, the concrete shall be removed.

7. Nondestructive Testing: Impact hammer, sonoscope, or other nondestructive device

may be used but shall not be used as the sole basis for acceptance or rejection.

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 41
 8. Additional Tests: The testing agency shall make additional tests of in-place concrete
when test results indicate specified concrete strengths and other characteristics have
not been attained in the structure, as directed by the Engineer. Testing agency may
conduct tests to determine adequacy of concrete by cored cylinders complying with
ASTM C 42/C42M, or by other methods as directed.

3.21 PROTECTION OF LIQUID FLOOR TREATMENTS

A. Protect liquid floor treatment from damage and wear during the remainder of
construction period. Use protective methods and materials, including temporary covering,
recommended in writing by liquid floor treatments installer.

END OF SECTION 033000

Cairo Alexandria Trade Logistics Development Project

April, 2025 033000 - 42
 SECTION 071613

POLYMER MODIFIED CEMENT WATERPROOFING

PART 1 – GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and

Supplementary Conditions and Division 0 I Specification Sections, apply to this Section.

1.2 SUMMARY

A. Section includes polymer-modified cement waterproofing for wet areas and where
indicated in drawings.

B. Related Requirements:

1) Division 03 Section 033000 "Cast-in-Place Concrete" for concrete slabs serving

as protective topping for waterproofing and the finishing of concrete walls and slabs
to receive waterproofing.
2) Division 09 Section "Tiling" fur waterproofing applied in wet area under tiling.

1.3 PREINSTALLATION MEETINGS

A. Preinstallation Conference: Conduct conference at Project site.

1.4 ACTION SUBMITTALS

A. Product Data: For each type of product.

1) Include construction details, material descriptions, and installation instructions.

B. Samples for Initial Selection: For each type of exposed product.

1) Include samples of available color selection.

C. Samples for Verification: For each type of waterproofing indicated, in manufacturer's

standard sizes.

1.5 INFORMATIONAL SUBMITTALS

A. Qualification Data: For Applicator.

B. Product Certificates: For each type of waterproofing, patching, and plugging material.

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 071613 - 1
 C. Product Test Reports: For each product formulation, for tests
performed by manufacturer and witnessed by a qualified testing agency.

D. Field quality-control reports.

1.6 QUALITY ASSURANCE

A. Applicator Qualifications: A firm experienced in applying polymer-modified cement

waterproofing similar in material, design, and extent to that indicated for this Project,
whose work has resulted in applications with a record of successful in-service
performance, and that employs workers trained and approved by manufacturer.

B. Mockups: Build mockups to verify selections made under Sample submittals, to

demonstrate aesthetic effects, and to set quality standards for materials and execution.

1) Build mockup of typical vertical and horizontal surfaces in locations and sizes as
directed by the Engineer.
2) Approval of mockups does not constitute approval of deviations from the Contract
Documents contained in mockups unless Engineer specifically approves such
deviations in writing.
3) Subject to compliance with requirements, approved mockups may become part
of the completed Work if undisturbed at time of Substantial Completion.

1.7 FIELD CONDITIONS

A. Weather Limitations: Proceed with application only when existing and forecasted
weather conditions permit polymer-modified cement waterproofing to be performed
according to manufacturer's written instructions.

B. Proceed with waterproofing work only after pipe sleeves, vents, curbs, inserts, drains, and
other projections through the substrate to be waterproofed have been completed. Proceed
only after substrate defects, including honeycombs, voids, and cracks, have been repaired
to provide a sound substrate free of forming materials, including reveal inserts.

C. Ambient Conditions: Proceed with waterproofing work only if temperature is maintained

at 4.4 deg C or above during work and cure period and space is well ventilated and kept
free of water.

1.8 WARRANTY

A. General Warranty: Any special warranty specified in this Article shall not deprive the
Employer of other rights Employer may have under other provisions of the Contract
Documents and shall be in addition to, and run concurrent with, other warranties made by
the Contractor under the requirements of the Contract Documents.

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 071613 - 2
 B. Special Warranty: Written warranty, signed by the Applicator and
countersigned by the Contractor agreeing to repair or replace
waterproofing that does not comply with requirements or !bat fails to
perform as required, and to maintain watertight conditions within
specified warranty period. Warranty includes responsibility for removing and replacing
other work that conceals modified cement waterproofing. During warranty period,
repairs and replacements required because of unusual weather phenomena and other
events beyond the Contractor's or the Applicator's control shall be completed by the
Contractor or the Applicator and paid for by the Employer at prevailing rates.

1) Warranty Period: 10 years from date of Substantial Completion.

PART 2- PRODUCTS

2.1 PREPACKAGED, POLYMER-MODIFIED CEMENT WATERPROOFING

A. Positive-Negative Side, Polymer-Modified Cement microfiber reinforced class A4 crack

bridging Waterproofing coating for concrete substrates: Manufacturer's proprietary
blend of dry cementitious and other ingredients for mixing with polymer admixture
to produce a waterproof coating that is suitable for vertical and horizontal applications
below or above grade, is breathable, resists positive and negative side hydrostatic
pressure, and has properties complying with or exceeding the criteria specified below.

B. Performance requirements when referred to 2 mm thickness:

Test method Performance (referred to 2 mm thick-ness)

Adhesion to the concrete, EN 1542: MC substrate (0.40) to EN 1766 > 1 MPa

Thermal compatibility: adhesion EN 1542 after 50 freeze-thaw cycles > 1 MPa

with de-icing salts EN 13687/1

-Class A4 {crack opening 1.25- 2.5 mm).

Crack bridging ability a 23oC. UNI EN 1062/7 -Static -Dynamic -Class B2 (1000 cycles, 0,03 Hz, crack opening WO= 0.15
mm and WU= 0.10 mm)

Resistance to artificial weathering (2000 hours of UV radiation and No blistering, cracking or flaking, no change
condensation), EN 1062/11 in color

Resistance to positive hydrostatic pressure, EN 12390/8 5 bar (equivalent to 50 m water column)

Resistance to negative hydraulic pressure UNI8298/B 2.5 bar (equivalent to 25 m water column)

Capillary absorption coefficient EN 1062/3 < 0.1 kg.m-2.h-0.5

Permeability to CO2 measured as air equivalent thickness Sd, EN Sd >50m

1062/6. Sd = µ.s, µ = coefficient diffusion to CO2, s =thickness of
coating

Impact resistance, EN ISO 6272 Class I:4 N·m Class II: 10 N·m Class III: Class Ill (equivalent to the fall of a 1 kg steel ball from a
20N·m height of 2 m)

Permeability to water vapour measured as air equivalent thickness

Sd, EN ISO 7783/1. Sd = µ.s, µ = water vapour diffusion resistance Class I
coefficient, s = thickness of coating Class I:Sd < 5 m (Permeable) Class
II: Sd 5 and 50 m Class III: Sd >50 (Not Permeable)

Abrasion resistance, EN ISO 5470/1 (Load 1000 g abrading wheel Weight loss < 3000 mg
H22/1000 cycles)

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 071613 - 3
 C. Chemical Resistance:

Resistance to Severe Chemical Attack, EN 13529

Class I : 3 days contact, reduction shore 50 % class II : 28 days contact, reduction shore 50 % Class Reduction Shore

Testing liquid 11 (20% sodium hydroxide) :Inorganic bases and their salts undergoing acid hy-drolysis
in aqueous solution (pH< 8) excepting ammonium solutions and oxidizing salt solutions (e.g II 0%
hypochlorite)
Testing liquid 12 (20% sodium chloride) : Non-oxidising inorganic salt solutions with pH= 6 - 8 II 0%

D. Color: As selected by Engineer from full range.

E. Locations: Wet areas floors and walls and where indicated.

2.2 ACCESSORY MATERIALS

A. Non-woven fabric for reinforcing waterproofing membrane: macro-holed polypropylene

fabric reinforcement with the following properties:

1) Type of: fiber: polypropylene.

2) Appearance: non-woven, macro holes l/24"(1 mm).
3) Weight: 0.26 U.S oz. per sq. ft. (80g per m2).
4) Thickness: 1/42" (0.6mm).
5) Tensile strength: 375lbs. per ft. (5KN perm).
6) Deformation at maximum strain: 90 % longitudinal, 60% transverse.
7) Crack bridge:
a. After 28 days at +23oc and 50% relative humidity: 1/8"(3mm)
b. After 7 days at +23oc and 50% relative humidity: 1/8" (3mm)
c. After 21 days submerged in water: 1/8" (3mm)

B. Patching Compound: Factory-premixed cementitious repair mortar, crack filler, or

sealant recommended by waterproofing manufacturer for filling and patching tie holes,
honeycombs, reveals, and other imperfections and compatible with substrate and other
materials indicated.

C. Plugging Compound: Factory-premixed cementitious compound with hydrophobic

properties and recommended by waterproofing manufacturer; resistant to water and
moisture but vapor permeable for all standard applications (vertical, overhead, and
horizontal surfaces not exposed to vehicular traffic); and compatible with substrate and
other materials indicated.

D. Portland cement: AS1M Cl50/Cl50M, Type I.

E. Slurry-Coat and Protective-Topping Sand ASTM Cl44.

F. Trowel-Coat Sand: AS1M C33/C33M, fine aggregate.

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 071613 - 4
 G. Protective-Topping Sand: ASTM Cl44.

H. Polymer Admixture for Protective Topping: Polymer bonding

agent and admixture designed to improve adhesion to prepared substrates
and to not create a vapor barrier.

I. Water: Potable.

2.3 MIXES

A. Prepackaged, Polymer-Modified Cement Waterproofing: Add prepackaged dry

ingredients to mixing liquid according to manufacturer's written instructions. Mix
together with mechanical mixer or by hand to required consistency.

PART 3 -EXECUTION

3.1 EXAMINATION

A. Examine substrates, areas, and conditions, with Applicator present, for suitable conditions
where waterproofing is to be applied.

B. Proceed with application only after unsatisfactory conditions have been corrected.

C. Notify Engineer in writing of active leaks or defects that would affect system
performance.

3.2 PREPARATION

A. Comply with manufacturer's written instructions.

B. Protect other work from damage caused by cleaning, preparation, and application of
waterproofing. Provide temporary enclosure to confine spraying operation and to ensure
adequate ambient temperatures and ventilation conditions for application.

C. Do not allow waterproofing, patching, and plugging materials to enter reveals or annular
spaces intended for resilient sealants or gaskets, such as joint spaces between pipes and
pipe sleeves.

D. Stop active water leaks with plugging compound.

E. Repair damaged or unsatisfactory substrate with patching compound.

1) At holes and cracks 1.6 mm wide or larger in substrate, remove loosened chips
and cut reveal with side’s perpendicular to surface, not tapered, and minimum 25
mm deep. Fill reveal with patching compound flush with surface.

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 071613 - 5
 F. Surface Preparation: Remove efflorescence, chalk, dust, dirt, mortar
spatter, grease, oils, paint, curing compounds, and form-release agents to
ensure that waterproofing bonds to surfaces.

1) Clean concrete surfaces according to ASTM D4258.

a) Scratch- and Float-Finished Concrete: Etch with 10 percent muriatic acid

solution according to ASTM D4260.
b) Smooth-Formed and Trowel-Finished Concrete: Prepare by mechanical
abrading or abrasive-blast cleaning according to ASTM 04259.

2) Clean concrete unit masonry surfaces according to ASTM D4261.

a) Lightweight Concrete Unit Masonry: Etch withI0 percent muriatic acid solution
or abrade surface by wire brushing. Remove acid residue until pH readings of
water after rinse are not more than 1.0 pH lower or 2.0 pH higher than pH of
water before rinse.
b) Medium- and Normal-Weight Concrete Unit Masonry: Sandblast or bush
hammer to a depth of 1.6 mm.

3) Clean clay masonry surfaces according to ASTM D5703.

4) Concrete Joints: Clean reveals.

3.3 APPLICATION

A. General: Comply with waterproofing manufacturer's written instructions for application

and curing.

1) Saturate surface with water for several hours and maintain damp condition until
applying waterproofing. Remove standing water.
2) Apply waterproofing to surfaces, and extend waterproofing onto adjacent
surfaces as follows:

a) Onto columns integral with treated walls.

b) Onto interior nontreated walls intersecting exterior treated walls, for a distance
of 600 mm fur cast-in-place concrete and 1200 mm for masonry.
c) Onto exterior walls and onto both exterior and interior columns, fur a height of
300 mm, where floors, but not walls, are treated.
d) Onto every substrate in areas indicated for treatment, including pipe trenches,
pipe chases, pits, sumps and similar offsets and features.

3) Number of Coats: Number required for specified water permeability

a) Coating Thickness: Maximum application thickness of 1.2 mm per coat for total
thickness as required for specified water permeability.
b) Apply first coat as a slurry with brush or roller, and apply subsequent coats with
brush, roller, spray, or trowel.

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 071613 - 6
 c) Vigorously work first coat onto the substrate, forcing the
material into surface voids. Apply each subsequent coat into full contact
with previous coat.

d) Allow manufacturer’s recommended time between coats. Dampen surface

between coats.

B. Final Coat Finish: Smooth troweled.

C. Curing: Cure waterproofing for not less than five days immediately after application and
prior to being placed in service.

D. Curing: Moist-cure waterproofing for not less than three days immediately after
application has set, followed by air drying prior to being placed in service unless
otherwise recommended in writing by manufacturer.

E. Protective Topping: Apply 25-mm thick, protective topping over floor surfaces. Moist-
cure topping for not less than three days.

3.4 PROTECTION

A. Protect applied polymer modified cement waterproofing from rapid drying, severe
weather exposure, and water accumulation. Maintain completed Work in moist condition
for not less than 7 days by covering with impervious sheeting or as recommended by
waterproofing manufacturer.

3.5 FIELD QUALITY CONTROL

A. Engage a site representative qualified by waterproofing system manufacturer to inspect

substrate conditions, surface preparation; system application, protection, and drainage
components, to test and inspect completed application of waterproofing, and to furnish
daily reports to Engineer.

B. Flood Testing: Flood test each deck area for leaks, according to ASTM D 5957, after
completing waterproofing but before overlying construction is placed. Install temporary
containment assemblies, plug or dam drains, and flood with potable water.

1) Flood to an average depth of 65 mm with a minimum depth of 25 mm and not

exceeding a depth of 100 mm Maintain 50 mm of clearance from top of sheet
flashings.
2) Flood each area for 48 hours.
3) After flood testing, repair leaks, repeat flood tests, and make further repairs
until waterproofing installation is watertight.

C. Prepare test and inspection reports.

END OF SECTION 071613

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 071613 - 7
 SECTION 321000

EARTH MOVING

PART 1 – GENERAL

1.1 RELATED DOCUMENTS

A. All tests listed in this document according to ASTM Standards are also accepted to be
conducted using equivalent BS/BS EN Standards or Egyptian Code of Practice ECP-203
(2017).

B. Drawings and general provisions of the Contract, including Conditions of Contract and
Division 1 Specification Sections, apply to this Section.

1.2 SUMMARY

A. Egyptian Construction Specifications forms the basis of the Specification for the WORK. The
following clauses are to be added and or supplemented to those of Construction
Specifications (ECP).

B. Excavate, backfill, compact and grade the site to the elevations shown on the drawings, as
specified herein and as needed to meet the requirements of the construction shown in the
Contract Documents, including, but not limited to, the following:
a. Construction of foundations
b. Reinforced concrete pits and trenches
c. Ground bearing slabs

C. Related Sections

In addition to the general conditions of contract, the Contractor shall also refer to the following
specifications:

a. Cast-in-place Concrete
b. Bored Piles
c. Sub-Structure Water Proofing

D. Parties And Persons

Employer – the person named as the employer in the Contract Agreement and the legal successors in
title to this person.

Contractor -The person(s) named as the contractor in the Contract Agreement and the l e g a l
successors in title to t h i s person(s). [Includes sub-contractors and consultants (Contractor’s
Representative) appointed by the Contractor to undertake the works]

1.3 REFERENCES

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 1
 A. GENERAL

1) Except where otherwise specified, work shall be in accordance with the Egyptian Standards
relevant to this specification. The latest editions shall be used, including all current
amendments and additions.

2) Any differences between the Contractor requirements and this specification shall be
submitted to the Employer for his ruling.

1.4 SUBMITTALS

1) Comply with pertinent provisions of ECP

2) Prior to starting work on the contract the Contractor shall submit for Employer
approval details of the proposed sources of all materials, and place of manufacture,
together with full documentary evidence that the materials and manufacture will
comply with the specification.

3) Further submissions shall be made for any change of material quality or source and the
Employer approval obtained before the new materials or place of manufacture are used.

1.5 QUALITY ASSURANCE

1) Material shall be obtained from suppliers operating quality systems accordance with an
in-house system approved by the Employer.

1.6 DELIVERY, STORAGE AND HANDLING

1) Materials shall be stored in a manner that will ensure preservation of their

specified quality and fitness for the work. They shall be placed on hard, clean surfaces
and, when required by the Employer they shall be placed under cover. Stored materials
shall be located in such a manner to facilitate prompt inspection and control.

PART 2 – PRODUCTS

2.1 GENERAL

2.1.1 APPROVAL OF MATERIALS

All materials, suppliers and sources must be approved in writing by the Employer
prior to their use in the works. Prior to approval being given all or any of the
following must be complied with, as required by the Employer:
a) Provision of a material to site and subsequent testing of the sample for compliance with
the Specification and standards. Refer “testing requirements” section contained in this
specification.
b) Site inspection at up to three locations where the material has been used over the previous
5 years.
c) Provision of test data for material produced at the supplier’s source over the previous 6

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 2
 months.
d) Works inspection.

2.2 CLASSIFICATION OF MATERIALS

2.2.1 Approval of Materials

a. Material which gives support to other parts of the works and which has to meet specific
requirements for strength and stability.
b. Material for this purpose shall be of Suitable Material as described below.
1) Material which is acceptable for retention information, use in fill and/or re- use after
excavation, and which excludes unsuitable material as described in the “Unsuitable
Material” clause contained on the following page.
2) Selected backfill material for structures, foundation pits, trenches and retaining walls
3) Suitable material for earthworks such as granular (sand, gravel and crushed rock) shall meet
the following requirements:
 Max. passing 0.075 mm sieve is 20%
 Max. liquid limit is 35%
 Max. plasticity index is 10%
 Max. organic matter is 2%
 Minimum soaked CBR of 15% when compacted to 95% of maximum dry density,

2.2.2 Approval of Materials

a. Material for all other purposes as shown on the drawings or otherwise specified.
b. Material for this purpose shall be of Structural Fill except the size limitation for granular
material may be increased with the Employer approval.

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 3
 2.3 UNSUITABLE MATERIALS

Material which is unsuitable for use in fill or retention in excavation as part of the formation and for
re-use after excavation and is as described below:

a. Top soil including materials from swamps, marshes, bogs & perishables.

b. Organic matter in soil > 2%

c. Rock particles exceeding 75mm in size

d. Materials susceptible to spontaneous combustion

e. . Soil of liquid limit > 40% and plasticity index > 11%

f. Material which is not well graded and with uniformity coefficient <3

g. Material having hazardous and /or unacceptable chemical and/or physical properties.

h. Other prescribed material described in the Contracts or as defined by the employer

i. Sabkha soil

j. Material containing more than 5% of water soluble salts by weight of dry soil
(individually, water soluble chloride exceeding 1% or water soluble sulphate exceeding
1.5%) as determined by BS 1377 part 3

k. Any other material which the Engineer may deem to be unsuitable for earthworks

2.4 SELECTED BACKFILL MATERIAL FOR STRUCTURES, FOUNDATION PITS,

TRENCHES AND RETAINING WALLS

1. Material shall comply with the requirements of structural fill where it supports the works
above, and non-structural fill elsewhere.

2. Any fill material used within 1.0 meters of concrete structures or cement- bound
materials shall not have a water-soluble sulphate content exceeding

2.5 GRANULAR FILL

Granular fill shall be a free-draining material complying with the following:

A. Material shall be granular crushed rock with maximum size 50 mm unless otherwise
specified by the Employer.

B. Aggregate crushing value shall not exceed 30% in accordance with ECP

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 4
 C. Material used for backfill adjacent to structures shall have a sulphate content of less than
• g/L when tested in accordance with ECP

D. Material on wet sieving, in accordance with ECP, shall comply with the requirements
shown in Table 1 below or as approved by Employer

% Passing
Sieve Class A Class B Class C
63 100 0 0
50 90 – 10 0 100 0
37.5 60 – 9 0 70 – 100 0
25 42 – 77 55 – 85 100
20 35 – 70 50 – 80 90 – 100
10 25 – 60 40 – 70 50 – 85
5 15 – 40 30 – 60 35 – 65
2.36 10 – 26 20 – 50 25 – 50
0.425 5 – 15 10 – 30 15 – 30
0.075 2–9 5 – 15 5 – 15

Table 1: Particle Size Distribution for Granular Fill

2.6 ROCK FILL (IF NEEDED)

Rock fill shall consist of hard durable inert natural material of suitable size for
deposition and compaction. The maximum size of such materials shall not exceed two-
thirds of the thickness of the compacted layer and shall be graded so that when the layer
compacted is uniformly dense and the surface is closed.

2.7 FILL MATERIAL FOR DEPOSITION BELOW STANDING WATER (IF NEEDED)

1. In circumstances where backfill has to be deposited below standing water, only rock, as
specified in Section 6, Road works, is to be used unless otherwise instructed by
Employer.

2. Also if agreed by the Employer, fill material for deposition below standing water shall be
granular material with a 10% fines value of not less than 50 KN as tested in accordance
with BS 812: part 103 (method 8), except that samples shall be soaked in water at room
temperature for 48 hours prior to testing without having been previously oven-dried. The
material shall have a maximum particle size not greater than 400 mm and shall have a
particle distribution size in the smaller fractions as shown in Table 2 below.

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 5
 Sieve Size Percentage by Mass Passing
37.5 mm 0-100

6.3 mm 0-100
3.35 mm 0-35
2.36 mm 0-10
600 micron 0-2

Table 2: Particle Size Distribution for material for Deposition below Standing Water

2.8 FILL MATERIAL FOR DEPOSITION ON SOFT GROUND

1. Fill material for deposition on soft ground shall be granular material with a 10% fines
value of not less than 50 KN as tested in accordance with ECP, except that samples shall
be soaked in water at room temperature for 48 hours prior to testing without having been
previously oven- dried.

2. The material shall consist of granular material graded from 400 mm to 150 mm, except
that not more than 10% shall be less than 150 mm size. For treatment of small areas of
soft ground, the Employer may require the size range to be reduced to such sizes as the
Employer may direct.

3. Soft spots are to be removed and backfilled with suitable excavation surplus material or
any other suitable soil as permitted by the Employer.

4. Filling to be on compacted layers not exceeding 150mm in thickness.

2.9 SOLID ROCK

1. Solid rock shall mean rock found in ledges or masses, greater than 0.3 m3 in volume in
its original position, which has to be loosened either by blasting, by hydraulic breaker, by
pneumatic tools or, if excavated by hand, by wedges and sledge hammers.

2. Descriptions of soils and rocks shall comply with the requirements of ECP when included
or otherwise agreed with the Employer. The criteria which are to be used to
distinguish between the various types of soil, soft rock and hard rock will be agreed
between the Contractor and the Employer on Site.

2.10 IMPROVED SUBGRADE MATERIAL

1. Material for Improved Subgrade layer shall meet the following requirements:

Subgrade: the compacted existing ground or fill for 500 mm beneath formation Which if
falls under clause 2.3 in this specs, shall be improved as following:

a. Replace with suitable surplus excavation soil or any other suitable soil as permitted by
the Employer.
b. The existing natural ground shall then be scarified in place to a minimum depth of
150 mm for the full width of the embankment except where the material is classified

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 6
 as rock. The scarified material shall be watered as required, thoroughly mixed, shaped
and compacted to a minimum of 95 % maximum dry density.

c. Soaked CBR value at 95% maximum dry density (soaked) not less than 30% when
tested .

2. A chemical analysis of the proposed material shall be carried out to satisfy the following
requirements:

1) The material shall be shown to 10% of acid-soluble salts (individually, acid

soluble chloride exceeding 2% or acid soluble sulphate exceeding 3%).

3. When approved by the Employer a sulphate content greater than that specified in
section 2 may be acceptable when the carbonate content is in the region of 40- 50% .

4. The moisture content of the compacted material shall not vary by more than ±3% of the
optimum moisture content when tested .

5. The material shall possess satisfactory binding characteristics to enable it to be

compacted to give a smooth well-knit surface as judged by the Employer.

2.11 GEOTEXTILES (IF NEEDED)

Geotextile fabrics where required below fill on soft ground, on fill below standing water and
where required by the Employer shall meet the following minimum requirements:

1. Geotextile fabric suitable for placing over fine sand

2. Non-woven fabric consisting only of long-chain polymeric filaments or yarns formed
into a stable network such that filaments or yarns retain their relative position to each other
3. Stabilized against ultra-violet light
4. Resistant to chemical attack from ground and water-borne salts
5. Weight of 135 g/m2
6. Thickness under load of 2 KN/m2 > 0.7 mm
7. Tensile strength of 200 mm width to ASTM D1682 > 1.6 KN
8. Puncture resilience to DIN 54307 > 1.5 KN
9. Permeability > 50 l/m²/s.

PART 3 – EXECUTION

3.1 GENERAL

3.1.1 LEVELS, REFERENCE POINTS AND SETTING OUT

A. The works are to be set out from primary datum level(s) and setting-out point(s)
indicated on the drawings or from information provided by the Employer.

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 7
 B. The Contractor shall submit his proposals, for setting out and controlling the
alignment of the Works, to the Employer and obtains his approval prior to the start of
construction. The Contractor shall supply the details of the level and location of all
temporary benchmarks and established reference points to the Employer.

C. Should the Contractor dispute the original ground levels shown on the Drawings he
shall agree these with the Employer before disturbing the original ground.

3.1.2 Method of Construction

A. Prior to the commencement of work, the Contractor shall submit to the Employer the
detailed proposals for methods of construction (including temporary works and
construction plant) for all earthworks. The detailed proposals shall include but not be
limited to the numbers and types of plant, routings and expected outputs, locations of
spoil heaps, installation and removal of Temporary Works, attendance and
supervision, protection of existing services and controls to ensure quality assurance
and safety.

3.1.3 Exiting Buried Services

A. The Contractor is to ascertain the position of all existing services within the area of the
construction Works.

B. All existing services must be maintained and protected during the progress of the
Works. The Contractor shall be responsible for any damage caused to the underground
services and/or any delays arising from such damage.

C. The location of all existing services is to be documented and details submitted to be

documented and details submitted to the Employer.

3.2 TESTING

1) Testing Laboratory

A. An on-site testing laboratory shall not be required. The Contractor shall be required
to provide the services of an independent testing laboratory approved by the
Employer for the purposes of carrying out the testing, all as prescribed in the
Specification.

B. Test equipment shall include for carrying out the following tests:

1. Mechanical analysis (particle size distribution) including fine analysis using

sedimentation and full pre-treatment,
2. Moisture determination in accordance with ECP.
3. Liquid limit.
4. Plasticity Index.
5. Dry density moisture content relationship.
6. Field Density of compacted soil.
7. All other tests as required in the Specification

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 8
 C. Where it is agreed with the Employer, and the extent of earthworks is small an
independent laboratory may be used to carry out all necessary testing. This terms
and clauses regarding independent laboratories are obligatory and considered to be
part of the contract conditions.

D. The Contractor shall follow and comply with regular Circulars regarding testing and
laboratories, Quality forms, Safety forms etc. Which are issued from the Employer
or relevant authorities.

E. The Contractor shall only engage independent laboratories from the latest approved
laboratory list issued by the Employer or relevant authorities for Quality Control
purposes.

F. The Contractor shall provide all necessary containers, plant, transport and labor for
obtaining and handling of samples.

G. The Contractor shall provide all necessary staff for testing including a suitably
qualified laboratory supervisor who will be subject to the Employer written
approval.

H. The frequency of testing which is to be carried out shall be as specified by the

Employer but not less than one set of tests a day or part thereof, when the relevant
works are in progress. The Employer shall be notified when tests are to be
undertaken. The Contractor shall supply the Employer with full reports (two copies)
and two copies of test results together with laboratory test worksheets within 24
hours of carrying out such tests.

3.3 WORKMANSHIP

1. In the setting-out and construction of excavations and filled areas the Contractor
shall allow for settlement, heave and lateral spreading of embankments whether caused
by consolidation of fill, settlement of foundation, heave in excavations or change in
volume of materials after excavation or any other cause.

2. The tolerance limits for the permanent finished earthworks shall be as follows:

a) Horizontal dimensions shall be only ± 2 0 mm of the dimensions shown on the

drawings
b) For slopes to embankments or cuttings the horizontal deviation between the top and
the bottom of the slope shall be within ± 5% of the horizontal component of the
slopes shown on or calculated from the Drawings, but shall not exceed the values in
section 3.3.1.
c) Formation levels shall be within +15 and -20 mm of the levels shown on the
Drawings.
d) All finished surfaces shall have the correct cambers and/or falls for drainage.

3. The moisture content and acceptability of material arising within the Site shall be
determined in its unexcavated state.

4. The Contractor shall employ plant and methods of working which maintain acceptable
material in a suitable condition for use and or reuse in the Works.
5. Should for any reason whatsoever the ground becomes unstable the Contractor
shall inform the Employer immediately and shall submit for the Employer approval proposals for
dealing with the unstable ground. If necessary the Contractor shall proceed with the work

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 9
 by day and night without intermission and to the extent required by the Employer. Records of all
labor, plant and material involved, including pumping, shall be agreed with the
Employer as work proceeds.

6. Adverse Conditions

A. The Contractor shall not carry out any excavation or placing of fill materials
when conditions are such that the Works or other Works would be adversely affected.
Once any operation has been stopped, owing to adverse weather or other
conditions, it shall not be re-started without the approval of the Employer.

B. The Contractor shall plan his operations so as to take account of the season and to
take full advantage of favorable climatic conditions. Additionally, the Contractor's
temporary drainage of the Works shall take these factors into account.

C. The Contractor shall seek the Employer approval to any changes in his method of
working that are necessary to ensure full compliance with this requirement before the
changes are implemented

7. Temporary Earthworks: Stockpiles and Subsoil Heaps

A. The Contractor shall make his own arrangements for stockpiles and for provision of
storage areas for soil but shall submit proposals for these, and other temporary
earthworks, for the approval of the Employer.

B. Such Works shall be stable under all conditions and shall not impede the natural
drainage of the area in which they may be situated. The Contractor shall satisfy the
Employer by testing and calculation as appropriate as to their stability.

C. Fill materials shall not be stockpiled in the vicinity of excavations nor shall they be
stockpiled on embankments.

8. Earthworks to be Kept Free of Water (Dewatering)

A. The Contractor shall arrange for the rapid disposal of water, from whatever
source, from all earthworks, excavations, stockpiles or completed formations of all
types during construction and, where practicable, the water shall be discharged into
the permanent drainage system. Adequate means for trapping silt, oil or other
deleterious matter shall be provided on temporary systems discharging into permanent
drainage systems. In depressions, pumping shall be used as necessary to keep them
free of water.

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 10
 B. The Contractor shall provide temporary water courses, ditches, drains, well points,
pumping or other means of maintaining the earthworks free from water. Such
provisions shall include carrying out the work of forming cuttings and embankments
in such a manner that their surfaces are sufficiently even and have at all times
sufficient minimum cross falls, cambers and longitudinal gradients to enable them to
shed water rapidly and prevent ponding. Excavations for foundations, pits and
trenches shall be dewatered such that groundwater level is kept at 300 mm below the
underside of any structure.

C. All temporary water courses, ditches, drains etc. shall be filled in or removed and the
ground reinstated prior to completion of the Works. Buried pipes may, subject to the
approval of the Employer, be left in position but in that case shall be completely filled
with grout.

9. Work Alongside Adjoining Property

A. Before carrying out excavations or associated Works, including pumping or

groundwater lowering, alongside adjacent properties the Contractor shall survey
such properties and record their levels and structural condition, take particular
note of any cracks, other damage or deformations. The survey shall include a
photographic record and a means of monitoring the movement of any adjacent
structures during excavations and site operations.

B. The Contractor shall supply the Employer with a copy of all such survey records
(including photographs). All such records shall be adequately referenced as to
location, direction of view, date, etc.

C. Before commencing work alongside adjoining property the Contractor shall submit to
the Employer his detailed proposals for carrying out the work including diagrams of
his proposed methods of support together with his calculations and estimates of
vertical and lateral movements, and his means for keeping the Works free of water.

10. Change of Groundwater Levels Due To Pumping/Dewatering (IF NEEDED)

A. In pumping out excavations or in any other operation, such as groundwater

lowering/dewatering which could vary the groundwater levels or affect in any
way the Permanent Works and/or nearby properties, the Contractor shall ensure
the stability and, in particular, prevent or minimize the settlement of such Permanent
Works and/or nearby properties.

B. The Contractor shall submit his proposals to the Employer for his approval
before starting such operations. The proposals shall include the Contractor's
assessment of likely settlement together with calculations and conditions assumed.

C. The Contractor shall take all necessary precautions to prevent any adjacent ground
from being adversely affected by loss of fines through any de-watering process.

11. Protection of all earthworks covered by this Specification shall be provided by the
Contractor, by methods approved by the Employer, until the Works are certified
complete by the Employer.

12. The Contractor shall notify the Employer immediately of any landslips, and shall then
deal with these without delay and as the Employer may direct. If any slip or fall
disturbs or weakens any foundation, support or potential support the Contractor shall

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 11
 execute such additional work immediately as the Employer may direct.

13. Contaminated, Disturbed or Man-Made Ground: Health and Safety

A. The Contractor's attention is drawn to the possibility of contamination of ground

and/or of disturbed or man-made ground masses and he shall pay additional attention
to the potential problems that can be posed in working in such conditions. The
Contractor shall ensure that full reference is made to any existing reports or other
relevant information on ground conditions, particularly with respect to possible
physical or chemical hazards for workers, whether in solid, liquid or gaseous forms.
Suitable precautions shall be taken to protect the workforce and the neighborhood
from environmental hazards that might result from the Contractor's operations. Such
hazards could relate to dust, flammability, explosiveness, skin contact, inhalation or
ingestion. The Employer shall advise the Contractor at the tender stage of any facts or
well- founded suspicions that may exist regarding the potential hazards.

B. If the Contractor has knowledge of or encounters material and conditions in

the ground mass, which may constitute an environmental hazard, or suspects they will
constitute an environmental hazard, he shall promptly advise the Employer and
request instructions from the Employer. The Contractor shall not carry out any further
work until satisfactory clearances have been received from the Employer and the local
authorities if required.

14. Disposal of Materials off Site

A. Contaminated and waste materials shall be removed from site in accordance with the
requirements of the Local Authorities. The Contractor shall satisfy the Employer
that all waste materials are taken only to a disposal site/treatment plant which is
licensed to accept waste of that nature.

B. No excavated acceptable or temporarily unacceptable material or topsoil other than

that agreed by the Employer to be surplus to the requirements of the
Contract shall be removed from the Site except on the instruction of the Employer.

C. All unacceptable material shall, unless the Employer permits or instructs otherwise,
be removed from the Site and run to either tips provided by the Contractor or
otherwise disposed of by the Contractor. Public roads may only be used for haulage if
arrangements acceptable to the Employer and the Approving Authority are agreed
beforehand.

15. Open ditches, culverts and outfalls for drainage purposes shall be maintained by the
Contractor. New ditches, culverts and outfalls shall be constructed before cuttings are
opened or embankments or filling begun. The sides shall be dressed fair throughout and
the bottoms accurately graded so as to carry off water to the outlet.

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 12
 16. Running Layers and Access Routes (Haul Roads)

A. Where the Contractors proposals include running over the location of the permanent
Works he shall provide, above the formation levels shown on the Drawings, a suitable
running layer of 300 mm minimum depth above formation levels for the movement
and operation of plant, materials and labor associated with his Works so that
material at formation and below is not adversely affected.

B. Prior to commencement of work, the Contractor shall submit his proposals to the
Employer for his approval for haul roads.

C. During the execution of the Works, the Contractor shall maintain the running layer to
the satisfaction of the Employer.

D. The running layer shall be removed in a manner which does not adversely
disturb the previous construction or interfere with subsequent operations for the
Permanent Works.

3.4 EXCAVATION

3.4.1 General

A. The Contractor shall record the strata through which he excavates together with their
locations and depths. He shall provide a copy of the records to the Employer as
the work proceeds. Where excavation produces a combination of acceptable and
unacceptable materials, the Contractor shall carry out the excavation in such a
manner that acceptable materials are excavated separately for use in the
Works without contamination by unacceptable materials which shall be removed
off site. Where excavation produces a combination of acceptable materials with
different characteristics, these materials shall be excavated and stored separately.

B. Any old foundations, tree roots, buried refuse or obstructions encountered during
the course of excavation shall be taken out and removed from the Site excluding
combustible materials which shall either, with the Employer and local authority
approval, be burnt under controlled conditions or removed from the Site. Care shall be
taken to ensure that roots to existing trees to be retained are not disturbed. Should
unforeseen services be encountered the Employer shall be notified immediately
and no action taken pending his instructions.

C. When rock is encountered, the Employer shall be notified immediately and it shall
then be removed only to the net extent to permit the Works to be properly executed.
The Contractor shall free the faces and bottoms of the excavations of loose material
which can be moved with a crowbar. For excavations in which concrete is to be
placed, the resulting cavities and any large fissures shall be filled with concrete. For
trenches filling shall be as shown on the Drawings and as directed by the Employer.
The quantities of material shall be measured and agreed with the Employer as work
proceeds and prior to removal. Rock projections, boulders or other hard spots in
excavations shall be removed to a depth not less than 100 mm below formation
level and as directed by the Employer and a new formation prepared, and the
excavation filled as specified. The quantities of these materials shall be measured
and agreed with the Employer as work proceeds and prior to removal.
D. The Contractor shall carry out his operations in such a manner as to ensure that
damage to or deterioration of the formation or final surface of the excavation and
the ground below is not caused. The natural moisture content of the ground below the

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 13
 formation shall be preserved. Excavation in error or for any other reason by the
Contractor to a greater extent than is indicated on the Drawings shall be made
good with a material approved by the Employer deposited and compacted as
specified or, if instructed by the Employer.

E. If the Contractor encounters ground in the formation which he considers

unacceptable, the Employer shall be informed immediately.

F. On completion of the excavation the formation shall be neatly finished leaving no

extraneous material. The permanent work shall be placed immediately or the
formation sealed to the approval of the Employer after the formation has been
inspected and approved by the Employer. The Contractor shall give adequate notice to
enable this to be done.

G. Excavations shall be kept free from noxious or explosive gases, whether generated in
strata by blasting or otherwise. The Contractor shall satisfy himself that each
excavation is safe before allowing entry of personnel. The Contractor shall carry out
tests for the presence of noxious or explosive gases, or to detect a lack of oxygen
before allowing personnel to enter any confined space or excavation, and he shall then
monitor conditions continuously during the period of work. He shall take such
measures (e.g. Ventilation, the provision of breathing apparatus, and back-up
personnel and equipment) as will avoid any risk of injury to personnel. The Employer
may order the withdrawal of personnel if dissatisfied with the Contractor's
arrangements.

3.4.2 Forming of Cuttings (IF NEEDED)

A. Cuttings shall be excavated to the lines and levels shown on the Drawings or
as directed by the Employer.

B. Toes to the slopes of cuttings shall only be undercut where Permanent Works
necessitate excavation(s). Such excavations shall be restricted in extent and shall
remain open only for the minimum period necessary. The Contractor shall submit to
the Employer for approval a method statement giving his procedure for carrying out
such work.

C. Where for reasons of program the excavation cannot immediately be completed,

sealed and the Permanent Works placed, excavation shall be restricted such that at
least 300 mm of material is left above formation level as a protective layer; the extent
of further protection to be provided in each case shall be defendant on the situation
and material involved. Trafficking shall only be allowed by approval of the Employer.

3.4.3 Dressing of Formation and Side Slopes of Rock Encountered in Cuttings (IF
NEEDED)

A. Where rock is encountered in cuttings, the side slopes shall be cut to the lines, levels
and slopes shown on the Drawings or as directed by the Employer.

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 14
 B. Surface irregularities remaining on the base of an excavation after completion of
the rock excavation shall be corrected to formation level by filling with a granular
material approved by the Employer. Such material

Shall have a maximum size not greater than one third the thickness to be compacted
and not exceeding one third the maximum allowable compacted layer thickness,
whichever is the less. The formation so constructed shall be formed to lines and
levels shown on the Drawings.

C. The sloping sides of all permanent cuttings shall be scaled of all rock fragments
which are loose or can be prized with a crowbar.

3.5.1 Excavations for Structures and Foundations

A. Excavations shall be to the lines and levels shown on the Drawings.

B. The sides of excavations for structures such as basements and foundations shall
be adequately supported at all times and, except where required as shown on the
Drawings or allowed by the Employer, shall not be battered. The Contractor shall
submit to the Employer proposals for his Temporary Works to ensure stability of the
excavation, temporary and Permanent Works, and these proposals shall include
detailed drawings and calculations, methods of installation and withdrawal and his
means of keeping the Works free of water.

C. The Contractor's attention is drawn to the possibility of bottom heave occurring in

deep excavations. And in his proposals, the stability of the excavation against bottom
heave shall be considered.

D. For excavation in soils such as over consolidated clays which are likely to heave and
swell, the Contractor shall submit to the Employer for his prior approval a detailed
method statement giving his procedure and proposed arrangements for minimizing
the effects of heave and swelling.

E. Where for reasons of program the excavation cannot immediately be completed,

sealed and the Permanent Works placed, excavation shall be restricted such that at
least 300 mm of material is left above formation level as a protective layer; the
extent of further protection to be provided in each case shall be dependent on the
situation and material involved. Trafficking shall only be allowed by approval of the
Employer and subject to clause 3.3 16.

F. When constructing structures and laying adjacent services, the construction or

services requiring the deepest excavation shall be excavated first and construction
brought to a safe level before starting further excavation. When this is impracticable,
the Contractor shall obtain the approval of the Employer to his proposals for
maintaining undisturbed the ground supporting the higher construction while
excavating, constructing and filling around and/or over the lower one.

G. Where blinding concrete is placed in the bottom of an excavation no trimming of side

faces shall be carried out until a period of 24 hours has elapsed.

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 15
 3.4.5 Should ground be excavated in error or otherwise disturbed wider or deeper than
is required all disturbed material shall be removed, and the excess excavation

Shall be made good with a material approved by the Employer deposited and compacted as
specified or, if instructed by the Employe.

3.4.6 Proving Formation in Excavation and Dealing with Soft or Unsound Spots

A. Formation in excavation shall be proof rolled or compacted by 1 pass of a smooth

wheeled roller having a mass of a meter width of roll not less than 2100 kg unless
otherwise specified by the Employer.

B. Any soft or unsound spots as may be found, by inspection, testing, proof rolling or
compaction or otherwise as may be specified, in the formation or under areas to be
filled, shall be excavated as required by the Specification and instructed by the
Employer. The resultant excavation shall be backfilled with approved material
deposited and compacted as specified for the forming of filled areas or, if instructed
by the Employer.

C. However, the Contractor's attention is drawn to the possibility that instability or

an apparent soft spot may be due to a pore pressure rise as a result of compaction
forces. In such circumstances the Employer shall be informed and in agreement with
the Employer the pore pressure may be allowed to dissipate before deciding on the
removal or otherwise of such an area.

D. An alternative method treatment using approved rock fill material may be permitted
or required by the Employer. If so it shall be placed directly on the naturally occurring
soft soil and compacted to such total depth that on completion of compaction
negligible deflection of the surface occurs by the passage of vehicles hauling in the
rock. The rock fill material shall be deposited and compacted as specified above.

E. Where the formation in excavation is of essentially granular material it shall be

compacted in accordance with the “Compaction of Earthworks” section of this
specification unless otherwise specified. Where the formation is of a cohesive nature
compaction or otherwise shall be related to its nature and natural condition, and
following inspection and testing the Contractor shall submit his proposals for
treatment for the Employer.

3.5 FILLING

3.5.1 Forming of Embankments and Other Areas of Fill

A. Embankments and other areas of fill shall be formed of acceptable material as

shown on the Drawings, and/or as specified by the Employer.

B. Haulage of material to areas of filling shall proceed only when sufficient spreading
and compaction plant is operating at the place of deposition.

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 16
 C. Areas to be filled shall be clear of sweet soil, rubbish, scrap material and standing
water (unless shown otherwise on the drawings) when fill is placed. No filling shall
be placed on areas or formation or already laid material or on a surface that has been
damaged or not cleaned of debris or mud and without the approval of the Employer.

D. All earthworks placed in or below embankments and other areas of fill such as
backfill to trenches, pits and structures such as retaining walls and basements, or
elsewhere in the Works, shall be deposited and compacted, as soon as practicable
after excavation, in layers of thickness appropriate to the compaction plant used, but
not exceeding 250 mm compacted thickness, unless otherwise permitted in the
appropriate clause or otherwise specified, or otherwise agreed by the Employer.

E. If there is a deficit in the 'cut-fill' balance of acceptable materials from excavations the
deficiency shall be made good by importation of acceptable material. In this case the
Contractor shall propose a source or sources of such material for the Employer
approval (refer to Part 2 - Products).

F. Where materials of different characteristics are available those of relatively

higher bearing capacity shall be placed in the topmost 600 mm below formation level.

G. Where non-cohesive material, on excavation, is too wet or too dry for satisfactory
compaction the Contractor shall raise or lower the moisture content until satisfactory
compaction is achieved and approved by the Employer.

H. Where for any reason the moisture content of acceptable material changes to a
value unacceptable for compaction, the Contractor shall raise or lower the
moisture content until satisfactory compaction is achieved and approved by the
Employer.

I. Areas of general fill and embankments shall be built up evenly over the full width,
and with side slopes not greater at any time than shown on the Drawings or directed
by the Employer. Areas of fill shall be kept free of water in compliance with the
“Workmanship” section of this specification. During construction of areas of general
fill and embankments the Contractor shall control and direct construction traffic
uniformly over their full width. Damage to compacted layers by constructional traffic
shall be made good by the Contractor.

J. In carrying embankments up to or over culverts, piped drains or other services, and

where required in the Contract, up to or over bridges; the Contractor shall bring the
embankments up equally on both sides. Where special forms of compaction, adjacent
to structures are described in the Contract, filling may proceed over widths less than
the full width of the embankment and in steps not exceeding the depth of one layer
above the adjoining area of fill.

K. If the Contractor wishes to continue to use the surface of embankments for

constructional plant before trimming to formation level the requirements of
Section 3.3.16 shall continue to apply. Additionally, the Contractor shall bring up
and maintain the area between the extremities of any carriageway, including any
central reserve and hard shoulder to a level not less than 150mm above the formation
level. The extent of the protection to be provided in each case shall be adjusted to
suit the situation and materials involved whereupon constructional plant will be
allowed to use the surface so formed but any damage to the sub- formation or
subgrade caused by the use of such surface shall be made good by the Contractor.
On compaction of sub-formation to formation level, the movement and use of

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 17
 constructional plant shall be only as permitted by the Employer.

L. Material used for haul roads or running layers shall not be re-used without the
permission of the Employer.

M. The layers of fill shall be graded, levelled and mixed, with water added as necessary,
to ensure homogeneous conditions throughout the full depth of the uncompacted
layer.

3.5.2 Backfilling of Trenches and Pits

A. The first 300 mm of main backfill shall be placed in layers not exceeding 100 mm
un-compacted thickness with each layer being thoroughly compacted before placing
the next layer. Only light compaction equipment subject to the approval of
the Employer shall be used. Otherwise mechanical rammers, rollers and the like
shall not be used to compact the fill until there is a minimum 600 mm of fill above
the top of the pipes.

B. The main backfill shall then be built up in layers not exceeding 150 mm in compacted
thickness. Compaction shall be according to clause 3.6.

C. As filling proceeds all trenches or pit supports shall be removed in a safe manner and
in accordance with the approved method of working.

D. Particularly under roads or existing works such as pipes, the fill shall be compacted to
a minimum relative compaction of 95% or bring it as nearly as possible to the
same condition of density and moisture content as that of the undisturbed soil in the
trench or pit sides provided the fill is of a similar nature; otherwise a selected material
approved by the Employer shall be used.

E. Unless otherwise specified, filling around manholes shall be as for trenches and shall
be carried out as part of the same operation. The fill shall be raised equally all-round
the manhole shaft.

F. Any settlement that occurs shall be made good by the Contractor with the surface
construction also being maintained in an acceptable condition.

3.5.3 Filling Against Structures

A. Fill to structures shall be selected material as shown on the Drawings or approved by

the Employer.

B. Fill shall be placed and compacted in accordance with the “Filling” and “Compaction
of Earthworks” sections of this specification excepting as otherwise specified in this
sub-clause.

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 18
 C. Where fill to structures is required to a similar level on more than one side of a
structural element, it shall be so placed that the difference in level of compacted
filling against adjacent or opposite sides does not exceed 250 mm, unless otherwise
permitted by the Employer.

D. Compaction plant used on fill within 2 m of a structure shall be restricted to:

1) Vibratory roller with mass a meter width of roll not exceeding 1300 kg with a
total mass not exceeding 1000 kg.
2) Vibrating plate compactor having a mass not exceeding 1000 kg or Vibro-tamper
having a mass not exceeding 75 kg.

E. Fill within this zone shall not differ in level during construction from the level of the
remainder of the adjoining fill to the structure by more than 250mm.

3.6 COMPACTION OF EARTHWORKS

3.6.1 Structural Fill

A. All filling material shall be compacted to a minimum relative compaction of 95%

based ECP.

B. Before filling and compaction works are commenced, and further as may be necessary
during the progress of the Works, the Contractor should have carried out
classification tests, including natural moisture content and compaction tests in
accordance with ECP, as appropriate, on the main types of materials originating
from the Site and any proposed to be imported to determine acceptability and
optimum compaction requirements.

C. For materials which are non-plastic and have not more than 10 per cent passing 75
microns .

D. The Employer shall be advised of when the tests are to be undertaken. Two copies of
all test results shall be forwarded to him for his approval prior to the commencement
of work and thereafter as the occasion arises (refer to the “Testing” section of this
specification).

E. The Contractor shall submit to the Employer his proposals giving the maximum
compacted depth of each layer, the type(s) of plant and the number of passes for
compaction of each type of material. The Contractor shall demonstrate to the
Employer satisfaction that he can achieve the requirements regarding compaction
before the Works commence by carrying out compaction trials.

F. Where compaction is required the Contractor shall submit his method of compaction
for each material to the Employer for approval.

G. Earth-moving plant will not be accepted as compaction equipment under this clause
nor shall the use of a lighter category of plant to provide any preliminary compaction
to assist the use of heavier plant be taken into account in assessing the amount of
compaction required for any layer.

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 19
 H. Where side slopes to fills are shown on the Drawings the Contractor shall submit for
the Employer approval his method for obtaining compaction, as specified, to the lines
and levels shown on the Drawings.

I. The frequency of testing the compacted fill shall be sufficient in relation to the
volume of particular works, the rate of placing and its purpose, and shall be as
agreed with the Employer in accordance with the “Testing” section of this
specification.

J. In case the method of compaction is specified by the Employer the Contractor will
be required to carry out tests in accordance with the above and when instructed
by the Employer or carry out comparative field density tests determined
Specifications which shall be calibrated on material similar to that which is being
tested for field density.

K. Works on the compaction of material shall proceed as soon as practicable after

excavation and/or placing. Compaction requirements where not fully stated within
this clause or given on the Drawings shall be as instructed by the Employer.

L. Work shall be continued until a state of compaction is reached throughout filled areas,
including slopes of embankments, such that dry density tests from the compacted
material has a dry density not less than that stated below.

M. For non-cohesive materials, within the limits of the “Structural Fill’ section of
this Specification and for materials with a plasticity index not 10%, the state of
compaction shall be such that the compacted material has a dry density not less than
95% of maximum dry density and a moisture content within the range of ±3%
optimum percentage as determined in ECP.

N. For intermediate materials the state of compaction shall be such that the compacted
material has a dry density not less than the specified percentage of maximum dry
density and a moisture content within the specified range related to optimum
percentage.

O. Where fill materials have particle sizes exceeding the maximum size allowable in the
relevant Test. the procedures for comparing test values with field values shall be
agreed with the Employer prior to such fill materials being used.

3.6.2 Non Structural Fill

A. Before filling, spreading and compacting operations are commenced; materials shall
be classified by the Contractor for acceptability in accordance with sub- clauses the
“structural fill” and “Unsuitable Materials” section of this specification, and agreed
by the Employer.

B. Fill shall be spread in layers not exceeding 300 mm in thickness unless otherwise
specified by the Employer. Spreading shall not be done when the ground or the fill is
excessively wet or otherwise in a condition detrimental to the work nor shall it be
done during heavy rain.

C. Compaction shall be as specified on the Drawings or elsewhere in the Contract.

3.6.3 Benching (IF NEEDED)

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 20
 A. Where filling is to be placed on sloping ground (steeper than one vertical to six
horizontal) the surface of the ground shall be benched in steps, or as shown on the
Drawings, to enable melding of the fill with the existing slope, and may include, as
necessary, under-draining for dealing with water.

B. Fill material in areas of benching shall be carefully and compacted to ensure that no
voids occur at the vertical steps of the benching.

C. Placing and compacting of fill material on a lower bench shall continue to a level one
compacted layer thickness above an adjacent higher bench before material is
placed upon the latter bench.

D. Four additional passes of the approved compaction plant shall be made over a
width of 2m each side of each vertical face immediately following the compaction of
the first layer of material on each bench.

3.6.4 Rock fill: spreading and compaction

A. Rock fill shall be as specified in the “Classification of Materials” section of this

Specification.

B. Material used in rock fill shall, except for any specified cover to slopes or near bottom
of capping layer or formation level, be of such size that it can be deposited in
horizontal layers each not exceeding 800 mm loose depth and extending over the
full width of the area or of the embankment. Material shall be spread and
levelled by a crawler tractor having a mass of not less than 15 tons and compacted.
The top surface and side slopes of embankments as formed shall be thoroughly
blinded with approved fine graded material to seal the surface and give a compacted
stable surface. Such fine graded material may on side slopes and verges be topsoil
except where the final surface may be such as paving or otherwise shown on the
Drawings.

C. Compaction shall be carried out by a vibratory roller with the minimum requirements
of ECP

D. Where rock is used as general fill and has the properties of rock fill it shall be spread
and compacted as for rock fill.

3.6.5 Improved Subgrade Material

A. The compacted density of the fill shall be equal to or greater than 95% of the
maximum dry density as determined. Samples for soil classification, moisture and
CBR tests shall be taken prior to incorporating the material in the works. For every
completed layer of material, 1 field density test point shall be performed on an area of
approximately 500m2 of prepared area.

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 21
 3.6.6 Preparation and Surface Treatment of Exposed Subgrade for Building
Foundations

A. Preparation and surface treatment of the subgrade shall be carried out only after
completion of any subgrade drainage or dewatering and, unless otherwise agreed by
the Employer, immediately prior to blinding with concrete or the construction of
the Works.

B. The sequence of operation shall be as follows:

1) The surface shall, after reinstatement of any soft areas, be well cleaned and
free from mud and slurry.
2) The surface shall be compacted by a minimum of 6 passes of a smooth-drum
vibrating roller having a minimum dead weight of 10 tons.
3) The surface shall be regulated and trimmed within a tolerance of ±20 mm.
4) Where the surface is too high it shall be trimmed and re-compacted in
accordance with this Specification. If the surface is too low the deficiency shall
be corrected by the addition of suitable material of the same classification and
moisture content or other approved material laid and compacted to Specification.

C. If the Contractor allows the moisture content of accepted compacted material to

reach a value above the maximum permitted in this Specification for the material
for compaction, the Contractor shall allow the material to revert to an acceptable
moisture content and, if directed by the Employer, make good the surface by re-
compaction before laying the capping layer or other pavement layer. Alternatively,
the Employer may allow or require the affected material or layer to be removed and
replaced with acceptable material.

3.7 REINSTATEMENT

3.7.1 General

1) These clauses cover the reinstatement of surfaces which existed before the Works
have commenced, which have been disturbed in the course of the Works and which
are not finished as part of other works.

2) Where reinstatement involves such as public utilities or services, or public highways,

roads, footpaths and bridle paths or such privately owned facility, the Contractor
shall ascertain the requirements of the relevant authority or owner, and carry out
reinstatement to the requirements of the relevant authority or owner where superior
to the requirements in this Specification.

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 22
 3.7.2 Reinstatement of Surfaces over Trenches

A. Those parts of the site and any areas outside the site disturbed by excavation for
service trenches shall be reinstated to the same standard as existed before the works
commenced unless otherwise shown on the drawings or instructed by the Employer.

B. Paved and hard surfaces shall be temporarily reinstated by the Contractor immediately
following backfilling and before reopening the disturbed areas to traffic. The
materials used shall be appropriate to the adjacent construction. Verges shall be
temporarily reinstated to match nearly as possible the adjacent areas.

C. Unless shown on the drawings or instructed otherwise by the Employer the surfaces
over disturbed areas shall be permanently reinstated by the Contractor, within 2
months of the temporary reinstatement, in materials and construction similar to the
adjoining surfaces and in a manner specified by the Employer to obtain proper
integration between these adjoining surfaces. To ensure satisfactory integration
between the new and existing construction each layer is to be stepped back beyond
the edges of excavation and underlying layers.

D. Throughout the duration of the Works, the Contractor shall ensure that all vehicle
wheels are thoroughly cleaned prior to leaving the site approaches and re-entering
public roads. The Contractor shall ensure that points of entry from and exit to public
roads are kept clean.

END OF SECTION 312000

SPECIFICATIONS FOR CAST-IN-PLACE CONCRETE PILES

April, 2025 312000 - 23