M&W Civil A5 Vol.2 (Sep 2022)

D/MTRCL/NW/CIV/M&W/002/A5
MATERIALS AND WORKMANSHIP SPECIFICATION
FOR
CIVIL ENGINEERING WORKS
Volume 2 of 3 : Sections 11 - 21
REVISION DATE PREPARED REVIEWED CONTROLLED APPROVED

AND BY BY BY
CHECKED
BY
A5 September CH Tse Edward Ngai Thomas Lau Robin Wong
2022
SEM-M CEM-C(CW) HoCE(CW) (GM-CWT)
Parker Ko Derek Kwok

SEM-GEOT CEM-GEOT
© MTR CORPORATION LIMITED 2022
All rights including, without limitation, intellectual property rights in and to this document
and any information contained in this document are proprietary and are solely and
absolutely owned by MTR Corporation Limited. The document and any information
contained in the document are strictly confidential and must not be used, disclosed,
transmitted, copied, printed or otherwise disseminated without the prior written consent of
MTR Corporation Limited. Violators will be subject to legal sanctions such as an injunction
order and will be held liable for any damages, losses, costs and expenses incurred by MTR
Corporation Limited.
September 2022
Materials and Workmanship
Specification for
Civil Engineering Works
Volume 2 of 3 : Sections 11 – 21
September 2022
MATERIALS AND WORKMANSHIP SPECIFICATION

FOR CIVIL ENGINEERING WORKS
VOLUME 2
SECTION SUBJECT PAGE
11 Concrete and Grout 11/1 - 11/114
12 Prestressing 12/1 - 12/25
13 Not Used
14 Waterproofing 14/1 - 14/13
15 Carriageways : Sub-base Materials and

Bituminous Materials 15/1 - 15/47
16 Concrete Carriageways 16/1 - 16/23
17 Miscellaneous Roadworks 17/1 - 17/35
18 Not Used
19 Deep Foundation Works 19/1 - 19/59
20 Bridgeworks 20/1 - 20/33
21 Work for Electrical and Mechanical Installations 21/1 - 21/9
September 2022
MATERIAL AND WORKMANSHIP SPECIFICATION
CIVIL ENGINEERING VOLUME 2
PREAMBLE
• All reference in this Specification to "in the Contract" shall be deemed to include
all Contract Documents.
• All materials & workmanship shall be in accordance with this Specification and
the Particular Specification. Where there may be a conflict the requirements of
the Particular Specification shall take precedence.
• Any reference to material and workmanship compliance criteria mentioned in this

Specification shall comply with other relevant Sections of this Specification unless
otherwise specified.
• Reference to Section numbers in Volumes 1, 2 and 3 shall refer to Volumes 1, 2

and 3 of this Material and Workmanship Specification.
• No Permanent Works shall be carried out until all methods and materials have
been approved by the Engineer.
• Unless noted otherwise in the Contract, all materials shall be applied in

accordance with the manufacturer's recommendations.
• All test results shall be recorded and presented in a format approved by the
Engineer and shall include graphical presentation of results as well as numeric
base data.
September 2022
SECTION 11
CONCRETE AND GROUT
Part 1, Concrete. Clauses 11.1 to 11.93
Part 2, Sprayed Concrete. Clauses 11.94 to 11.109
Part 3, Grout. Clauses 11.110 to 11.118
Part 4, Pre-cast Concrete. Clauses 11.119 to 11.127
Part 5, Glassfibre Reinforced Concrete. Clauses 11.128 to

11.134
Part 6, Silane Treatment of Concrete. Clauses 11.135 to

11.139
Part 7, Repair of Concrete and Filling of Tie Holes. Clauses

11.140 to 11.154
PART 1 : CONCRETE
Glossary of 11.1 (1) "Cementitious Content" is the total weight of Portland

Terms Cement (PC), Pulverised Fuel Ash (PFA), Ground
Granulated Blastfurnace Slag (GGBS), Condensed
Silica fume (CSF) or Pulverised Fuel Ash Cement
(PFAC) contained in the mix.
(2) "Water Content" is the total weight of the free water

contained in the aggregates plus the weight of the
added mixing water plus the weight of water contained
in any admixtures or additives used.
(3) "W/C ratio" is the ratio of the water content divided by

the cementitious content.
(4) "Design Cementitious Content" is the total

cementitious content used in the Contractor's concrete
mix design.
(5) "TRET" is a Temperature Rise Evaluation Test as

required by the Specification which is undertaken as
part of the mix approval process.
(6) "Acceptance Workability tests" are workability tests
June 2022
11/1
conducted by the Contractor to ascertain if the

delivered workability of the concrete is within the
specified limits.
(7) "Compliance tests" are all tests which the Contractor is

required to conduct to prove compliance with the
Specification.
(8) "Class"; all concrete will be defined by its Class which

will be denoted by a symbol consisting of a number
denoting the Grade of concrete followed by "/" stroke,
followed by another number denoting the size in mm
of the largest fraction of aggregate used to make the
concrete.
(9) "Grade" is the first number in the symbol for the class
of concrete and denotes the grade of the concrete,
which is its characteristic strength in MPa.
(10) "Characteristic Strength" of concrete is a value of cube

strength at 28 days below which 5% of all compressive
test results would be expected to fall.
(11) “Self-compacting concrete” (SCC) is concrete that is

able to flow and compact under its own weight, fill the
formwork with its reinforcement, ducts, boxouts etc.,
whilst maintaining homogeneity.
(12) “High Strength Concrete” is the concrete mix with

grade exceeding C60.
General Requirements
General 11.2 (1) The water-tightness of completed concrete structures

shall be in accordance with the following:
(a) in all areas where waterproof membranes are

specified in the Contract at the extrados of a
concrete element, water inflows, drips of water
or damp patches arising from the surrounding
groundwater or ground mass shall not be
present;
(b) elsewhere without waterproof membrane,

leakage shall be restricted to damp patches on
the face of the concrete element;
(c) where diaphragm walls form elements of the
June 2022
11/2
structure, the performance requirements of

Section 19 shall be complied with.
(2) The designs are based generally on the grades as

follows and this is reflected in this Specification:
60 50 45 40 30 and 20
(3) Other grades of concrete called for in the Contract are

required to comply with this Specification.
(4) Concrete of Grade 20 shall be unreinforced concrete.

All blinding concrete shall not be less than Grade 20.
(5) High strength concrete (>60MPa) or concrete with

either durability or materials requirements additional to
that specified in this section, requires a specifically
documented QA system, in accordance with the
Buildings Department's Practice Note for Authorized
Persons and Registered Structural Engineers, which
shall be implemented prior to the commencement of
concreting.
(6) Requirements for all cementitious materials and

aggregates, mix design, batching, mixing, transporting,
placing and curing requirements for in-situ and precast
concrete are covered in this Part 1 of Section 11; the
same requirements for sprayed concrete and grout are
set in out in Part 2 and Part 3.
(7) All cementitious materials (PC, PFA, GGBS, CSF,

etc.) shall be shown to conform to their respective
manufacturing Standards by certificates produced in
accordance with those Standards.
(8) Additional sampling and testing of materials on

delivery to the batching plant shall be as instructed by
the Engineer.
(9) Where the cement is supplied as a blend of PC and

PFA or GGBS, the certification shall cover the major
constituents.
(10) Cements supplied as a blend shall comply with Clause

11.58 of this Specification for each constituent with
certification of the weight.
June 2022
11/3
Concrete 11.3 (1) Concrete is classified with regard to temperature,

Category cement content, cementitious content, testing and
other technical requirements as Category A, B or C.
Details of the technical requirements are given
elsewhere in this Section. Definition of the category
of individual elements of the Works shall be as stated
in the sub-clauses (2) to (4) unless otherwise stated in
the Contract.
(2) Category A concrete shall generally include concrete

elements for the external structural envelope of
underground structures, concrete for watertight
structures, water retaining structures and bridges but
excluding those concrete elements classified as C in
(4) below.
(3) Category B concrete shall include concrete elements

of all other structures not classified as A or C.
(4) Category C concrete shall include concrete elements

of:
(a) deep foundations;

(b) diaphragm walls and cast in-situ pile walls as
external structural envelope of underground structures;
(c) discrete pile caps and ground beams; and
(d) grade 20 concrete.
However, it shall be demonstrated that the durability of

concrete elements as described in (b) above but with
thickness exceeding 1500mm will not be adversely affected
due to high thermal gradient.
(5) Blinding concrete and other grades shall be defined by

strength only.
Constituents 11.4 (1) The only materials permitted to be used to make

concrete are:
(a) PC;
(b) PFA;
(c) GGBS;
(d) CSF;
(e) PFAC;
June 2022
11/4
(f) natural stone aggregates;
(g) liquid admixtures; and
(h) potable water.
(2) Monofilament polypropylene (PP) fibres shall comply

with BS EN 14889-2, Part 2, 2006.
(3) Steel fibres shall comply with BS EN 14889-1 except

that the minimum tensile strength shall be 800N/mm2.
(4) In exceptional circumstances the Engineer may

require special additives or ingredients to be
incorporated in mixes, and in such cases these will be
specified in the Contract. Alternatively, the Contractor
may propose such special additives or ingredients, the
use of which will be subject to the Engineer's Approval.
(5) All materials used in concrete shall be fully identified

and shall be traceable to their sources of extraction or
manufacture.
Mix Design 11.5 (1) Unless otherwise stated in the Contract, concrete
Responsibility mixes shall be designed by the Contractor and shall
comply with the requirements stated in this
Specification. However it is recognised that the
Contractor may wish to use mixes which are in regular
use and which are obtainable from, and designed by,
a specialist concrete supplier. Subject to the prior
approval of the Engineer such commercially available
mixes may be used. These mixes shall meet all the
requirements stated in this Specification and the
Engineer will require evidence of the methods by
which it is intended to achieve the compressive
strength and standard deviations hitherto achieved for
each mix, before Approval is given.
(2) The source of any external supply of concrete

designed by the concrete supplier shall not be
changed without the prior approval of the Engineer.
Workability 11.6 (1) The workability of concrete is not specified but shall be
proposed by the Contractor. Concrete workability of
less than 75mm slump will not normally be acceptable.
Self-compacting concrete (SCC), if used, shall
conform to BS EN 206:2013. The Contractor will be
June 2022
11/5
required to carry out specific mock-up trials to

demonstrate to the satisfaction of the Engineer that the
proposed workability, not limited to SCC mixes, will
enable the concrete to be placed and compacted to
form a dense homogenous mass of concrete. Trial
concrete shall be placed and compacted simulating
the actual locations where the concrete is proposed to
be used.
(2) Except for medium workability mixes (80-200mm

slump) the Contractor shall not use the slump test as
the sole means of measuring workability or deciding
upon what level of workability to choose. Approved
dynamic or flowability assessment methods for
measuring and controlling the workability and filling
ability of concrete delivered to the Works shall also be
used. Suitable methods of test are given in Table
11.1.
(3) Workability tests may be performed on a sample

obtained from the initial discharge in accordance with
CS1 provided that the workability is then determined in
duplicate. The concrete shall be deemed to be
acceptable provided that neither result is outside the
specified range and the value reported shall then be
the average of the two determinations.
TABLE 11.1 : Suitable Workability Test Methods
Suitable Workability Test Methods

Low Workability Medium High Workability
0-75 mm slump Workability (designed flow value
80-200 mm slump from 340 mm to 600
mm)
Vebe Time or Slump Flow Table or
Compaction Factor
Slump-flow (for SCC )
(See the Note to
Clause 2.1.1 of
CS1 for slump
value > 175mm
and ≤ 200mm)
Mixing 11.7 (1) Concrete shall be mixed in a power driven central

batch type mixer. Small quantities of concrete for
June 2022
11/6
minor works may be prepared in small mixers. No

concrete shall be mixed manually.
(2) The batching sequence and minimum mixing time

shall be submitted for the approval of the Engineer and
shall be verified during the plant trial. No change in
the approved batching sequence and minimum mixing
time shall be allowed.
Control of 11.8 (1) Whether the concrete is produced by the Contractor or

Concrete by an outside specialist supplier, the plant producing it
Production shall be operated in accordance with the quality
and Delivery scheme for the production and supply of concrete
(QSPSC) of the Hong Kong Quality Assurance Agency
(HKQAA) or similar equivalent accredited by Hong
Kong Accreditation Service. The requirements of this
Specification shall prevail over those of the QSPSC.
(2) Concrete for Permanent Works shall only be supplied

by concrete plants approved by the Engineer.
(3) The Contractor shall demonstrate that the concrete

plant and backup plant has met the requirements of
the Contract and shall be subjected to the approval of
the Engineer. A formal assessment of the concrete
plants will be conducted by the Engineer prior to
Approval being given.
(4) At any time during the Contract the concrete plant(s)

will be subject to re-assessment by the Engineer.
Should any non-conformance be found that is likely to
jeopardise the quality of the concrete, Approval will be
withdrawn and no concrete shall be supplied to the
Works until the non-conformance is rectified. The
Contractor shall ensure that an appropriate backup
supply of concrete is available at all times.
(5) The Contractor shall ensure that the Engineer has free
access to the concrete plant(s) at all times, without
prior notice, to allow unannounced conformance
assessments to be made. The Contractor shall
attend all such assessments.
(6) Each delivery of concrete to the Works shall be

accompanied by a certificate giving full details of its
origin and composition. The weights/volumes of
materials in each batch of concrete are to be recorded
automatically by the batching equipment and the
June 2022
11/7
printed records are to be available to the Engineer.

Manually prepared records of batch composition will
not normally be acceptable to the Engineer other than
for the recording of the quantity of superplastisizer
added on site.
(7) When delivered to the Works, each delivery of

concrete shall be tested by the Contractor for
workability by a workability test approved by the
Engineer.
(8) All concrete test cubes shall be 100mm for concrete

with the maximum aggregate size not exceeding
20mm and shall be 150mm with maximum aggregate
size exceeding 20mm in dimension and shall be
prepared, transported, stored and tested in
accordance with Clause 11.78 and Appendix 11.4.
Placing 11.9 Concrete shall be distributed and placed in the Works by an

approved method and in accordance with Clauses 11.84 to
11.88. The Contractor shall ensure that the placed
concrete is a dense homogenous mass free from
discontinuities except planned joints, and achieves the
properties specified by the Contract.
Temperature 11.10 (1) The temperature of concrete at the time of placing and
following shall be measured and controlled by the
Contractor in accordance with Clause 11.82.
(2) The Contractor shall take all necessary measures

such as appropriately designed mixes, pre-cooled
concrete, insulation, formwork materials, embedded
cooling/heating pipes and selection of appropriate pour
cycle times to ensure that after placing the concrete,
both the maximum temperature attained in the
concrete and the temperature differentials within it do
not exceed the specified levels.
Compliance 11.11 The objective of the scheme of Compliance Testing in this

Testing Specification is to ensure that the probability of
non-compliant concrete specified for the Permanent Works
will be reduced to the lowest practicable level.
Notification of 11.12 The Contractor shall give the Engineer reasonable notice of
Concreting his intention to concrete which shall in any case be in
accordance with the approved Quality Plan. The
permission of the Engineer shall be obtained before
concrete is placed in any part of the Permanent Works. If
June 2022
11/8
placing of concrete is not started within 24 hours of

permission having been given, permission shall again be
obtained from the Engineer.
Use of 11.13 Where their use is approved, displacers shall be thoroughly

Displacers wetted with potable water and carefully placed into the
concrete as pouring proceeds. There shall be at least
225mm between any two pieces, or between the displacer
and the face of the concrete. Displacers shall be an
approved material and shall not exceed 30% by weight of
concrete in the structure.
Cutting 11.14 Holes in concrete which are not formed shall be cut by
Holes in rotary coring unless otherwise agreed by the Engineer.
Concrete
Hot Weather 11.15 When the ambient temperature at the formwork face
Curing exceeds 32oC, full hot weather curing techniques as
described in ACI document 305R, shall be implemented.
Absorptive wood forms remaining in place should not be
considered as a satisfactory means of curing in hot, drying
weather. Such forms shall be covered with polythene
sheets and kept moist.
Chloride 11.16 (1) The Contractor shall take the necessary precautionary
Ingress measures to ensure that the chloride content of any
Protection part of any exposed reinforced concrete, measured at
any time within the first 42 days, shall not exceed 0.2%
by weight of the designed cementitious content.
Unless otherwise approved by the Engineer, concrete
shall be sampled and tested to determine the chloride
content as follows:
(a) from hardened concrete, by grinding or

percussion rotary drilling of a maximum 20mm
diameter hole, in the region of 0 to 5mm, 5 to
10mm and 10 to 15mm from the exposed
concrete surface, in three randomly selected
areas of concrete aged between 28 and 35
days;
(b) from fresh concrete, at three locations selected

by the Engineer, during the placing of the
concrete.
(2) If it is detected that the limit specified in Clause

11.16(1) has been exceeded, the Contractor shall
June 2022
11/9
submit his proposals for remedial works and

avoidance of future occurrence for the approval of the
Engineer.
Submission Required Before the Start of Concrete

Works
Mix Design 11.17 Individual mix design details shall be submitted in the format
Submission shown in Appendix 11.8. Details submitted shall include,
but shall not be limited to, the following:
(1) the type and source of all cementitious materials;
(2) the type and source of fine and coarse aggregates;
(3) admixtures and fibre content;
(4) grading and grading zone details, in both tabular and

graphical form, of the fine and coarse aggregates;
(5) grading details, in tabular and graphical form, of the

combined aggregates, together with details of the
proportions in which the fine and coarse aggregates
are to be combined;
(6) the aggregate/cementitious material ratio, by weight;
(7) w/c ratio, by weight;
(8) the calculated chloride content of the mix as a

percentage of the cementitious content;
(9) the calculated total alkali content of the mix in kg/m3

with certificates no older than 6 months giving results
complying with Appendix 11.7 as well as
documentation of a quality system to control total alkali
content;
(10) the design workability, in terms of slump, flow table,

compacting factor, Vebe time or other approved
dynamic measurement of workability; and for SCC, the
designed slump-flow SF, viscosity VS or VF, passing
ability PL or PJ and segregation resistance SR;
(11) the relationship between W/C ratio and strength for the
PC to be used, as provided by the results of the mortar
and concrete tests made to BS EN 196 at the
specified water/PC ratios of 0.40 and 0.60
June 2022
11/10
respectively, in that standard;
(12) the results of laboratory trials when available;
(13) the estimated maximum temperature rise of the mix;
(14) the name and location of the manufacturing plant and

backup plant to be used;
(15) certificates, no older than 6 months for;
– each cementitious material;

– each aggregate;
– each admixture;
– each source of water;
The above Certificates shall contain the manufacturing

details and results of both chemical composition and
physical tests as specified in Clauses 11.23 to 11.32.
Curing 11.18 A certificate shall be submitted, no older than 6 months, for

Membrane the proposed curing membrane giving the details and
Submission results of tests as specified in Clause 11.33.
Method 11.19 (1) Before commencement of concreting at any location

Statement the Contractor shall submit a method statement
Submissions covering the aspects of concrete placement. For
SCC, additional requirements on consistence retention
time, delivery and placing rate shall be included to
ensure the concrete maintain its fresh properties and
avoid interruptions to placing due to delay after the
concrete reaches site. The method statement shall
include, but shall not be limited to, the following:
(a) all items of plant to be used and their respective

layout;
(b) the extent of bays;
(c) construction sequence and locations of

construction joints;
(d) formwork design, handling and cleaning;
(e) proposals for stop ends;
June 2022
11/11
(f) details of waterstops to be used where required;
(g) ordering of concrete;
(h) placement of concrete;
(i) compaction of concrete;
(j) curing of concrete; and
(k) details of the permanent external waterproofing

membrane (where required) to be used.
(2) Two months before the commencement of any

Category A or B concreting the Contractor shall submit
a method statement for temperature control. The
information to be submitted shall include, but shall not
be limited to, the following:
(a) concrete mix details including heat of hydration

and specific heat characteristics of the
cementitious constituents, expected concrete
temperature rise and the proposed initial
concrete placing temperature;
(b) formwork type and insulation;
(c) curing details related to temperature effects;
(d) maximum and minimum concrete placing

temperature;
(e) minimum and maximum time before formwork is

stripped;
(f) any additional methods for controlling the

concrete temperature;
(g) concrete temperature monitoring proposals which

shall be sufficient to demonstrate that the
requirements of the Contract will be met;
(h) analyses and calculations to prove that the

proposals will meet the requirements of the
Contract.
Submissions Required During Concrete Production
June 2022
11/12
Certificates 11.20 During each month of concrete delivery the Contractor shall
obtain and submit to the Engineer a certificate applicable to
each consignment and type of material used to make
concrete delivered to the Works, giving the certified results of
the manufacturer's tests. The test certificates shall include
the result of tests accompanied by calculations of total alkali
content showing compliance with this Specification. All
results contained within test certificates shall be provided by
a HOKLAS registered laboratory.
Analyses of 11.21 During each month of concrete delivery the Contractor shall
Materials provide the Engineer with detailed analyses applicable to
Results each of the materials used in the production, including the
following details:
(1) individual test results;
(2) average values;
(3) standard deviations of all tests required by this

Specification.
Analyses of 11.22 During each month of concrete delivery the Contractor shall
Cube Strength provide the Engineer with detailed analyses of each
Results individual concrete mix used, including the following details:
(1) individual test results;
(2) average values;
(3) running averages of four results and standard

deviations.
Particular Material Requirements
PC 11.23 (1) Cement shall be PC (Type CEM1) Strength Class

52.5N complying with BS EN 197-1. Other cements
shall only be used on the instructions of, or when
approved by, the Engineer.
(2) The chemical analysis of PC shall include the

percentage content by weight of:
– Loss on ignition;
– Alkalis as K2O and Na2O;
June 2022
11/13
– Sulphate as CaSO4;
– Chloride as Cl;
– Insoluble residue.
(3) The physical tests of the PC shall include the results of:
– fineness;
– compressive strength at 2, 7 and 28 days;
– initial and final setting time;
– soundness;
– density.
(4) Aluminous cement (High Alumina Cement, Cement

Fondu) shall not be used anywhere in the Works.
PFA 11.24 (1) PFA shall comply with the requirements of either BS
EN 450-1. The loss on ignition shall be either
Category A or B. The fineness of Category N PFA, if
used, shall be declared.
or BS 3892:Part 1 with the following modifications:
(a) Use Portland cement BS EN 197-1: CEM I (52.5N)

to determine water requirement, strength factor at 28
days, soundness and initial setting time.
(b) The criteria for water requirement and strength

factor at 28 days shall not apply.
(c) PFA of total lime content over 10% but not over 20%
and with soundness value not more than 10 mm is
acceptable as “high-lime PFA’. When “high-lime PFA” is
used, it shall be reported in certificates that accompany
delivery of “high-lime PFA”.
(2) The chemical analysis of PFA shall include the

– Reactive Silicon Dioxide;

– Sum of Silicon Dioxide, Aluminium Oxide and
Iron Oxide;
– Free Calcium Oxide;
– Reactive Calcium Oxide;
– Sulphuric anhydride as S03;
– Chloride as Cl;
June 2022
11/14
– Total content of alkalis;
– Magnesium Oxide as MgO;
– Soluble Phosphate as P2O5.
(3) The physical tests of PFA shall include the results of:
– fineness;
– activity Index;
– water requirement (Category S only);
– initial setting time;
– soundness;
– moisture content;
– particle density.
Where cement is to be used for the above tests, it shall

conform to BS EN 197-1: CEM1, Class 42.5 or higher
and with the following additional characteristics:
- finess (Blaine): at least 300 m2/kg;

- Tricalcium Aluminate: 6% to 12% and
- Alkalis (Na2O eqv): 0.5% to 1.2 %.
Fineness may be either Category ‘N’ or ‘S’, but shall be

determined by the mix trials and maintained throughout
production.
The source and both chemical and physical tests results of

the PC used in the tests for initial setting time, soundness,
water requirement and activity index shall also be included.
Blended Cement, 11.25 Blended cement and blast furnace cement shall comply with
Blast Furnace the requirements of BS EN 197-1.
Cement
GGBS 11.26 (1) GGBS shall comply with the requirements of BS EN

15167-1 except that the scheme for the evaluation of
conformity of GGBS specified in BS EN 15167-2 is not
required. The glass content as determined by X-ray
diffraction or optical-microscopy method shall be not
less than 67%. The X-ray diffraction method detailed in
Appendix D of BS 6699 is acceptable.
(2) The chemical analysis of GGBS shall include the

June 2022
11/15
– Silica as SiO2;
– Alumina as Al2O3;
– Manganese as Mn2O3;
– Magnesia as MgO;
– Calcium Oxide as CaO;
– Titanium Dioxide as TiO2;
– Sulfide as S;
– Sulfate as SO3 ;
– Chloride as Cl;
– Insoluble residue;
– Acid soluble alkali;
– Chemical modulus (CaO+MgO+Al2O3)/SiO2;
– Lime / silica ratio as CaO / SiO2.
(3) The physical tests of GGBS shall include the results of:
– fineness;
– compressive strength at 7 and 28 days;
– glass content ≥ 67%;
– initial setting time;
– soundness;
– moisture content;
– activity index.
(4) The fineness of GGBS shall be at least 350m2/kg.
CSF 11.27 (1) CSF shall comply with the requirements of BS EN

13263-1 or CSA-A3000 (Canadian Standard).
(2) The chemical analysis of CSF shall include the

– Silicon dioxide as SiO2;

– Elemental silicon, Si;
– Sulfate as SO3;
– Calcium Oxide as free CaO;
– Chloride as Cl;
– Alkalis as Na2O equivalent;
– Loss on ignition.
(3) The physical tests of CSF shall include the results of:
– Specific surface;
June 2022
11/16
– activity index; and

– dry mass.
Aggregates: 11.28 (1) Aggregates shall comply with CS3. All aggregates
General shall be shown to the satisfaction of the Engineer to be
free from any substance likely to undergo an expansive
reaction in the presence of alkali and water.
Aggregates shall be tested for the geometric, physical
and chemical properties in accordance with CS3.
The aggregate producer shall operate a quality
assurance system certified to the ISO 9001 standard
by a certification body accredited by Hong Kong
Accreditation Service (HKAS) or its Multilateral
Recognition Arrangement (MLA) partner for Quality
Management System (QMS) certification.
(2) The Contractor shall carry out tests for potential

reactivity by an approved independent laboratory using.
The “Ultra-accelerated Mortar Bar Test” in accordance
with CS1. The aggregate shall be considered
acceptable if the average expansion result at 14 days is
less than 0.1% (Non-reactive). Each aggregate shall
be tested initially, prior to supply, and then at a
minimum frequency of twice per year.
(3) Sands of alluvial origin or natural sand are not

acceptable for use in structural concrete unless they
have been specified in the Contract and approved by
the Engineer. If specified in the Contract the material
and source shall be such that they are entirely and
continuously free from substances which might be
suspected of being likely to react expansively with
alkalis, and are proven to be chloride free.
(4) Aggregates of marine origin shall not be used in the

Works. All-in aggregate shall not be used.
(5) Both the fine and coarse aggregate in any mix shall be
from the same source, except where the fine
aggregates is specified in the Contract as being of
alluvial origin.
(6) Recycled aggregates may be used in concrete less

than Grade 40 subject to the prior agreement of
Engineer. Recycled aggregates shall comply with
CS3 and the following requirements:
June 2022
11/17
Requirements Limits Testing Method

Minimum dry particle
2000kg/m3 CS3
density
Maximum water
10% CS3
absorption
Maximum content of
wood and other
0.5%
materials less dense
than water Manual sorting in
Maximum content of accordance with
other foreign materials BRE Digest 433
(e.g. metals, plastics, 1%
clay lumps, asphalt
and tar, glass etc.)
Maximum content of
4% CS3
fines
Maximum content of
5% CS3
sand (<4mm) (%m/m)
Maximum content of
1% CS3
sulphate (%m/m)
Flakiness index 40% CS3
10% fines test 100kN CS3
Grading Section 3 of CS3
Acid-soluble sulphate
Section 5 of CS3 – 1% by mass
content
Maximum chloride Section 5 of CS3 – 0.05% by mass of
content acid soluble chloride ion of combined
aggregates
Fine 11.29 (1) Fine aggregate shall, except where specified in the
Aggregate Contract, consist of crushed rock complying with the
requirements of CS3. The particular type or types to
be used shall be approved by the Engineer and the
source shall be stated and be subject to the Engineer's
Approval.
(2) Fine aggregate shall comply with the requirements of

Section 3 of CS3 for grading and shall conform to the
range of one of the specified zones C, M or F. The
grading zone of the Fine Aggregate shall be stated in
the mix design submission. Fine aggregate not
complying with these requirements shall be rejected
unless a change of proportions is approved by the
Engineer.
(3) Fine aggregate test certificates showing that the

aggregates comply with the CS3 requirements shall
include the following:
June 2022
11/18
– grading and grading zone;

– fines content and methylene blue value for Class II
natural aggregate;
– chlorides content;
– acid-soluble sulphate content;
– total sulphur content;
– water absorption;
– particle density;
– drying shrinkage;
– potential alkali-reactivity; and
– organic content if any.
Coarse 11.30 (1) Coarse aggregates shall be crushed rock complying

Aggregate with the requirements of CS3. The particular type or
types to be used shall be approved by the Engineer
and the source shall be stated and be subject to the
Engineer's Approval.
(2) The grading of coarse aggregate shall conform to the

requirements of Section 1 of CS3 for single sized
aggregates. Allowable sizes of coarse aggregate are:
40 mm 20 mm 14 mm 10 mm
(3) Coarse aggregate test certificates showing that the

aggregates comply with the CS3 requirements shall
include the following:
– grading;
– fines content;
– shell content;
– chlorides content;
– acid-soluble sulphate content;
– total sulphur content;
– water absorption;
– particle density;
– flakiness Index;
– elongation Index;
– ten percent fines value;
– aggregate impact value;
– Los Angeles Value;
– soundness;
– drying shrinkage;
– magnesium sulphate soundness;
June 2022
11/19
– potential alkali-reactivity; and

– organic substances, if any.
(4) Coarse aggregate shall have a flakiness index not

exceeding 30% when tested by the sieve method of
CS3.
(5) Coarse aggregate shall have an elongation index not

exceeding 35% when tested in accordance with CS3.
(6) The mechanical properties of the coarse aggregate

shall be such that its "10% fines value" is not less than
100kN and its “aggregate impact value” not exceeds
30% when tested in a dry condition.
(7) For high strength concrete above Grade 60, the

mechanical properties of the coarse aggregate shall be
such that its “10% fine value” is not less than 150kN
when tested in a dry condition.
(8) The Los Angeles Value shall not exceed 30% loss and
magnesium sulphate soundness weighted average loss
shall not exceed 6%.
Water 11.31 (1) Water for mixing concrete, for curing test specimens
and for curing concrete placed in the works, shall be
mains water of potable quality supplied by the Hong
Kong Water Supplies Department.
(2) The Engineer may permit non-saline water from other

sources to be used provided that it can be
demonstrated that the water is neutral in pH value, is
free from suspended solids and liquid contaminants
non-miscible with water and that when tested according
to the procedures given in BS EN 1008, it has no
significant effect on the setting time or strength of
concrete.
(3) Water test certificates shall relate to tests from a

representative sample of the water used at the batching
plant for concrete mixing, or on-site for concrete curing
and shall include the following details:
– preliminary assessment for suitability for use in

concrete;
– chloride content;
– PH value;
June 2022
11/20
– sulphate;
– alakli;
– harmful contamination;
– setting time;
– strength.
Admixtures 11.32 (1) Admixtures or additives shall only be used where

and Additives specified or with the Approval of the Engineer.
Admixtures or additives shall comply with BS EN 934.
(2) No admixture or additive containing water-soluble

chloride (e.g. calcium chloride) shall be used.
(3) Admixture or additive test certificates shall include the

following:
(a) manufacturer's data sheet;
(b) all ingredients in the admixture or additive;
(c) whether or not the admixture or additive leads to

the entrainment of air when used at the
manufacturer's recommended dosage;
(d) description of the physical state, colour,

homogeneity, corrosion behaviour and
composition;
(e) the effect of under-dosage or over-dosage;
(f) recommended storage conditions and shelf life;
(g) recommended method of addition to the

concrete;
(h) any known or likely incompatibility with any other

admixtures, additives or cementitious materials;
(i) results of pH value, absolute density, dry material

content and silicon oxide content ;
(j) recommended dosage;
(k) chloride content;
(l) acid soluble alkali content;
June 2022
11/21
(m) certificate of compliance with the relevant

standard.
(4) Admixtures and additives will normally only be

approved if they are liquids but they may be measured
by volume or weight. If the Engineer permits the use
of a solid or paste admixture or additives, this shall be
thoroughly dispersed or dissolved in at least 10 times
its weight of water so as to demonstrate to the approval
of the Engineer that it will be distributed uniformly in the
concrete before any concrete is placed. The water
used for dispersing the admixture or additive, shall be
considered as part of the mixing water in the concrete
and shall be included in the calculation of the
water/cementitious material ratio of the concrete.
probe h
Liquid 11.33 (1) 3 Liquid curing compound shall be a proprietary type with
Curing a proven history of use and have a curing efficiency of
Compound greater than 85% when tested by the method specified
in Appendix 11.6. Resin-based curing compound shall
not be used unless approved by the Engineer.
(2) Liquid curing compound shall contain a fugitive dye

unless otherwise specified in the Contract.
(3) Liquid curing compound containing organic solvents

shall not be used.
(4) The liquid curing compound shall comply with all the
following criteria:
(a) become stable and achieve the specified

resistance to evaporation of water from the
concrete within 60 minutes after application;
(b) not react chemically with the concrete surface to

be cured;
(c) not crack, peel or disintegrate within one week

from application;
(d) degenerate completely within 28 days from

application.
(5) Liquid curing compound certificates shall include the

following details:
(a) manufacturer's data sheet;
June 2022
11/22
(b) description of composition and colour;
(c) active ingredients and solvents;
(d) recommended rate of application;
(e) method of application;
(f) test results of the curing efficiency from an

approved independent laboratory.
Particular Mix Design Requirements
Composition 11.34 (1) 3 The cementitious content of the mix shall be expressed
of Designed in kg/m3. The ‘k’ factor approach of BS EN 206-1 shall
Mixes: General not be used.
(2) The volumes of each constituent shall be calculated on

the basis of the Specific Gravity of the constituents from
suitably verified test results. The volume of air
contained in the concrete shall be assumed to be 0.8%
unless verified otherwise by test results.
(3) PFA or GGBS shall be an ingredient of the concrete

mix.
(4) For mixes containing PFA the following criteria shall

apply:
(a) the PC content of any mix shall be 65% to 75%

by weight of the total cementitious content;
(b) the PFA content shall be no less than 25% by

weight of the total cementitious content;
(c) the PFA content shall be no more than 35% by

weight of the total cementitious content; and
(d) The additional requirements by Buildings

Department, if any, should be addressed
accordingly
(5) For mixes containing GGBS, the GGBS content shall

be between 35% and 75% of the total cementitious
content.
(6) Where CSF is specified in the Contract, it shall be
June 2022
11/23
between 5% and 10% of the design cementitious

content, except for high strength concrete for the
consideration of explosive spalling that 6% CSF should
be used.
(7) Cementitious blends shall not contain both PFA and

GGBS. However CSF may be used in conjunction
with either PC/PFA or PC/GGBS cementitious blends.
Minimum 11.35 The minimum cementitious content for classes of concrete

Cementitious which will most commonly be used is given in Table 11.2.
Content Concrete of other classes may be called for and if so,
particular requirements will be specified in the Contract.
Table 11.2 : Designed Mixes Cementitious Contents
Class of Concrete Grade Minimum Cementitious Content,

Strength / Aggregate Size (kg/m3)
60/20 400
50/20 400
45/20 375
40/20 350
30/20 325
20/20 290
Note: CSF shall be added where specified in the

Contract.
Maximum 11.36 (1) Category A Concrete:

Cementitious
Content The maximum cementitious content of any mix shall be
450 kg/m3.
The maximum PC content of any mix shall be 330

kg/m3.
(2) Category B and Category C Concrete:
The maximum cementitious content of any mix shall be

550 kg/m3.
The maximum PC content shall be 400 kg/m3.
Maximum 11.37 (1) Except as stated in the Contract the maximum W/C
W/C Ratio ratio of designed mixes shall not exceed the following:
– 0.350 for concrete of Grade 55 or above;
June 2022
11/24
– 0.380 for concrete of Grade 40 or above and below

Grade 55;
– 0.450 for concrete of Grade 30;
– 0.600 for concrete below Grade 30.
(2) Not used.
(3) When calculated from production concrete the

individual W/C ratio results shall not exceed 0.010
above the maximum specified value.
(4) When calculated from production concrete the average

W/C ratio of any three consecutive calculations shall
not exceed the maximum specified value.
(5) Upon failure to meet any of the tolerances stated above

the mix shall be redesigned.
Concrete 11.38 Not Used.

Mix Design:
Strength
Design of 11.39 (1) 3 No-fines concrete is to be made from a mix composed

No-Fines of aggregate particles of a single size coated with a free
Concrete flowing grout having a low water/cement ratio.
Mixes
(2) The Contractor shall demonstrate to the satisfaction of
the Engineer that the mix design will enable a material
to be produced which will have adequate strength and
will permit water to flow freely through it.
(3) No-fines concrete shall comply with the following

requirements:
Aggregate grading:
Passing 40 mm sieve 100%
Passing 20 mm sieve not less than 85%
Passing 10 mm sieve not more than 10%
Aggregate/PC ratio in the order of 8:1 to 10:1
W/C ratio not more than 0.45
June 2022
11/25
(4) When require, cubes to be made of no-fines concrete

shall be prepared and cured according to the
instructions given in BS 1881:Part 113 and shall
achieve a strength of 10 MPa at 28 days.
(5) No-fines concrete shall be placed with the minimum of

punning. No traffic shall be allowed on the finished
work and the surface shall be kept clean.
(6) Before placing normal concrete over no-fines concrete

a layer of approved polyethylene sheet of 500 grade
(0.5 mm thickness) shall be laid over it maintaining a
taped lap joint of at least 250 mm wide, to ensure that
no mortar from the overlying concrete penetrates into
the no-fines concrete.
Procedure for Trial Mixes and Approval of Concrete

Mixes
Concrete 11.40 Trial mixes are not required for concrete Grade 20 and
Trial mix below. Trial mixes shall not be prepared until the Engineer
has approved the Contractor's mix design proposal. Trial
mixes shall be prepared at least 35 days before the
commencement of concreting under the supervision of the
Engineer. For each class of concrete the following
procedure shall apply :
(1) Three plant trial mixes shall be made at the proposed

concrete plant, each on a different day and the
workability of each mix shall be determined by either
slump, flow table, slump-flow, compacting factor, Vebe
time or other approved dynamic test. Only one
workability test method shall be approved and used to
establish workability criteria of the concrete. For SCC,
additional workability tests shall be performed to
demonstrate that in the design slump-flow range the
mix retains the declared properties and workability
ranges in terms of viscosity, passing ability and
segregation resistance as specified in BS EN
206:2013.
(2) Three sub-samples shall be taken in accordance with

CS1 from each trial mix. Each sub-sample shall be of
sufficient size to conduct the workability tests, make
two test cubes and have a minimum of 10 litres left to
form part of the workability retention sample. Two test
cubes shall be made from each sub-sample. One
cube from each sub-sample shall be tested at 7 days
June 2022
11/26
and the other at 28 days.
(3) A combined sample of concrete shall be retained for

workability retention testing. The workability retention
tests shall be carried out at 30 minute intervals up to
two hours or longer if required by the Engineer.
(4) Three sub-sample cubes from each trial mix (nine

cubes in all) shall be tested for compressive strength at
7 days and three cubes from each mix (nine cubes in
all) at 28 days.
(5) Cubes shall be made, cured and tested in accordance

with the requirements of CS1. The temperature at
which cubes are cured shall be 27 ± 3oC at all times.
(6) A representative sample of the concrete shall be tested

for bleeding in accordance with ASTM C232 Method A,
using a container with an internal diameter of 255 ± 5
mm and height of 280 ± 5 mm (14 litre capacity). The
concrete sample shall fill the mould to a height of 255 ±
5 mm and compacted using the method used in the
works (e.g. vibration).
If the bleeding of the concrete is > 0.2% by volume of
the sample, the Engineer may require the mix to be
re-proportioned to reduce the bleeding.
(7) A representative sample of the concrete shall be

obtained and tested for total chloride content in
accordance with CS1.

obtained and tested for the fresh density of compacted
concrete in accordance with CS1.

obtained and tested for initial and final stiffening time
in accordance with CS1.
(10) During each trial mix for all Category A and Category B
concrete, a Temperature Rise Evaluation Test (TRET)
shall be made. The test shall consist of an insulated
800x800x800mm concrete block constructed to the
approval of the Engineer. The block shall be
instrumented with a minimum of three centrally located
thermocouples connected to an automatic data logger
and hourly readings shall be taken until the temperature
has fallen to >10oC below the peak temperature. The
June 2022
11/27
insulation of the concrete block shall be complete and

equivalent to at least 200 mm of expanded polystyrene
with additional protection provided as necessary. The
concrete block shall be constructed and instrumented
to the approval of the Engineer. The information
gained during this test shall be used by the Contractor
in the formulation of the temperature control methods
for the mix. The concrete block shall be retained in a
manner to ensure that damage or degradation does not
occur for a minimum of 3 months or as directed by the
Engineer. The results of the TRET shall be used in
conjunction with the Contractor's proposed
insulation/cooling methods to evaluate compliance with
the temperature control requirements.
(11) Category A concrete shall be tested in accordance with

CS1 “Concrete’s Ability to Resist Chloride Ion
Penetration Test” (RCPT). The RCPT shall be
conducted on three cores taken from the TRET block at
28±1 days and tested at 35±1 days.
(12) All Category A concrete shall be tested for absorption in

accordance with BS 1881:Part 122 on three cores
obtained at 21±1 days from the TRET block and tested
at 28 days.
Trial Mix: 11.41 (1) The 9 cubes taken from the trial mix tested at 28 day
Performance shall have an average strength of 12MPa greater than
Requirements the specified grade strength, for Grade 30 concrete and
above. Similarly for concrete below Grade 30, the
average strength shall be 10MPa greater than the
specified grade strength.
In addition:
(a) the range, i.e. the maximum strength minus the

minimum strength of the three cubes in any set
shall not exceed 15% of the average strength of
the set;
(b) for both 7-day and 28-day tests the range of the
averages of the three sets shall not exceed 20%
of the average of the sets; and
(c) compliance with the characteristic strength may

be demonstrated by cube strength at 56 days. If
so, compliance of the trial and in production shall
be demonstrated by sets of cubes tested at both
June 2022
11/28
28 days and 56 days.
(2) For Category A concrete the results of the RCPT shall

be average 35 day electrical resistance less than 1500
Coulombs.
(3) For Category A concrete the results of the absorption

tests shall be average absorption value at 28 days of
less than 1.5%.
(4) For Category A and Category B concrete the results of

the TRET shall be less than 70oC and 80oC peak
temperature respectively. The maximum temperature
difference between a point at the centre and the
surface of concrete block shall not exceed the
requirements in Clauses 11.82(2)(c) and 11.82(3)(c).
(5) The total calculated reactive alkali content of any

concrete mix shall be less than 3 kg/m3.
(6) The total chloride content of any concrete mix, from the
results of tests conducted in accordance with CS1 or
calculated from the chloride contents of each
constituent and the proportion of each constituent in the
mix, when expressed as a percentage of chloride ion
by mass of the cementitious material shall not exceed
0.2% by weight of the cementitious content, or 0.1% if it
is to be prestressed. The maximum for concrete with
no steel reinforcement or inserts is 1.0%.
Mixes already in 11.42 Where concrete is to be supplied by a concrete producer

Production other than the Contractor and the supplier has in regular
production a mix which complies with the requirements of
the Specification, the Engineer may permit the Contractor, in
lieu of preparing trial mixes, to submit recent records, not
more than 24 months old. These records shall give the
following details:
(1) a minimum of 60 consecutive cube test certificates;
(2) the results of all concrete properties required in Clause

11.41 within 24 months;
(3) calculated mean strength;
(4) variability of that mix;
(5) proof that it is currently in regular production by the
June 2022
11/29
concrete supplier.
Approval of 11.43 (1) No concrete of any class shall be placed in the Works
Concrete Mixes until the Engineer has approved, in writing, the use of
the particular mix.
(2) When the mix has been approved, no variations shall

be made in the proportions, the original source of the
cement, admixtures, or aggregates or in the type, size
or grading zone of the aggregates without the prior
approval of the Engineer, who may require further tests
to be made.
(3) On the basis of the results from the trial mix tests and
calculations, or the submitted backup data, the
Engineer shall inform the Contractor whether the mix
design is approved. If the mix design is not approved,
the Contractor shall adjust the mix design and repeat
the tests until results complying with the Specification
are obtained.
Re-Trial of 11.44 Should the ambient temperature, source or grading of

Concrete materials significantly change from the situation during the
Mixes approval of trial mixes, additional trial mixes will be required
by the Engineer to be conducted under the new situation.
Laboratory 11.45 Laboratory trials will not normally be acceptable. However,

Trials if they are permitted by the Engineer, they shall follow the
procedures given above for plant trials. The materials used
for preparation of any laboratory trial mixes shall be at a
temperature of 27 ±5oC at the time of mixing.
Concrete Production
Cementitious 11.46 (1) 3 Cementitious material shall be stored in a manner so as

Materials: Delivery to be fully protected against dampness and other
and Storage environmental factors that may lead to deterioration of
the materials.
(2) Cementitious material shall normally be delivered and

stored in bulk containers.
(3) Exceptionally, and only with the prior approval of the

Engineer, cementitious material may be delivered and
stored in bags. During transit the bags shall be
protected from the weather and each consignment of
bagged cementitious material shall be stacked
separately and used in order of delivery. Sheds for
June 2022
11/30
cementitious material shall be waterproof and the floor

shall be raised above the adjacent ground level to
provide protection against dampness.
(4) Bulk cementitious material shall be stored in dry

waterproof containers. The bulk containers used for
transit and storage shall be of a type approved by the
Engineer. They shall be completely enclosed
water-tight containers of metal construction.
(5) Separate storage of different types of cementitious

material shall be provided. Containers may be used to
store cementitious material of different types provided
that these are properly emptied and cleaned before
loading the new cementitious material.
(6) Bins or silos shall be weatherproof and permit free flow

and efficient discharge of the cementitious material.
(7) Each silo or compartment of a silo shall be completely

separate and be fitted with a filter or an alternative
method of dust control. Each filter or dust control
system shall be of sufficient size to allow for delivery of
cementitious material to be maintained under pressure,
and shall be properly maintained to prevent emission of
cementitious material dust, so as to comply with the
current environmental regulations and prevent
interference with weighing accuracy by build-up of
pressure.
Aggregate / 11.47 (1) All aggregates brought to the Site or to the approved
Polypropylene batching plant shall be kept free from contact with
Fibre: deleterious matter and, in the case of aggregates
Delivery and passing a 5mm sieve, they shall be deposited at the
Storage mixing location not less than 8 hours before use.
Aggregates of different sizes or from different sources
shall be stored in different hoppers or different
stockpiles, which shall be separated from each other.
Recycled aggregates shall be stored separately.
Adequate storage capacity shall be provided, either at
the source of supply or at the mixing location, for ample
supplies of both fine and coarse aggregate of the
approved quality and grading to be available to
maintain continuity of work.
(2) Aggregates shall be stored on specially prepared well

drained concrete floors divided into compartments as
necessary.
June 2022
11/31
(3) Polypropylene fibre shall be either delivered in bulk or

in bags and shall be stored separately in silos or
specially stored in room area respectively.
Admixture and 11.48 (1) Tanks or drums containing liquid admixtures or

Additive: additives shall be clearly labelled for identification
Delivery and purposes and stored in such a way as to avoid damage
Storage or contamination.
(2) Agitation shall be provided for liquid admixtures or

additives that do not remain homogenous in storage.
Admixture and 11.49 The specific gravity of all admixtures and additives stored at
Additive the batching plant or on-site shall be tested weekly or for
Specific Gravity each delivery consignment whichever occurs first.
Control
Aggregate 11.50 (1) 3 For the purposes of controlling the grading of aggregate
Grading from any one source, preliminary samples of each size
Control shall be submitted prior to first deliveries. These
samples shall be representative of the material which it
is proposed to supply. Any delivery of the aggregate
made during the progress of work which shows a
variation in grading outside the range of the approved
grading zone specified in CS3 will be rejected, and
shall be removed from the Site.
(2) The grading and fines content of each type and size of
aggregate shall be tested by the Contractor on a
weekly basis or once per 500 tonnes of material,
whichever occurs sooner. The coarse aggregate shall
be tested by the Contractor for flakiness index,
elongation index and 10% fines value on a monthly
basis. The test methods shall be in accordance with
CS3.
Library 11.51 (1) 3 The Contractor shall obtain a library sample of each
Samples of material used in the production of concrete on each day
Materials of concrete production. The library samples shall be
retained for a minimum of 6 weeks. The library
samples shall be identified and stored by the Contractor
in such a manner that will ensure no degradation of the
material occurs during the retention period.
(2) The library samples shall be of the following minimum

weight/volume:
June 2022
11/32
– Admixture or Additives 1 litre
– Water 1 litre
– Aggregate 50 kg
– Cementitious material 35 kg
(3) The Contractor shall, in the event of a strength failure or

other non compliance, conduct tests on the library
samples at an approved independent laboratory as
directed by the Engineer.
Training of 11.52 (1) All personnel shall receive training appropriate to the
Production duties they perform.
Personnel
(2) Concrete mixes shall be batched by operators who
have received proper instruction in the mode of
operation of the equipment used and are able to
comply with the specified accuracy of batching.
(3) The batcher or mixer operator (whether for central or

truck mixers) is responsible for the quality and
workability of the concrete produced, and shall have
attended a suitable course and reached an acceptable
standard. He/she shall be trained to recognize any
errors or deficiencies in the mixed concrete and be
instructed in the methods of rectifying them.
(4) Notwithstanding the above, any operators failing to

comply with the requirements for production of concrete
shall be suspended from concrete production activities.
Plant and 11.53 All plant and equipment shall be maintained in a clean and
Equipment: efficient working condition and regular routine maintenance
General checks shall be carried out as defined in Appendix 11.1.
Batching 11.54 (1) Hoppers for weighing cementitious material, aggregate

Equipment and water shall consist of suitable containers freely
suspended from a scale or other suitable
load-measuring device and equipped with a suitable
discharging mechanism.
(2) The method of control of the loading mechanism shall

be such that as the quantity required in the weighing
hopper is approached, the material may be added at a
controllable rate and shut off precisely with the
weighing tolerances specified.
June 2022
11/33
(3) The weighing hoppers for cementitious material and

aggregate shall be capable of receiving their rated load
without the weighed material coming into contact with
the loading mechanism. Additional precautions shall
be taken to ensure that the correct number of batches
is loaded into the truck mixer.
(4) Dust seals shall be provided on cementitious material

hoppers between the loading mechanism and weighing
hopper, and shall be fitted so as to prevent the
emission of cementitious material dust without affecting
weighing accuracy. The hopper shall be vented to
permit escape of air without emission of cementitious
material dust.
(5) Vibrators or other attachments, where fitted, shall not

affect the accuracy of weighing.
(6) There shall be sufficient protection to cementitious

material and aggregate weight hoppers and weighing
mechanisms to prevent interferences with weighing
accuracy by weather conditions or external build-up of
materials.
(7) Where a continuous mixer with ribbon loading is used,

the batching procedure specified by the manufacturer
of the plant shall be followed.
Mixing of 11.55 (1) The weighing and water dispensing mechanisms shall
Concrete be maintained in good order. Their accuracy shall be
maintained within the tolerances given in Clause 11.56
and be checked against accurate weights and volumes
on a monthly basis or when required by the Engineer.
(2) The weights of all materials as indicated by the

mechanisms employed shall be within the tolerances
stated in Clause 11.58.
(3) Concrete shall be mixed in a power-driven batch type

mixer approved by the Engineer. The batch capacity,
method of loading, mixing time and speed of operation
shall be as recommended by the mixer manufacturer.
(4) Mixers which have been out of use for more than 30
minutes shall be thoroughly cleaned before any fresh
concrete is mixed. Mixing plants shall be thoroughly
cleaned before changing from one type of cement to
June 2022
11/34
another.
(5) Cementitious materials shall only be measured by

weight and shall be weighed in a hopper or
compartment separate from those used for other
materials. The scale increments of the weighing
device shall not exceed 5kg.
(6) Subject to the approval of the Engineer, cement may

be measured in whole bags as delivered by the
manufacturer but only for small quantities of concrete
for minor works.
(7) Aggregates shall be measured by weight. The

weights of the fine and coarse aggregates shall be
adjusted to allow for the free water contained in them.
The water to be added to the mix shall be reduced by
the quantity of free water contained in the both fine and
coarse aggregates. The method of moisture
determination shall be proposed by the Contractor for
approval by the Engineer. The moisture shall be
measured immediately before mixing begins and then
hourly during production. All the results shall be
recorded and submitted to the Engineer.
(8) Admixtures and additives shall be measured by volume

or weight. The batching plant shall be so designed
that the measured dosage of admixture or additives is
discharged into the mixing water, and is not added as a
separate concentrated solution, thereby ensuring good
distribution throughout the mix. The exception to this
requirement is superplastisizing admixtures, which may
be added prior to discharge from the
transporting/mixing vehicle using a method approved
by the Engineer.
(9) It shall not be permissible for the workability of concrete

to be increased by adding water to it after it has left the
batching plant and any concrete which has had water
added to it after leaving the batching plant shall be
rejected and removed from the Site.
(10) If the Contractor decides to reduce the water content of

future deliveries of concrete to bring the workability
within tolerance this does not release him from the
necessity of maintaining a standard deviation of
strength not exceeding 5.5 MPa for 100mm test cubes
or 5 MPa for 150mm test cubes if compliance criterion
June 2022
11/35
C2 as stated in Table 11.4 is to remain in force.
(11) When assessment of the moisture content of the

aggregate is carried out continuously, using a suitable
instrument, a calibrated chart, based on the average
moisture contents of the aggregate, shall be provided
indicating the necessary changes in the added water
for each 1% change in the moisture content.
(12) When weighing materials, any build-up in the hopper

during the day must be tared out or allowed for in the
batch weights.
Accuracy of 11.56 (1) The weighing and metering mechanisms shall be

Scales and calibrated within an accuracy of 2% for all cementitious
Meters materials, aggregates and water and within an
accuracy of 5% for admixtures and additives.
(2) Sufficient test weights shall always be available for

checking the accuracy of the scales and at least once
per month all loading-measuring mechanisms shall be
checked.
Batching 11.57 For all concrete mixes, the materials batch weights shall be
System recorded in a computer system and readily inspected by the
Engineer if necessary.
Accuracy of 11.58 The batcher operator shall measure out materials within the
Batching following tolerances:
Cementitious ± 2% of the weight of the material in

Material the batch, except 0% to +5% of the
weight for CSF.
Aggregate ± 2% of the weight of each aggregate in

the batch
Water ± 2% of the weight of water added
Admixtures ± 5% of the amount to be added
Yield Checking 11.59 (1) A monthly check shall be made on the yield of each mix
and Control currently in production at the batching plant, from the
total weight of a given batch, using a weighbridge,
divided by the weight per unit volume of the fully
compacted concrete determined in accordance with
CS1. The procedures for conducting yield checking
June 2022
11/36
shall be proposed by the Contractor for the approval of

the Engineer.
(2) Individual results of Yield checks shall be between

98.5% and 101.5% of the design value of the mix, upon
failure to meet this tolerance the mix shall be
redesigned. Should two successive results fall below
99% or above 101% the mix shall be redesigned.
Washing-out 11.60 Before loading concrete materials or mixed concrete into

Water either central or truck-type concrete mixers, any water
retained in the mixing drum for washing-out purposes must
be completely discharged.
Loading 11.61 (1) To ensure that the concrete materials can be mixed
Concrete most readily in central and truck-type concrete mixers
Mixers into a homogenous mass, the cementitious material,
aggregates and water shall be fed into the drum
simultaneously and at a uniform rate.
(2) When mixing concrete containing CSF the CSF shall

be added and mixed with the dry aggregates for an
agreed period prior to the introduction of the other
constituents.
Central or 11.62 Where a central or plant mixer is used for the mixing of
Plant Mixers concrete, it shall comply with Appendix 11.3, in so far as this
applies. Central or plant mixers shall not be loaded in
excess of the manufacturer's rated capacity.
11.63 (1) Where a central or plant mixer is used for the mixing of
concrete, it shall comply with Appendix 11.3, in so far
as this applies. Central or plant mixers shall not be
loaded in excess of the manufacturer's rated capacity.
(2) In order to produce a satisfactory mix, and where no

uniformity tests have been carried out, the mixing time
shall not be less than 2 minutes. Where uniformity
tests have been carried out and a shorter mixing time
has been shown to be satisfactory, this time shall be
displayed on a suitable metal plate attached to the
mixer and can be adopted.
(3) When a continuous mixing plant is used for the

complete mixing of concrete, the mixing time shall be
sufficient to ensure that the concrete is of the required
uniformity. When a continuous mixing plant is used for
the partial mixing of the concrete and the mixing is
June 2022
11/37
completed in a truck mixer, the total mixing time shall

be sufficient to ensure that the concrete is of the
required uniformity.
Truck Mixing 11.64 (1) Truck mixing or dry batching will only be permitted with
the prior approval of the Engineer and shall conform to
the Engineer's supplementary Specification for Truck
Mixed Concrete as detailed in Appendix 11.3. When a
truck mixer is used for the partial or complete mixing of
concrete, mixing shall be considered to commence
from the moment when all the materials required for the
batch, including water, are in the rotating drum of the
truck mixer.
(2) Truck mixers, used for mixing concrete, shall be fitted

with an operational revolution counter which shall be
set to zero at the start of the mixing cycle. Revolutions
during the loading period shall not be included in the
mixing revolutions.
(3) In order to produce a satisfactory mix, mixing shall

continue for not less than 100 revolutions of the truck
mixer drum at a rate of not less than 7 revolutions per
minute.
(4) When the cementitious materials and aggregates are

batched dry, no liquid admixtures or additives shall be
added to the concrete before the water is added.
Conditions of 11.65 (1) Central and truck-type mixers shall be maintained in an

Mixers efficient and clean condition with no appreciable
build-up of hardened cementitious material or concrete
in the mixing drum, on the mixing blades, or on the
loading hopper or discharge chutes.
(2) When, due to wear, the height or depth of the mixing

blades or paddles is less than the manufacturer's
recommended minimum height, or less than 75% of the
original height, the blades or paddles shall be repaired
or replaced.
Delivery 11.66 Before discharging the concrete at the point of delivery, the
Tickets Contractor shall provide a delivery ticket copied to the
Engineer for each batch of concrete. The delivery ticket
shall be indelibly marked by printing, stamping or
autographic recording by the batching equipment and shall
contain the following information:
June 2022
11/38
(1) name and assigned MTRCL plant code of the concrete

depot;
(2) serial number of ticket;
(3) date;
(4) truck number;
(5) name and location of job;
(6) specified grade of concrete;
(7) designed workability type and value;
(8) type of cementitious material;
(9) maximum size of aggregate;
(10) type, name and quantity of admixture or additive with

provision for site addition of superplastisizer if required;
(11) amount of concrete in cubic metres in this delivery;
(12) time of loading;
(13) the assigned MTRCL mix code of the concrete;
(14) a Quick Response (QR) code encoding the concrete

delivery ticket information required by the MTR Mobile
Materials Testing Application or the QR code appended
to the concrete delivery ticket. The QR code shall be
used for scanning and automatically transferring the
required concrete information into the Materials Testing
System (MTS).
Records of Contractor's Tests
Records and 11.67 Continuous records, control charts and statistical analyses of
Analysis of Tests all materials and concrete tests from the batching plant or
on Concrete and site shall be continuously maintained by the Contractor.
it's Constituents The records, control charts and statistical analyses shall be
made available for inspection by the Engineer at all times.
Concreting 11.68 The Contractor shall maintain records of the concreting

Records During operations. The concreting records shall be continuously
June 2022
11/39
the Placement maintained and kept on site. The concreting records shall
of Concrete be made available for inspection by the Engineer at all times.
The concreting records shall include, but shall not be limited
to, the following:
(1) date;
(2) approved MTRCL mix code and workability;
(3) arrival time of delivery vehicle;
(4) serial number of delivery ticket;
(5) quantity of concrete in the delivery vehicle;
(6) continuous running total of concrete delivered;
(7) quantity of admixture or additive added on-site (if

applicable);
(8) measured temperature of the fresh concrete;
(9) measured individual and average workability value;
(10) identification number of test cubes (if any taken);
(11) location where concrete is placed;
(12) observations on the weather condition.
Transportation of Concrete
Transport of 11.69 The method of transporting and placing concrete shall be to

Concrete the approval of the Engineer. Concrete shall be so
General transported and placed that contamination, segregation, or
loss of the constituent materials does not occur.
Transport by 11.70 Truck mixers, used either as mixers or as agitators for

Truck Mixers transporting the concrete, shall comply with a recognised
and Agitators international standard. Truck mixers and agitators shall not
be loaded in excess of the manufacturer's rated capacity.
Transport by 11.71 Non-agitating equipment or transport hoppers shall comprise

Non-Agitating smooth, water-tight containers and shall be equipped with a
Equipment suitable discharge mechanism. Suitable covers or other
protection for the concrete shall be provided against the
weather.
June 2022
11/40
Transport by 11.72 (1) Concrete pumps shall be operated by mechanically or

Concrete Pump hydraulically applied pressure and shall produce a
continuous stream of concrete without air pockets. No
part of the pump or delivery line may be made of an
aluminium alloy. Grout or water may be used to
charge the pump at the start of pumping and shall be
discharged and discarded on a suitable place outside
the form together with such amount of pumped
concrete as in the opinion of the Engineer will be
needed to ensure that the quality of the emergent
concrete is satisfactory. Grout for charging the pump
shall be made from PC and water.
(2) When pumping is completed, the concrete remaining in

the pipeline, if it is to be used in the Works, is to be
ejected in such a manner that there will be no
contamination of the concrete or separation of the
ingredients. After this operation, the entire equipment
is to be thoroughly cleaned.
(3) No addition of water may be made at the pump after

the lines have been primed and pumping of concrete
has commenced.
Transport by 11.73 Pneumatic placer units shall not be used.

Placer Units
Delivery Time 11.74 (1) Where a truck mixer or agitator is used for transporting
concrete, the discharge shall be completed within a
period approved by the Engineer.
(2) Where concrete is transported in non-agitating

equipment, discharge shall be completed within a
period approved by the Engineer.
Quality Control and Testing
General 11.75 (1) All compliance and acceptance tests shall be carried
out in accordance with Appendix 11.4 and CS1. For
SCC, in addition to slump-flow, tests to demonstrate
meeting the designed ranges of viscosity, passing
ability and segregation resistance shall be conducted if
required by the Engineer.
(2) The results of these tests shall form the official record
of concrete quality.
Workability 11.76 The batches or mixing operator shall maintain the workability
June 2022
11/41
Limits of the concrete mixes when delivered to the Works within the
following tolerances:
Slump ± 25 mm or ±33% of the specified value,

whichever is the greater, up to the limit
of ± 50 mm
Vebe time The lesser of ± 3 seconds or ± 20% of

the specified value for all mixes
Flow Table ± 60 mm of the specified value, for all

mixes
Slump-flow ± 80 mm of the specified value with no

segregration, for all mixes
Compacting ± 0.03 for all mixes

Factor
Acceptance 11.77 (1) Acceptance workability tests shall be conducted on

Workability each delivery of concrete to the Works.
Testing Plan
(2) The Contractor shall carry out the sampling and
acceptance workability in accordance with the
procedures detailed in Appendix 11.4.
(3) The acceptance workability tests shall be conducted in

duplicate and the average value used to measure
acceptance.
(4) The sample for the acceptance workability tests shall

be taken after a quantity of 0.3m3 of concrete has been
discharged.
Sampling of 11.78 (1) One sample of concrete for each concrete mix shall be
Concrete for provided at the rate specified in Table 11.3 or from the
Compliance amount of concrete of each mix used in each half shift,
Tests whichever is less. Each sample shall be taken from
single batch. A shift is ten hours of production or a
figure approved by the Engineer.
Table 11.3 : Rate of sampling of concrete
June 2022
11/42
Type of Structure Rate

Masts
Cantilevers 3m or more in length
One sample each 10m3 or
Columns
10 batches whichever is the
Shear walls
less
Prestressed or precast elements
Other critical elements
Solid rafts
One sample each 50m3 or
Pile caps
Mass concrete
less
Tunnel linings
Types other than the above One sample each 25m3 or
less.
(2) Two cubes shall be prepared by the Contractor in

accordance with CS1 from each randomly selected
sample of concrete. They shall be compacted using
a vibrating table as provided for in Section 7 of CS1.
Vibrating hammers or compacting bars shall not be
used. The concrete in the mould shall be vibrated
until no further entrained air is seen to be emerging.
The vibration time shall be minimised when
compacting high workability concrete to ensure that
over compaction and segregation of the concrete does
not occur.
(3) The compliance cube test sample shall be taken,

when practicable, at the point of discharge from the
delivery vehicle and shall be taken from the full
discharge of the load as required by CS1.
Cube Tests 11.79 (1) A cube test result shall be defined as the average of
the compressive strength measurements made on two
cubes taken from a single sample.
(2) If the difference between the compressive strengths of

the two cubes exceeds 15% of the test results for that
pair of cubes, then action shall be taken to ensure
that the sampling and testing procedures as required
are being followed. If the difference between the
compressive strengths of the two cubes exceeds 20%
of the test results for that pair of cubes, then that test
results for that pair should be disregarded and
June 2022
11/43
investigations shall be made to establish whether the

concrete represented by the test result is acceptable
or not.
Compliance 11.80 (1)3 For the purpose of this Specification two criteria are
Criteria stated, namely, C1 and C2, as stated in Table 11.4.
(2) The test results of designed mixes shall comply with

the following requirements:
(a) each test result shall be not less than the grade
strength minus the amount stated in column A of
Table 11.4;
(b) the average of any four consecutive test results,

or the average of 2 or 3 test results if less than 4
test results are available, shall not be less than
the grade strength plus the amount stated in
column B of Table 11.4.
Table 11.4 : Compliance Criteria for Concrete
A B
Compliance
Criteria 100mm 150mm 100mm 150mm
cubes cubes cubes cubes
C1 2 MPa 3 MPa 7 MPa 5 MPa
C2 2 MPa 3 MPa 5 MPa 3 MPa
(3) Criterion C1 is the more rigorous of the two and shall

be applied until the Engineer is satisfied that the
quality and uniformity of the concrete supplied justifies
application of criterion C2.
(4) If in the opinion of the Engineer, the proposed

concrete supplier can provide sufficient evidence that
his standard of quality control, using similar materials
and plant to that proposed for the work, is such that
the standard deviation for at least 40 consecutive test
results will not exceed 5.5 MPa for 100mm test cubes
or 5 MPa for 150mm test cubes, then criterion C2 may
be applied from the commencement of the work.
(5) In all other cases criterion C1 shall be used until 40
June 2022
11/44
consecutive test results are available. If the standard

deviation of these does not exceed 5.5 MPa for
100mm test cubes or 5 MPa for 150mm test cubes
then criterion C2 may be applied to all subsequent test
results. If however the standard deviation of any 40
consecutive test results rises thereafter and exceeds
5.5 MPa for 100mm test cubes or 5 MPa for 150mm
test cubes at any time then criterion C1 shall apply to
all subsequent test results.
(6) When the following situation occurs, no further

concrete of that mix shall be placed until the Engineer
is satisfied that control has been re-established over
the concrete production process:
(i) For concrete grade not exceeding C60, the

standard deviation of any 40 consecutive test results
exceeds 8.5 MPa for 100mm test cubes or 8 MPa for
150mm test cubes at any time
(ii) For concrete grade exceeding C60, the coefficient

of variation exceeds 14%
(7) If the compliance criterion is changed from C1 to C2 or

vice versa, the new compliance criterion shall apply
from the 35th day after casting the last pair of cubes in
the set of 40 on which the decision to make the
change is based.
(8) If there is a period exceeding 14 days between the

taking of any two consecutive test results, then if
agreed by the Engineer, the test results obtained
before and immediately after the period may be
treated separately for the purpose of Clause 11.80(2b)
above.
(9) The Engineer may instruct that additional cubes be

made to check the attained strength levels in parts of
the structure or for other particular purposes. These
cubes shall be taken, stored and tested in a manner
directed by the Engineer.
(10) The Contractor will be supplied with the cube test

report by the Engineer. The Contractor shall use the
results to ascertain that correct quality control is being
maintained.
June 2022
11/45
Non-Compliance 11.81 (1)3 A batch of concrete shall be considered as not

complying with specified requirements for compressive
strength if any test result of concrete from the batch
does not satisfy the requirements of column A of Table
11.4.
(2) If the average of any group of four consecutive test

results does not meet the requirements of column B of
Table 11.4 then the concrete from all the batches
which provided all the test results in that group shall be
considered as not complying with the specified
requirements for compressive strength.
(3) If any concrete tests fail to comply with the specified

requirements for compressive strength, tests may be
made on the placed concrete to demonstrate
compliance. The tests will entail cutting out concrete
or taking of cores, as detailed in Appendix 11.5.
(4) Should the Engineer direct the Contractor to obtain

cores, each occurrence of an individual or running
average failure shall require a set of three cores to be
obtained from the location where the non-compliant
cube(s) were obtained, within 7 days from the
notification of the failure. The estimated equivalent
cube strength shall be calculated in accordance with
CS1. Conformance of the cores shall be as follows:
(a) for any set of cores representing a test location,

the average estimated cube strength shall be at
least 85% of the specified grade; and
(b) for any set of cores representing a test location,

the individual estimated cube strength shall be at
least 75% of the specified grade.
(5) Rejected concrete shall be removed from the Works.
Concrete 11.82 (1) Temperature control for concrete shall be in

Temperature accordance with the following sub-clauses.
Limits
(2) Category A Concrete shall comply with the following
requirements:
(a) The Contractor shall employ effective means

such as shading the aggregates, precooling
mixing water and adding flaked ice to ensure the
temperature of concrete prior to and including the
June 2022
11/46
time at which it is placed shall not exceed 25C.
(b) After the concrete has been placed, its peak

temperature in any part of the structure shall not
be permitted to rise above 70C.
(c) After the concrete has been placed, the

maximum temperature difference between a
point at the centre of a concrete section and
adjacent surface shall not be greater than 20C
times the shortest distance, in metres, between
the concrete section centre and surface for
structural element of section greater than 500
mm.
(d) For structural elements of section greater than

500 mm, the Contractor shall employ effective
means such as insulation, selection of
appropriate pour cycle times, or heating/cooling
as necessary, to ensure that at any time within 3
weeks after concrete has been placed, the
temperature differential between any point in the
freshly placed concrete of any structural element
at a distance of 600 mm from a construction joint
and the corresponding point 600mm from the
construction joint in the adjacent previously
placed structural element, shall not exceed 20oC.
(e) Cracks with more than 0.2mm in width in

concrete which may be attributable to thermal
effects shall be investigated and adjustments
made to the production process to minimize the
occurrence of cracking.
(3) Category B Concrete shall comply with the following

requirements:

such as shading the aggregates, precooling
mixing water and adding flaked ice to ensure the
temperature of concrete prior to and including the
time at which it is placed shall not exceed 30C.
(b) After the concrete has been placed, its

temperature in any part of the structure shall not
be permitted to rise above 80C.
(c) After the concrete has been placed, the
June 2022
11/47
maximum temperature difference between a

point at the centre of a concrete section and
adjacent surface shall not be greater than 25C
times the shortest distance, in metres, between
the concrete section centre and surface.
(4) Category C Concrete shall comply with the following

requirements:

such as precooling the aggregates and mixing
water to ensure the temperature of concrete prior
to and including the time at which it is placed
shall not exceed 30C.
(b) Other limits shall be as stated in the Contract.
Concrete 11.83 (1)3 The initial placed temperature of the concrete shall be
Temperature measured by placing a calibrated probe-type
Measurement thermometer, with a ± 1oC accuracy, into each delivery
of the concrete at the time of discharge from the
vehicle transporting it or not later than 15 minutes
thereafter. The thermometer shall be checked
weekly.
(2) The Contractor shall continuously compare the real

time results of the on-going temperature monitoring
with the predicted values and make appropriate
adjustments to the temperature control methods used
on current and subsequent pours to ensure
compliance with the Specification.
(3) (i) The temperature of hydrating concrete shall be

measured for each Category A and Category B
concrete pour until 3 weeks after pouring using a
sufficient number of calibrated thermocouples to
demonstrate that the requirements of Clause 11.82
have been achieved, within a ±2oC accuracy.
(ii) The temperature of Category A and Category B

concrete mix with the use of GGBS shall be measured
to demonstrate that requirements of Clause 11.82
have been achieved, within a ±2oC accuracy. With
the steady and satisfactory results, the Engineer may
consider to relief the measurement frequency.
(4) The thermocouple shall be suitably robust to withstand

concrete placing, adequately protected and firmly fixed
June 2022
11/48
in position on the reinforcement cage. The

thermocouple shall not be placed in the immediate
vicinity of cooling water pipes (300mm radius) to
ensure that they give representative temperature
readings.
(5) The output of the thermocouple shall be continuously

recorded using an automated data logger. The
power supply to the data logger shall be
non-interruptible and the equipment shall be
maintained and checked at least twice during each
shift to ensure that they are operating satisfactorily.
(6) The thermocouple shall be calibrated in conjunction

with the working and backup data logger(s) and the
calibration results shall be submitted at least 14 days
prior to incorporation within the Works.
(7) After installation of the thermocouple within the pour

and immediately prior to concreting, the thermocouple
shall be checked by comparing the relative ambient
temperature readings. Any damaged or
malfunctioning thermocouple shall be replaced prior to
the commencement of concreting.
(8) After the placing of concrete, the temperature readings

shall be taken at a minimum of hourly intervals for the
initial 7 days after placing. The monitoring frequency
can be reduced to 12 ± 1 hours thereafter until 21 days
after placing or until the maximum temperature is less
than 15oC above the daily minimum ambient
temperature.
(9) The output from the data loggers shall be down loaded
daily by the Contractor. A copy of the data shall be
given to the Engineer immediately after down loading
in an agreed electronic and hard copy format.
(10) Within 7 days from the completion of the temperature

monitoring period the Contractor shall submit a report.
The report shall include the individual tabulated
temperature results and calculated values indicating
compliance, as required by the Specification, for all
maximum and differential temperature measurements.
The report shall be presented in both tabulated and
graphical format and shall include all thermocouples
within the same measurement plane on the same
graph to ensure that the temperature differentials
June 2022
11/49
between the core, surface and ambient are readily

discernable. Any non-compliance with the
Specification shall be highlighted and proposals given
for remedial works and ensuring compliance in
subsequent pours.
Concrete 11.84 (1) All formwork and reinforcement contained in it shall be

Placing: clean and free from standing water immediately before
General the placing of the concrete.
(2) Tests to the approval of the Engineer shall be made

prior to each pour to ensure that no determinable level
of chloride is present on the surface of the
reinforcement. Any found shall be removed by high
pressure water cleaning and the test repeated.
(3) Concrete shall not be placed in any part of the

structure until the Engineer's Approval to proceed has
been obtained.
(4) Concreting shall proceed continuously over the area

between construction joints. Before depositing fresh
concrete against concrete which has been in position
for more than two hours, surface laitance shall be
removed to the satisfaction of the Engineer.
(5) Concrete shall be compacted in its final position within

1 hour of discharge from the mixer unless carried in
purpose made agitators, operating continuously, when
the time shall be within 150 minutes (2½ hours) of the
introduction of cement to the mix and within 30
minutes of discharge from the agitator. Concrete
shall be deposited in horizontal layers to a compacted
depth not exceeding 450mm where internal vibrators
are used or 150 mm in all other cases.
(6) Concrete shall not be dropped into place from a height

exceeding 2 m. When trunking or chutes are used
they shall be kept clean and used in such a way as to
avoid segregation. In general, trunking or chutes
shall not be more than 45 off the vertical.
(7) Concrete shall not be placed in ground or water which

has a temperature below 5C.
(8) All concreting operations shall be under the direct

control of an experienced supervisor at the pour
location, to oversee the delivery and general quality of
June 2022
11/50
fresh concrete, and to ensure that the concrete is

properly placed and compacted.
Placing 11.85 (1)3 Where it is necessary to deposit concrete under water,

Concrete details of the methods, equipment, materials and
Under Water proportions of the mixes to be used shall be submitted
to the Engineer for Approval at least 4 weeks before
the work is expected to commence.
(2) Where concrete is to be placed under water it shall be

deposited continuously until it is brought to the
required height. Whilst depositing the concrete, the
top surface shall be kept as near level as possible and
the formation of seams avoided. However, where the
Engineer is satisfied that this is not practicable, the
surface of previously deposited concrete shall be
suitably prepared and cleaned off by a diver.
(3) No concrete shall be placed in free-flowing water.

Cofferdams or forms shall be sufficiently tight to
reduce the flow or current of water through the space
where the concrete is to be deposited to a velocity
approved by the Engineer. Cofferdams or forms in
still water shall be sufficiently tight to prevent loss of
mortar through the walls.
(4) Where the concrete is placed by a tremie, its size and

method of operation shall be in accordance with BS
8004 and Clauses 11.86 and 11.87. During and after
concreting under water, pumping or de-watering
operations in the immediate vicinity shall be
suspended until the Engineer permits them to be
continued.
Concrete for 11.86 Concrete

3 to be placed by the tremie method shall comply
Tremie with the following:
Placement
(1) have a design workability of not less than 550mm flow
or 175mm slump;
(2) maintain a workability of not less than 450mm flow or

150 mm slump at 2 hours;
(3) show no signs of segregation at the design workability;

and
June 2022
11/51
(4) have an initial set of not less than 10 hours at 25oC.
Tremie Pipe 11.87 The

3 tremie pipe shall have an internal diameter of not less
and Hopper than 150mm for concrete with 20mm maximum size
aggregate and not less than 200mm for concrete with a
40mm maximum size aggregate. The tremie pipe shall
have no internal projections and external projections shall
be minimised. The receiving hopper for the tremie pipe
shall have a capacity at least equal to that of the tremie
pipe.
Tremie 11.88 (1)3 The tremie pipe shall initially be lowered within 300mm
Concreting to the bottom of the structure to be concreted.
Operation
(2) At all times the tremie pipe shall be kept clear of the
reinforcement, any embedded steel section and box
out and the side of the foundation.
(3) A suitable plug of buoyant material shall be inserted in

the tremie pipe prior to the concrete being placed.
The plug shall be capable of retaining the concrete
within the tremie pipe and rise to the surface when
expelled from the tremie pipe. Initial charging
operation which composed of cement slurry shall be
carried out prior to commencement of concreting.
(4) Concrete shall be placed continuously to ensure that

entrapment of air within the tremie pipe is minimised
and at all times a sufficient quantity of concrete shall
be maintained within the tremie pipe to ensure that the
pressure from it exceeds that from the water or
support fluid.
(5) At all times the tremie pipe shall be embedded within

the concrete by at least 2m during concrete
placement.
(6) The depth to the concrete surface shall be measured

and the embedded length recorded at regular intervals
corresponding to the placing of each load of concrete.
The depth measured and the volumes of concrete
placed shall be plotted immediately on a graph and
compared to the theoretical relationship between
depth and volume.
Preparation of 11.89 (1) Before concrete is placed on a rock foundation the

Rock Surfaces rock surface shall be clean and free from soft rock and
loose rock dust or other debris. The final cleaning
June 2022
11/52
shall be done with air and/or water jets and hand

excavation with small tools.
(2) After the rock surface has been prepared to the

satisfaction of the Engineer and immediately before
placing blinding or other concrete, the surface of the
rock shall be covered with a layer of grout 6mm thick.
The grout shall have the consistency of a stiff paste
and it shall be well brushed over the rock and into all
crevices.
(3) Rock surfaces preparation for sprayed concrete is

specified in Part 2 of this Section.
Compaction of 11.90 (1) All concrete shall be compacted to produce a dense

Concrete homogeneous mass using internal vibrators.
Sufficient additional vibrators, in a serviceable
condition, shall be on Site to ensure that spare
equipment is always available in the event of
breakdowns
(2) Internal vibrators shall be generally 75mm diameter

and shall be capable of producing not less than 10,000
cycles per minute. In areas of particularly heavy
reinforcement congestion smaller vibrators may be
proposed for the approval of the Engineer. When
permitted by the Engineer external vibrators shall be of
sufficient weight and be capable of not less than 3,000
cycles per minute.
(3) Vibration shall not be applied by way of the

reinforcement. Where vibrators of the immersion type
are used, contact with reinforcement and all inserts
shall be avoided, so far as is practicable.
(4) Concrete shall not be subjected to vibration due to

vibrators or any external source for the period between
the initial set of concrete and the time when the
concrete reaches 5MPa compressive strength, except
as noted in Section 25 of this Specification.
Protection of 11.91 The

3 Contractor shall plan the casting sequence to avoid
Concrete from placing concrete during periods of heavy rainfall, unless
Rainfall adequate tented protection is provided. Any concrete that
has been damaged, contaminated or diluted by rainfall shall
be deemed to be non-compliant with the Contract.
Curing of 11.92 (1)3 Immediately after compaction and for 7 days
June 2022
11/53
Concrete thereafter, concrete shall be protected against loss of

moisture and the harmful effects of wind, sun, rain and
running water. Additional measures to control
temperature shall be implemented as necessary.
(2) Protection shall be provided as follows:
(a) Vertical surfaces shall be protected by the

retention in position of the formwork where the
formwork material is non-permeable, or a liquid
curing membrane applied by low pressure spray
immediately after removing the formwork.
Immediately after application of the liquid curing
membrane the concrete shall be further protected
by means of a plastic sheet securely attached to
the concrete;
(b) Horizontal surfaces shall be protected by

covering immediately after trowelling using a
vapour proof enclosure such as a polythene
sheet frame or other approved method, which
can be removed before any final trowelling.
After initial set, protection shall be either by
covering with a layer of hessian, packing canvas,
or similar absorbent material or a layer of fine
aggregate, to be kept constantly saturated with
water and with plastic sheeting as additional
evaporation protection.
(3) Water curing shall be permitted providing the Engineer

is satisfied that this shall be uninterrupted and that
water sprayed continuously on concrete at any time
after demoulding shall only be in the form of a fine
mist.
(4) Water shall not be applied to any concrete surface

which is at a temperature more then 5C higher than
the ambient temperature, unless the water is first
heated to within 5oC of the concrete surface
temperature.
(5) Protective covers to all curing regimes shall be

provided on all surfaces to avoid damage due to
storage of materials, construction activities,
pedestrian/vehicle movements, climatic and
environmental effects.
Concrete Remedial 11.93 (1) The Contractor shall take all necessary measures to
June 2022
11/54
prevent plastic shrinkage/settlement cracking,

including but not limited to, the following :
(a) trowelling or re-vibration to be carried out while

the concrete is still workable but in a manner
which does not encourage the formation of
laitance on the trowelled surface;
(b) protection from direct sunlight and drying winds;
(c) limiting the speed of placing.
(2) Remedial works for all concrete defects shall be

classified and repaired in accordance with Section 11,
Part 7 of this Specification.
June 2022
11/55
PART 2: SPRAYED CONCRETE FOR TEMPORARY

WORKS
General 11.94 (1)3 The incorporation of sprayed concrete into the

Permanent Works shall not be permitted.
(2) "Sprayed concrete" is defined as fresh concrete

applied by means of a high velocity pressurised spray
through a nozzle on to the casting location to produce
a dense homogeneous structural mass.
(3) Sprayed concrete shall comply with the all

requirements of Part 1 of this Section unless modified
by the contents of this Sub-section.
(4) Sprayed concrete for the Works shall be wet-mix,

except for slope works where dry-mix may be used.
Truck-mixing of sprayed concrete shall not be
permitted.
(5) Except for slope works CSF shall form part of the
cementitious content at a rate of 5-10%. CSF shall
be added at the same time as the other constituents at
the batching plant.
Method 11.95 (1) The Contractor shall submit a method statement in

Statement accordance with Clause 11.19 and in addition the
Contractor shall submit full details of the following:
(a) spraying equipment;
(b) personnel;
(c) mixing and spraying method;
(d) finishing;
(e) the proposed method for the early strength

testing.
(2) The method statement shall be submitted at least 56

days before the commencement of any sprayed
concrete works.
Types of 11.96 Sprayed concrete shall be classified by type as follows:

Sprayed
Concrete Type S1 - steel fibre reinforced with a strength of 40 MPa;
June 2022
11/56
Type S2 - steel fibre reinforced with a strength of 30 MPa;
Type P1 - plain with a strength of 30 MPa;
Type P2 - plain with a strength of 20 MPa.
Mixing 11.97 (1) Mixing plant shall be suitable for the efficient mixing
and and discharge of material. The location and method
Placing of the introduction of admixtures shall replicate the
approved trials and shall not be varied.
(2) Mixed materials for dry sprayed concrete shall be

placed within 2 hours of the addition of PC otherwise
the material shall be discarded and a fresh mix made.
Placing time for wet sprayed concrete shall be in
accordance with the requirements for concrete in Part
1 of this Section.
(3) Where sprayed concrete is stabilised by a hydration

control admixture the placing time may be extended
provided that the sprayed concrete remains sufficiently
workable. The stabilisation time shall be included on
the delivery ticket.
Personnel 11.98 Only experienced personnel shall mix and place sprayed
concrete. The Contractor shall submit the names and
details of the nozzlemen who will carry out the Works for
approval by the Engineer.
June 2022
11/57
Material Requirements
Materials for 11.99 (1) Constituent material shall comply with Section 11 of
Sprayed Concrete except as stated in this Section.
(2) Aggregate :
Nominal aggregate size shall be 10 mm unless

otherwise submitted to the Engineer for review. The
grading shall be within the following envelope unless
otherwise submitted to the Engineer for review.
Percentage Passing by
Sieve Size (mm) Weight
Maximum minimum
10 100 100
5 100 70
2.36 100 45
1.18 75 30
0.6 50 18
0.3 30 10
0.15 15 5
(3) Admixtures:
(a) Admixtures for sprayed concrete shall comply with

the requirements of Clause 11.32 except as stated
in this clause.
(b) The use of admixture is subject to the site trials

required as in Clause 11.105 of this Section.
(c) Compatibility of all admixtures with each other and

with all other sprayed concrete constituents shall
be verified during site trials.
(d) Plasticisers and retarders may be used to reduce

the quantity of the mixing water and to improve the
pumpability of the sprayed concrete. The effects
of the plasticiser shall be determined by site trials.
Sprayed concrete made with plasticisers and
retarders shall be checked regularly for the setting
time, water reduction and the development of
strength as compared with the unmodified mix in
accordance with BS EN 934.
(e) Admixtures shall be added to the sprayed
June 2022
11/58
concrete by mechanical means, which shall

incorporate a metering device, to prevent
unauthorised alteration of the agreed dosage.
(f) Admixtures, including accelerators, shall have a

documented history demonstrating satisfactory
performance in sprayed concrete with mixes of
similar proportions and applied by the same
process.
(g) Admixtures shall not contain materials corrosive to

steel or materials which may cause detrimental
effects in the sprayed concrete such as cracking
or spalling.
(h) Admixtures shall be used at the rate and

introduced into the mix by the method specified by
the manufacturer.
(i) Admixtures shall have a chloride content less

than 0.1% by weight of admixture.
(j) Hydration control admixtures may be proposed.

Where hydration control admixtures are approved,
it shall be demonstrated to the approval of the
Engineer that they are compatible with other
admixtures and cementitious materials used in the
sprayed concrete and do not reduce its long term
strength.
(4) Accelerator:
(a) Accelerators shall be a liquid type.
(b) Accelerators shall be high performance, of

minimal alkali content, non-caustic and of low
toxicity.
(c) Accelerators shall be used at the minimum

quantity necessary to achieve the required
performance and shall be less than 4% for S1
and less than 9% for S2 and P1 sprayed
concrete.
(d) Water glass (unrefined Sodium Silicate) shall not

be used.
(e) The effect of accelerating and stabilising
June 2022
11/59
admixtures on the mix in terms of setting time,

early strength gain, reduction in final strength,
overdosing and application in low temperatures
shall be verified by trials before commencement
of work.
(f) Only the minimum quantity of accelerator

necessary shall be permitted in normal sprayed
concrete operations. This quantity shall be
determined by trials.
(g) The accelerators delivered to the site shall be

tested in accordance with this Specification not
less than once every two months for their
reaction with the cement used (strength
decrease). In the case of accelerators in liquid
form, their stability during storage shall be
visually inspected and checked for crystallisation
at the same intervals. Storage times and
working temperature ranges shall be in
accordance with the manufacturer's
recommendations. The manufacturer's safety
instructions shall be observed.
(5) Mesh Reinforcement
(a) Steel Fabric Reinforcement shall comply with

Section 10.
(b) Mesh reinforcement of sprayed concrete shall

be placed only where specified by the Contract,
or approved by the Engineer. Steel mesh
reinforcement shall be mild steel square
"weldmesh" complying with BS 4483. The size
of mesh and method of fixing shall be subject to
the Approval by the Engineer and shall be such
that hollow areas are not formed behind the
sprayed concrete. Chainlink mesh shall not be
used where sprayed concrete is to be applied.
(6) Steel Fibre
(a) Steel fibres shall comply with BS EN 14889

Part 1.
(b) Steel fibres shall have a minimum tensile

strength of 800MPa.
June 2022
11/60
(c) Steel fibres shall not be galvanised.
(d) Steel fibres shall be collated with a fast-acting

water-soluble glue.
(e) Steel fibres shall have an aspect ratio in the

range of 45 to 70 with a length between 12mm
and 65mm. Tolerances shall be in accordance
with BS EN 14889 Part 1.
(f) The weight of fibre used in spayed concrete

shall be a minimum of 40kg per cubic metre of
concrete.
(g) The contractor is to propose a range of fibre

dosages and types and demonstrate the most
effective mix by means of specified tests.
(h) Steel fibres shall be stored in dry, sealed

containers until ready for use and shall be free
from corrosion, oil, grease, chlorides and any
other deleterious materials which may effect the
mixing or spray process, or which may reduce
the bond between fibres and the sprayed
concrete.
(i) Steel fibres which form balls during batching

and mixing shall not be used.
(7) Polymer Fibres
(a) Polymer fibres shall be in accordance with BS EN

14889 Part 2.
(b) The weight of fibre used in sprayed concrete shall

not be less than 5 kg per cubic metre of concrete.
Permanent Works 11.100 Not Used.
Performance 11.101 Not Used.

Requirements
Mix Requirements 11.102 (1) Minimum cementitious content shall be 400 kg/m3.
(2) Maximum water cementitious content ratio shall be 0.5

(water shall include liquid content of liquid admixtures).
(3) Where CSF forms part of the mix the microsilica
June 2022
11/61
content shall be 5-10%.
(4) The workability of the mix shall be defined and

controlled as stated in clause 11.6.
Mix Design 11.103 (1) Sprayed concrete shall have a minimum cementitious
content of 350kg/m3 as discharged from the nozzle.
(2) The in-place W/C ratio shall not exceed 0.5.
(3) The maximum size of aggregate shall be compatible

with the equipment being used and shall not be
greater than 10mm.
(4) The moisture content of the fine aggregate shall be in

the range 3 to 6 percent.
(5) Aggregates shall comply with BS 882. However it

may be found necessary to control grading of the
aggregate within tighter limits to achieve the required
sprayed concrete properties.
(6) If packaged pre-mixed material is used for dry-mix

sprayed concrete, pre-dampening equipment shall be
used to bring the moisture content to within the range
3 to 6 percent. Pre-dampening shall be carried out
immediately after flow of the material out of its
packaging in order to minimize dust.
Trials for Acceptance
General 11.104 (1) Prior to commencement of work on site and not less
than 56 days prior to the application of sprayed
concrete, the Contractor shall submit full details of
proposed mixes and trials shall be carried out to prove
both the adequacy of the mix design and the methods
of mixing and spraying.
(2) Mix proportions shall be proposed by the Contractor.

The proportions shall be established using weigh
batching. Once the proportions are established,
either weigh batching or volumetric batching shall be
used. Weigh or volumetric batching shall have an
accuracy of ±3%.
Site Trial: Testing 11.105 (1) Sprayed concrete trials shall be carried out by the
on Trial Panels Contractor using the same personnel and plant to be
used for the Works and shall be undertaken at least 45
June 2022
11/62
days before application of sprayed concrete. At least

7 days notice shall be given to the Engineer of these
trials.
(2) Individual trial panels shall be sprayed for each mix

designed for testing in accordance with the
requirements of Table 11.5. These include six panels
to test for both compressive strength and flexural
strengths and, in addition, three panels for energy
absorption capacity tests. Each panel shall be made
in a mould constructed of steel or other non-absorbent
rigid material with a smooth finish. The size of the
trial panels for strength tests shall be at least 750mm x
750mm and 200mm thick, and the panels for energy
absorption capacity tests shall be 600mm x 600mm
and100 mm thick after spraying. For compressive
and flexural strengths tests, the sides of the mould
shall be splayed outwards at 45o to prevent the
entrapment of rebound, and two panels shall be fixed
vertically, two shall be fixed at 45 degrees to the
horizontal facing downwards and two shall be fixed in
an overhead position facing downwards. For energy
absorption tests, all three panels shall be fixed
vertically.
(3) Three 100 mm cores shall be taken full depth from

each of the six trial panels to determine the
compressive strength for each specified compressive
strength requirement. Three beams shall be cut from
the same sprayed panel to determine the flexural
strengths.
(4) Compressive strength at 8 hours shall be carried out in

accordance with BS EN 14488-2, Method B (stud
driving) or other internationally recognised method
approved by the Engineer.
(5) Compressive strength at 1 day shall be generally in

accordance with CS1 except that the curing measures
are not required. The cores shall be obtained at
between 18 and 20 hours and delivered to the
Engineer's laboratory within a total of 24 hours from
spraying. Testing shall be conducted between 26
and 30 hours.
(6) Compressive strength at 7 days and 28 days shall be

in accordance with CS1 with the cores being obtained
between 18 hours and 3 days and delivered to the
June 2022
11/63
laboratory within a total of 4 days from spraying.
(7) Flexural strengths tests at 7 days and 28 days shall be

conducted in accordance with BS EN 14488-3 to
determine the first peak flexural strength and residual
strength for each specified strength class.
(8) The test results of the compressive strength, first peak

flexural and residual strength of the samples shall
meet the requirements as stated in Clause 11.107(1)
to 11.107(3).
(9) Energy absorption capacity test shall be carried out in

accordance with BS EN 14488-1 and BS EN 14488-5.
Prior to production of samples, the mould shall be
pre-oiled and placed against props and checked to
ensure the bases are flat and free for distortion. The
specimens shall be shot by the same personnel
charged with completing the in-situ shotcreting
required for construction using the same equipment
intended for this purpose. Panels shall be prepared
and tested for determining the 28 day energy
absorption capacity. The test results of at least two of
the three test panels at 28 days shall not be less than
the specified energy absorption capacity stated in
Table 11.5.
Site Trial: In-situ (10) A suitable trial area exposed to rock at vertical
Testing position shall be sprayed to determine the bond
strength between shotcrete layers and rock. The
thickness of the concrete shall be at least 200mm
sprayed in two layers each approximately 100mm.
(11) Three core samples of at least 50 mm diameter shall

be drilled through the sprayed shotcrete layers and
the rock substrate for determining the bond strengths
to shotcrete layers and rock surface at 28 days in
accordance with BS EN 14488-4. The test result
shall meet the requirements as stated in Clause
11.107(4).
Tests for Compliance in Production
Works Tests 11.106 (1) After trial mixes and methods of placing have been
approved, in every 500m3 of sprayed concrete placed
in works or in any two weeks within which the
Contractor carries out any sprayed concrete work
whichever is more frequent, the Contractor shall spray
June 2022
11/64
three test panels for compressive and flexural

strengths tests in accordance with Clause 11.105(2),
with one panel in each of the three different positions.
(2) The works test panels shall be tested in accordance

with Clause 11.105(3) to 11.105(8).
(3) In-situ bond strength test shall be carried out in every

2500m2 of sprayed concrete placed in works. Each
selected location shall be tested in accordance with
Clause 11.105(11).
Compliance 11.107 (1) The average of the 3 test results at 8 hours, 1 day, 7
Criteria days and 28 days for each panel shall not be less than
the specified compressive strength stated in Table
11.5. In addition, all compressive strength values
shall be within 20% of the average value.
(2) The average of the 3 test results for first peak flexural
strength at 7 days and 28 days for each panel shall not
be less than the specified flexural strength stated in
Table 11.5. In addition, all individual values shall be
within 20% of the average value.
(3) The average of the 3 test results for residual strength

at 28 days for each panel shall conform to the
specified strength class given in Table 11.5. No
individual test result shall in any point show a residual
stress that is lower than 10 % of the stress
corresponding to the boundary of the specified
strength class.
(4) The average of the 3 test results for bond strength

between shotcrete layers and rock surfaces at 28 days
shall not be less than the specified bond strength
stated in Table 11.5. No single value shall be lower
than 75% of the specified value.
(5) The Engineer may require further testing to be carried

out until he is satisfied with the mix design, plan and
procedures. The Contractor shall not proceed with
sprayed concrete work until the Engineer has
approved the mix design, plant and procedures.
Thereafter the mix design, plant and procedures shall
not be altered without further testing and subsequent
approval by the Engineer.
(6) In the event that any works test core fails to meet the
June 2022
11/65
required compressive strengths, the Engineer may

require further in-situ core(s) to be taken from the
sprayed concrete where the non-compliant core was
obtained. In the event of failure of the subsequent
in-situ core the sprayed concrete represented by the
failed tests shall be rejected and removed from the
Works. The Contractor shall dispose of test panels
after the completion of all testing. Coreholes shall be
made good to the approval of the Engineer in any
areas of the applied sprayed concrete where it is
subsequently accepted by the Engineer.
Table 11.5 : Sprayed Concrete Performance Requirements

(minimum)
Test Type S1 Type S2 Type P1 Type P2
Compressive Strength
BS EN 14488-2 at 8 hours N/A 4 MPa N/A N/A
CS1 at 1 day 8 MPa 8 MPa N/A N/A
CS1 at 7 days 25 MPa 25 MPa 18 MPa 10 MPa
CS1 at 28 days 40 MPa 30 MPa 30 MPa 20 MPa
Flexural Strength (First Crack)

BS EN 14488-3 at 7 days 3.5 MPa 3.0 MPa N/A N/A
BS EN 14488-3 at 28 days 4.2 MPa 3.4 MPa N/A N/A
Energy Absorption for 1000 700 N/A N/A

deflection up to 25 mm Joules Joules
BS EN 14488-5 at 28 days
Residual Strength 4 MPa 2 MPa N/A N/A
(deflection range) (0.5-4mm) (0.5-2mm)
Bond strength 0.5 MPa 0.5 MPa 0.5 MPa 0.5MPa
Workmanship
Surface 11.108 Surfaces which are to receive sprayed concrete shall

Preparation comply with the following:
(1) Rock faces
The rock surface shall be cleaned of loose material,

mud, highly weathered material, rebound, vegetation
and other foreign matter which might prevent bond of
the sprayed concrete onto the rock surface. Prior to
the application of sprayed concrete, rock surfaces
shall be washed with an air-water jet or high pressure
June 2022
11/66
water jet. Compressed air alone shall not be used.

After washing down, surfaces shall be damp, but
exhibiting no free water prior to the application of
sprayed concrete.
(2) Wet surfaces
Where a flow of water could interfere with the

application of sprayed concrete or cause leaching of
PC, the water shall be cut off and drained by
pre-formed channel drainage to a point where it can be
connected to the invert drainage. Small flows may be
stemmed using grout containing admixtures which will
induce accelerated set. The grout shall not be
considered to form part of the structural thickness.
(3) Steelwork and reinforcement
Loose rust, oil, scale, paint, rebound or any coating

over the steelwork or reinforcement shall be removed
prior to the application of sprayed concrete.
(4) Concrete, brickwork or masonry
Loose and unsound material shall be removed before

applying sprayed concrete. The surface shall be
damp prior to application of sprayed concrete and shall
be prepared so that no abrupt changes in thickness of
the sprayed concrete occur.
(5) Clayey zones
Sprayed concrete for support to clayey zones greater

than 300mm wide with P1 sprayed concrete or 500mm
wide with either S1 or S2 sprayed concrete, shall be
reinforced with fabric reinforcement complying with
Section 10 of this Specification. The fabric
reinforcement shall be firmly fixed to the rock on either
side of the zone with an overlap of at least 500mm.
Where the zone is greater than 1000mm wide,
rockbolts in accordance with Section 22 and not less
than 1500mm long shall be installed within the zone at
not greater than 1000mm spacing to provide additional
anchorages for the mesh.
(6) Rockbolts
Where grouting of tensioned rockbolts is to be carried
June 2022
11/67
out after the application of sprayed concrete, the grout

tubes shall be protected from blockage, concealment
and dislodgement during spraying.
Spraying 11.109 (1) Rebound shall not be worked into the sprayed
concrete and shall not be salvaged for re-use or
included in later batches.
(2) The minimum thickness of any sprayed concrete layer

applied at one time shall be 40 mm.
(3) Sprayed concrete shall be applied in uniform layers to

minimize rebound and segregation and to prevent
slumping or sagging. The sprayed concrete surface
shall be brought to a reasonably regular profile, free
from abrupt steps or angles in the surface.
(4) Laitance, loose material and rebound shall be

removed and each layer of sprayed concrete shall be
sounded with a hammer or length of rebar to detect
voids, rebound or aggregate pockets and unbonded
areas. Defective areas shall be removed and
replaced, to a minimum area of 0.3m x 0.3m.
(5) No elements of Temporary Works such as timber or

scaffolding or any other foreign matter shall be
incorporated in the sprayed concrete.
(6) Full records of all materials delivered to the sprayed

concrete mixer and used shall be kept and made
available for inspection by the Engineer at all times.
(7) The thickness of sprayed concrete shall be controlled,

checked and rectified by the following methods unless
other methods which will achieve better results are
approved:
(a) the thickness of sprayed concrete shall be

controlled by measuring the volume of material
placed per unit area with appropriate allowances
made for surface irregularity and losses due to
rebound. Records of the area sprayed,
quantities used, and rebound losses shall be
kept by the Contractor for inspection by the
Engineer at all times;
(b) the thickness of sprayed concrete shall be

checked after final set within 72 hours of placing
June 2022
11/68
by drilling holes of a diameter not less than

35mm or one third of the specified thickness
whichever is greater and on a maximum 3 metre
grid or at random locations greater than 3 m
apart as directed by the Engineer. Where
membranes are used, the Contractor shall
propose a method to avoid damage of the
membrane;
(c) where areas of deficient thickness are found, an

additional layer of sprayed concrete not less than
40mm thick shall be placed within 24 hours of
detecting the non-compliance, to achieve the
minimum specified thickness. The additional
layer shall extend at least 1.5 m beyond the edge
of the area of deficient thickness.
June 2022
11/69
PART 3 : CEMENT GROUT
General
Glossary 11.110 (1) A "batch" of cement grout is any quantity of grout used
of Terms for grouting works in one continuous operation in one
shift.
(2) A "mix" of cement grout is the volume of grout

produced from a grout mixer from the materials
charged into the mixer at any one time.
Cement Grout 11.111 (1) Cement grout shall consist of PC, water and
Composition admixtures. Combination of PC and PFA or PPFAC
complying with BS EN 197-1 may be used with the
approval of the Engineer. Admixtures shall be
provided to produce expansion, water reduction and
retardation.
(2) Admixtures used in the production of grout shall

comply with the requirements of Clause 11.32.
Performance Requirements
Performance 11.112 Cement grout, except as stated in Section 12, shall comply
with the following requirements:
Chloride content < 0.1 % of the PC content

Water cement ratio ≦ 0.42
Compressive strength > 30 MPa at 28 days
Flow Cone Efflux time between 15 and 35 seconds
Expansion between 0 and 5%
Bleeding < 2% in the first 3 hours, and
< 4% in total with all bleeding to
being re-absorbed by the
grout within 24 hours after
mixing
Trial Mix 11.113 (1) Trial mixes shall be conducted on three mixes for each
grout mix proposed, using the plant and personnel
which will be used in the full scale production of the
grout.
(2) During each trial mix, six test cubes shall be

manufactured, for testing three at 7 days and three at
28 days.
(3) During each trial mix a sample shall be tested for
June 2022
11/70
expansion and bleeding.
(4) During each trial mix a sample shall be tested for flow
cone efflux time at 0 minutes, 15 minutes and at 30
minutes after mixing has been completed. The grout
shall be kept continuously agitated during the 30
minutes.
Mix Approval 11.114 (1) The Engineer shall approve the grout mix when all of
the specified requirements have been met. An
approved mix code shall be assigned to the grout and
no change in the composition or proportions shall be
made.
(2) Approval of the grout mix shall be withdrawn if the

grout fails to meet any of the Specification
requirements.
(3) If the result of any test for bleeding, expansion Flow

Cone Efflux time or crushing strength of grout does not
comply with the specified requirements for grout,
details of proposed changes to the materials, grout mix
or method of production shall be submitted to the
Engineer for Approval.
Testing
Testing 11.115 Grout shall be tested at the frequency given below:

Frequency
Type of Test Required Frequency
Bleeding and expansion Each batch
Flow Cone Efflux Time Each batch or 10 mixes,
whichever occurs sooner
Crushing Strength Each batch or 25 mixes,
whichever occurs sooner
Bleeding and 11.116 (1) Samples shall be provided not more than 30 minutes
Expansion after the grout has been mixed and shall be protected
from rain at all times.
(2) Each sample of grout taken shall be divided into

3 specimens. Each specimen shall be tested to
determine the amount of bleeding and expansion as
ASTM C232-07 and comply with the requirements as
June 2022
11/71
(3) Each specimen shall be contained in a 100mm

diameter air tight calibrated glass container. The
depth of grout in the container shall be 100mm. The
amount of bleeding and expansion shall be measured
by a scale fixed on the outside of the container. The
test shall be carried out at the ambient temperature
with the sample stored securely in a shaded location.
(4) The tolerances for testing shall be as follows:
(a) diameter of container ± 5mm;
(b) depth of grout ± 5mm.
(5) After the 3 hour bleeding test the sample shall be

sealed using plastic sheet and adhesive tape or other
means to create an air tight seal. The seal shall not
be broken until 24 hours after mixing in the presence
of the Engineer at which time the total expansion and
re-absorption of bleed water shall be measured and
recorded.
Bleeding = 100% x (H2-Hg) / H1
Free Expansion = 100% x (H2-H1) /H1
Where H1 – initial height of grout sample
H2 – height of sample measured at upper

surface of water layer or hardened
grout surface if water is fully absorbed
Hg – height of grout portion of sample at

upper surface of grout
Flow Cone 11.117 Each sample of grout taken shall be tested to determine the
Efflux Time flow cone efflux time. The method of testing shall be in
accordance with ASTM C939 at ambient air temperature.
Crushing Strength 11.118 (1) Samples of grout shall be provided not more than one
hour after the grout has been mixed and shall be
protected from rain before test cubes are made.
(2) Two 100mm test cubes shall be made from each

sample of grout and tested for compressive strength at
28 days. The test results shall be assessed for
compliance with the requirements of Clause 11.79 and
June 2022
11/72
11.80.
(3) The method of making, curing and testing the test

cubes shall be as stated in CS1 except that
compaction shall not be required and restraint shall be
provided to the cast face.
June 2022
11/73
PART 4 : PRECAST CONCRETE UNITS
General 11.119 Precast concrete shall comply with all the requirements of
Part 1 of this Section unless modified by the contents of this
sub-section.
Submissions 11.120 (1) The following particulars of the proposed precast

concrete units shall be submitted to the Engineer:
(a) details of precasting yards;
(b) a certificate showing the manufacturer's name,

the date and place of manufacture, the
identification numbers of the precast units and
including results of tests for:
(i) compressive strength of production

concrete cubes at 28 days;
(ii) routine tests, including loading tests, carried

out at the precasting yard.
(c) details of lifting points and methods of handling;
(d) procedure for testing precast units.
(2) The particulars, other than certificates, shall be

submitted to the Engineer at least 56 days before the
first delivery of the precast concrete units to the Site.
The certificates shall be submitted for each batch of
precast concrete units delivered to the Site.
(3) Full Scale Sample
Before mass production of panels or units commences

a full scale sample of each panel or unit type shall be
submitted to the Engineer for approval of colour,
texture, finish, consistency and tolerance. When a
sample has been completed to the satisfaction of the
Engineer it shall be marked as the "Approved Sample"
and used as a reference to compare with other panels.
When the mass produced units vary from the
"Approved Sample" the Contractor shall carry out such
modifications as may be required to achieve the
approved standard to the approval of the Engineer.
June 2022
11/74
Tolerances 11.121 The construction tolerances of precast concrete units shall

be as stated in the Contract.
Handling 11.122 (1) A unique identification number, date of casting and

and lifting points shall be marked on precast concrete units
Storage as stated in the Contract or as approved by the
Engineer.
(2) Precast concrete units shall be lifted and supported

only at the designed lifting points and shall not be
subjected to rough handling, shock loading or
dropping.
(3) Precast concrete units shall be stored off the ground

on level supports and in a manner which will not result
in damage or deformation of the units or in
contamination of the concrete. Precast concrete units
shall be protected from damage and any damaged
units shall not be used in the Permanent Works.
Installation 11.123 (1) Contact surfaces between in-situ concrete and precast
concrete units shall be prepared as stated in the
Contract. Dimensional tolerances shall be checked
before the precast units are lifted into position.
(2) Temporary supports and connections shall be

provided as soon as practicable during installation of
precast concrete units.
(3) Final structural connections shall be completed as

soon as practicable after the precast concrete units
have been installed.
(4) Levelling devices which have no load bearing function

in the finished structure shall be slackened, released
or removed after the precast concrete units have been
installed.
Testing
Batch 11.124 A batch of precast units is any quantity of precast units,

including prestressed units, of the same type and size, of
the same concrete mix, manufactured in the same place,
covered by the same certificates and delivered to the Site at
any one time.
Samples 11.125 The number of precast units to be provided for testing from
each batch shall be as stated in the Contract.
June 2022
11/75
Load Tests 11.126 (1) Load tests shall be carried out to determine the
deflection and recovery of each precast unit, including
prestressed units, provided for testing and to
determine the resistance to cracking of all units
provided for testing.
(2) The age at which the units are to be tested, the test
load, the points at which the loads are to be applied
and the points at which the unit is to be supported
shall be as stated in the Contract.
(3) The method of testing shall be as stated in Appendix

11.2.
(4) Post-tensioned units shall not be tested until at least 7

days after the ducts have been grouted.
Compliance 11.127 The Contractor shall demonstrate that the precast units
Criteria comply in all respects with the requirements stated in the
Contract.
June 2022
11/76
PART 5 : GLASSFIBRE REINFORCED CONCRETE

(GRC)
General 11.128 (1) This section specifies materials and workmanship for
the manufacture, testing, curing and storage of GRC
panels.
(2) GRC shall consist of a mixture of PC, fine aggregate,

water, copolymer admixture and alkaline-resistant
glassfibres. Other admixtures may be proposed by
the Contractor and shall be subject to the approval of
the Engineer.
(3) GRC shall be made by a specialist manufacturer, with

a proven level of expertise in performing similar types
of work and shall be subject to the approval of the
Engineer.
(4) GRC units and panels shall be manufactured by either

hand spray or vibration cast premix methods.
(5) All GRC units and panels shall have all surfaces
treated with silane after the curing period.
(6) GRC units and panels which are to be exposed to

weather or moist atmosphere shall have either an
acrylic or styrene-butadene copolymer added to the
mixing water at a rate equivalent to 20% of the weight
of PC in the GRC.
Full Scale 11.129 Before the mass production of panels or units commences
Sample a full scale sample of each panel or unit type shall be
submitted to the Engineer for Approval of colour, texture,
finish, consistency and tolerance. When a sample has
been completed to the satisfaction of the Engineer it shall
be marked as the "Approved Sample" and used as a
reference to compare with other panels or units. When the
mass produced panels or units vary from the "Approved
Sample" the Contractor shall carry out such modifications
as may be required to achieve the approved standard to the
approval of the Engineer.
Trial Testing 11.130 (1) Preliminary Testing

and Samples
The Engineer shall require trial testing to be carried out
before manufacture commences using the actual mix,
equipment, personnel and technique proposed for
manufacture. The factors to be established by this
June 2022
11/77
work are as follows:
(a) that the LOP and MOR strengths and quality

control requirements can be achieved;
(b) the relationship between 7 day and 28 day MOR

and LOP;
(c) that the quality of the finished product is

acceptable.
(2) Work for Trial Testing
The trial testing shall be carried out on an agreed

number of test boards in accordance with Clause
11.134. A minimum of four results shall be used for
each of the tests required.
(3) Submission and Approval of Results
Results of tests shall be submitted to the Engineer not

less than two weeks before manufacture is due to
commence.
Materials 11.131 (1) All materials used in the manufacture of GRC panels
or units shall comply with Section 11.
(2) The glassfibre shall be of alkaline-resistant quality and

have a strand-in-cement value of over 330MPa after
96 hours in water at 80C as specified in GRC
Association publication "Method of test for strength
retention of glassfibre in cements and mortars".
(3) The minimum glassfibre content shall be 3% for

Premix and 5% for Hand Spray.
(4) The mix-design of GRC shall be proposed by the

manufacturer and approved by the Engineer. The
proportions shall be chosen to achieve the
performance as stated in the Contract.
(5) Release agents shall be a proprietary type, compatible

with the mould lining material and the required finish.
(6) Fixings cast inside GRC shall be of non-ferrous metal

or galvanised steel and shall comply with the
requirements of Section 7 and Section 10 as
appropriate.
June 2022
11/78
Performance 11.132 (1) Panels formed in GRC shall achieve the shape and
profile as stated in the Contract.
(2) The colour, texture and finish shall be as stated in the

Contract and match those of the approved sample
prepared previously by the Contractor and approved
by the Engineer.
(3) The finished units shall be free from surface

imperfections such as blow holes, voids and ridges
which are visible when inspected from a distance of 5
metres.
(4) Any dirt and stains appearing on the exposed outside

surface of the units shall be cleaned.
Workmanship 11.133 (1) For premix GRC the following shall apply:
and
Construction (a) mixing of the GRC mortar shall be carried out by
a high speed mixer to achieve a consistent
mortar paste;
(b) glassfibre shall be carefully blended into the

mortar paste using low speed mixing;
(c) the total mixing time after the addition of

glassfibre shall be minimized to ensure that
damage to the glassfibre is avoided;
(d) the GRC shall be vibration cast in to a mould

using suitable vibrators. The energy input of
the vibration equipment shall be adequate to
achieve thorough compaction without causing
segregation of the fibre and slurry.
(2) For hand spray GRC the following shall apply:
(a) mixing of the GRC mortar shall be carried out by

a high-speed mixer to achieve a consistent
mortar paste;
(b) the mortar shall be transported and pumped to a

spray gun which chops the glassfibre and
deposits both the mortar and the chopped
glassfibre onto mould;
(c) rollers shall be used to properly compact the
June 2022
11/79
GRC mixture;
(d) a succession of layers shall be sprayed to

achieve the required thickness.
(3) Any trowelling of the material shall be carried out as

soon as possible after placing and always before initial
set has occurred.
(4) The construction tolerances of GRC units shall be as

stated in the Contract.
(5) Panels and units shall only be demoulded after the

GRC has been demonstrated to have attained a
Characteristic Modulus of Rupture (MOR) of 2.0MPa,
using demoulding sockets cast into the GRC. On
demoulding, the panel shall be supported uniformly to
avoid overstressing of the GRC material. Panels and
units shall be cured in accordance with the concrete
curing clauses of this Specification.
(6) Surface treatment of the panels and units, if required,

shall be applied after demoulding and the application
of silane.
(7) Panels and units shall be handled, stored and

transported in a manner to avoid damage or marking
to the exposed outside surface and to avoid
overstressing.
(8) Panels and units shall be marked individually to

indicate the type, serial number and date of
manufacture.
(9) Making good of the exposed outside surface shall only

be permitted subject to the approval of the Engineer.
Any such making good shall provide a long-lasting
effect without deterioration.
Quality 11.134 (1) Four sets of test boards shall be prepared at equally
Control spaced intervals during each shift. Each test board
Testing shall be manufactured, handled and cured in the same
manner as the panels or units and tested in
accordance with BS EN 1170-2. No additional
compaction or curing shall be provided other than that
provided for the panels or units.
(2) The test for the determination of glassfibre content
June 2022
11/80
shall comply with the following:
Frequency : each shift

Method : BS EN 1170
Requirement : the average glassfibre content
shall not be less than 90% of the
mix design value
(3) The test for the determination of dry bulk density shall
comply with the following:
Frequency : each test board

Method : BS EN 1170
Requirement : No test board mean shall be less
than 1800kg/m3
(4) The test for the determination of Modulus of Rupture

(MOR) at time of demoulding, without conditioning the
specimens, shall be in accordance with BS EN 1170
and the following:

Method : BS EN 1170
Requirement : 2 MPa
(5) The test for the determination of Characteristic Limit of

Proportionality (LOP) / Modulus of Rupture (MOR)
shall be in accordance with the following:

Method : BS EN 1170
Requirement Premix Hand Spray
LOP at 28 days 6 MPa 8 MPa

MOR at 28 days 8 MPa 21 MPa
The test will be considered compliant if all the following

conditions are met:
(a) at 28 days the mean test result from each test

board shall not fall below the required LOP or
MOR value;
(b) at 28 days no individual test result shall fall

below 85% of the required LOP or MOR value;
June 2022
11/81
(c) the average LOP calculated from any

consecutive group of four test board means shall
exceed 1.12 times the characteristic LOP value;
(d) the average MOR calculated from any

consecutive group of four test board means shall
exceed 1.12 times the characteristic MOR value;
(6) If any single test board fails to meet any of the

compliance requirements, the GRC deemed not to
comply with this Specification shall be that produced
between the previous complying test board and the
next complying test board.
(7) Where failure to comply arises from consideration of

consecutive groups of four boards the GRC deemed
not to comply with this Specification shall be that
represented by the first and fourth test boards together
with all intervening material.
(8) GRC panels and units which do not comply with this
Specification shall be rejected and removed from the
Works.
June 2022
11/82
PART 6 : SILANE TREATMENT OF CONCRETE
Material 11.135 Silane shall have the following characteristics:

Characteristics
Active ingredient Isobutyl Silane >98%
Solvent Solvent free
Viscosity < 1.00 mPa.s
Method 11.136 The Contractor shall submit a method statement giving full
Statements details of the materials, equipment, safety precautions,
method of application and testing at least 56 days before
the application of silane treatment.
11.137 Not Used.
Application 11.138 (1) No silane treatment shall be carried out until the
Contractor has shown that the materials and method
of application can achieve the required depth of
penetration as stated in the Contract. All method
statements and safety precautions shall be approved
prior to the commencement of any silane treatment.
(2) Silane shall be applied by flow coating the concrete

surface to saturation. Brush or spray application shall
not be used for vertical surfaces. The soffit of
concrete shall be treated using a low pressure spray
with a minimum of two applications.
(3) Concrete surfaces to be treated with silane shall be

dry and clean. All dust, oil and other contaminants
shall be removed prior to the application of the silane.
(4) Silane shall not be applied during periods of rain or

strong wind. The surface temperature of the concrete
to receive silane treatment shall be between 10oC and
45oC.
(5) All cracks in the concrete  0.2 mm shall be repaired

to the approval of the Engineer prior to the application
of the silane treatment.
(6) Silane shall be applied by fully trained operatives

under the direct supervision and control of the silane
manufacturer.
(7) Silane shall not be used in the presence of any naked

flame and all necessary protective equipment shall be
June 2022
11/83
used by the operatives.
Testing of 11.139 The depth of silane penetration shall be measured using

Silane Chemical Indicators at three randomly selected locations,
Penetration as directed by the Engineer, for every shift or orientation of
application whichever comes first. Should the depth of
penetration be less than the specified depth, all areas which
were treated since the last acceptable result shall receive
other applications of the silane treatment until such time as
an acceptable penetration is achieved.
June 2022
11/84
PART 7 : REPAIR OF CONCRETE AND FILLING OF

TIE HOLES
General 11.140 (1) A test certificate from an approved testing laboratory,

confirming the minimum performance requirements for
any material used in the repair of concrete, is required
28 days before the commencement of repair works.
(2) A trial mix using the equipment, personnel and

materials to be used in the repair work shall be
conducted 35 days before any repair work is carried
out, to the approval of the Engineer.
(3) All proprietary products shall be stored, mixed and

placed in accordance with the manufacturers’
recommendations, including preparation of the
substrate. Where this Specification is inconsistent
with the manufacturers’ recommendations the higher
standard shall prevail.
Materials
Mortar 11.141 (1) The mortar used shall be a pre-bagged single

component, cementitious, non-shrink, polymer
modified proprietary type. The mortar for filling and
repair of concrete surfaces with F3, F4 and F5 finishes
shall be the same colour as the hardened concrete.
In order to achieve the colour match pigments may be
added into the mortar mix to the approval of the
Engineer.
(2) The mortar shall have a compressive strength at least

equal to the compressive strength of the parent
concrete and the minimum performance requirements
shall be as follows:
Compressive strength at 7 days > 35 MPa
Flexural strength at 28 days > 8 MPa
Hardened density at 28 days >2250 kg/m3
Micro 11.142 (1) The micro concrete used shall be a pre-bagged single
Concrete component proprietary type approved by the Engineer.
(2) The micro concrete shall have a compressive strength
June 2022
11/85
at least equal to the compressive strength of the

parent concrete and the minimum performance
requirements shall be as follows:
Compressive strength at 7 days > 35 Pa
Hardened density at 28 days > 2200 kg/m3
Drying Shrinkage at 7 days < 500 µstrain
Alkali content < 3.0 kg/m3
(3) The maximum aggregate particle size contained in

micro concrete shall be 10 mm.
Bonding 11.143 (1) Bonding agent shall be a proprietary type; either

Agent epoxy, acrylic, SIR or PVA based materials.
(2) Bonding agent shall be used strictly in accordance with

the manufacturer's recommendations.
Injection 11.144 (1) Injection resin shall be a proprietary two component

Resin compound; solvent free; ultra low viscosity; water
tolerant; 100% solids.
(2) The minimum performance requirements for injection

resin shall be as follows:
Tensile strength at 7 days > 20 MPa
Viscosity at 25oC < 200 cps

25oC<
Viscosity at 200 cps
Mixing of 11.145 (1) Materials shall be mixed in a forced action mixer.
Mortar & Micro Free fall type mixers shall not be used. Mixing shall
Concrete be carried out using full bags. The mixing of part
bags shall not be permitted.
(2) Materials shall be mixed by slowly adding the powder

to a pre-measured amount of water already placed in
the operating mixer and continuing the mixing until the
June 2022
11/86
mortar is fully homogeneous. The amount of water

added shall be the minimum amount of water needed
to achieve the required consistency and shall at no
time be more than the manufacturer's recommended
maximum amount.
Testing of 11.146 A minimum of one set of two number 100mm test cubes
Mortar & Micro shall be manufactured and cured in accordance with CS1
Concrete on each day of repair material production. The test cubes
shall be tested for hardened density and compressive
strength at 28 days. Any repair material failing to meet
either the minimum compressive strength or hardened
density shall be deemed to be non-compliant with the
Contract.
Methods
Method 11.147 (1) The method of repair of concrete defects shall be

Classification approved by the Engineer prior to any repair being
undertaken.
(2) Concrete defects repairs shall be carried out in

accordance with Table 11.6.
(3) The Contractor shall propose alternative methods for

repairs not covered by Table 11.6 for the approval of
the Engineer.
June 2022
11/87
Table 11.6 : Classification of Concrete Repairs and Tie Hole

Filling
Concrete Defect Method of Repair
Concrete surface of a vertical element beyond the required Type 1

profile
Poor quality concrete extends to a depth < 30 mm below Type 1

the concrete surface in a vertical or horizontal element
Poor quality concrete extends to a depth 30 - 60 mm Type 2

below the surface of a vertical element
Poor quality concrete extends to a depth > 60 mm below Type 3

the surface of a vertical element
Poor quality concrete extends to a depth > 30 mm below Type 4

the top surface of a horizontal element
Poor quality concrete extends to a depth > 30 mm above Type 1

the bottom surface of a horizontal element
Cracks weeping water Type 5
Cracks > 0.2 mm in width Type 5
Cracks < 0.2 mm in width and not weeping water Type 6
Filling of tie holes Type 7
Type 1 11.148 (1) The perimeter of the defective area shall be saw cut to
Method of a depth of 10mm below the finished surface level, to
Repair create a square or rectangular shape.
(2) The defective or surplus concrete shall be broken out

using a hand operated compressed air or electric
percussion chisel.
(3) All loose material shall be removed and the surface of

the concrete shall be washed. A bonding agent shall
be applied in accordance with the manufacturer's
recommendations.
(4) Mortar shall be applied in 10mm maximum depth

layers avoiding sagging or setting of the mortar prior to
subsequent layers being applied. Additional layers
shall be applied until the repair material reaches the
required surface level where a steel trowel float finish
shall be obtained.
(5) A curing membrane shall be spray or brush applied to
June 2022
11/88
a minimum of 100mm in excess of the repaired area

immediately after trowelling has been completed.
Method of a depth of 30mm below the finished surface level, to
(2) The defective concrete shall be broken out using a

hand operated compressed air or electric percussion
chisel.

recommendations.
(4) Pre-prepared letter box shutters shall be constructed

as quickly as possible to avoid the drying out of the
bonding agent.
(5) After confirming that the bonding agent is still effective

the micro concrete shall be poured or pumped into the
shutter in layers no greater than 200mm. The shutter
face shall be vibrated or tapped as the micro concrete
progresses up the shutter, to improve compaction and
remove entrapped air, until the shutter is full.
(6) The shutter shall be removed after no less than 3 days

and the surplus material at the "letter box" shall be
trimmed. A curing membrane shall be spray or brush
applied to a minimum of 100mm in excess of the
repaired area.
(7) The "letter box" concrete shall be made good using

Type 1 repair mortar.
Type 3 11.150 The same method as in a Type 2 repair shall be used

Method of except that structural concrete in accordance with Section
Repair 11, Part 1 shall be used in place of the micro concrete and
that internal poker vibration shall be used in addition to the
tapping of the shutter to ensure compaction is achieved.
Method of a depth of 30mm below the finished surface level to
(2) The defective concrete shall be broken out using a

hand operated compressed air or electric percussion
June 2022
11/89
chisel.

recommendations.
(4) When it has been confirmed that the bonding agent is

still effective, the structural concrete shall be placed or
pumped, in accordance with Section 11, Part 1, into
the repair area. The concrete shall be vibrated using
internal poker vibration to compact and remove
entrapped air.
(5) The required finish shall be obtained using a steel

trowel float and a curing membrane shall be spray or
brush applied to a minimum of 100mm in excess of the
repaired area immediately after trowelling has been
completed.
Type 5 11.152 (1) Angled injection holes shall be drilled at 300mm

Method of centres staggered across the crack and extending into
Repair the concrete to a minimum 200mm below the concrete
surface or to the middle of the concrete whichever is
the lesser and intersecting with the crack.
(2) Proprietary injection tubes/nipples shall be attached to

the injection holes.
(3) The crack shall be flushed with potable water injected

through the injection holes to remove any debris from
the drilling process or other sources.
(4) The crack surface shall be completely sealed with a

fast setting material of sufficient bond and strength to
resist the applied grouting pressure.
(5) Using a suitable pump the resin shall be injected into

the bottom injection pipe until uncontaminated resin
flows freely from the next injection hole above.
(6) The hole being injected shall be sealed and the

process shall be repeated at the successive hole(s)
until the crack has been completely grouted.
(7) After 24 hours the injection tubes/nipples and sealing

material shall be removed.
June 2022
11/90
(8) If in the opinion of the Engineer any area of the crack

appears not to be injected properly or if water ingress
occurs, the process shall be repeated in the area
affected until the process is considered by the
Engineer to be completed successfully.
(9) The surface shall be made good to the required

surface finish.
(10) All necessary precautions shall be taken to avoid

damage to reinforcement.
Type 6 11.153 Cracks less than 0.2mm shall be rubbed up with a

Method of proprietary repair mortar containing CSF.
Repair
Type 7 11.154 (1) The surface of holes left by formwork ties and
Filling of components shall be roughened by the use of grit
Tie Holes blasting, high pressure water jetting or light scabbling.
(2) The tie-bolt hole shall be cleaned using high pressure

water or compressed air.
(3) A bonding agent shall be applied in accordance with

the manufacturer's recommendation.
(4) A repair mortar shall be used which has been mixed

with a very low water content to provide a very stiff
mortar. The repair mortar shall be packed in 20mm
maximum depth layers using a suitable wooden
ramming device until the repair material is at the
required surface level. The required surface finish
shall be obtained using a steel trowel.
(5) A curing membrane shall be spray or brush applied to

a minimum of 25mm in excess of the repaired area
immediately after the trowelling has been completed.
June 2022
11/91
APPENDIX 11.1
Routine Checks for Plant and Equipment
BATCHING AND MIXING EQUIPMENT
Daily Routine
Adjust tare weights and clean weighing dials.

Ensure weighing hoppers empty properly.
Wash-out central mixer drum or pan.
Check operation of automatic printout equipment.
Check operation of truckmixer revolution counters.
Weekly Routine
Maintain all hoppers and doors in clean and efficient working order.
Remove any cement or concrete build-up in mixer.
Shake out cement silo filler sock and maintain in efficient working order.
Clean knife edges on weighing equipment.
Check calibration of moisture meter.
Monthly Routine
Check calibration of all weigh scales.

Check calibration of water meter/weigh scales.
Check calibration of admixture dispenser/weigh scales.
Quarterly Routine
Inspection and testing of all weigh scales over their complete range.
TRANSPORTING EQUIPMENT- MIXER AND AGITATOR UNITS
Daily Routine
Wash out truck mixer drum.
Monthly Routine
Check operation of revolution counters.

Check calibration of truck water meter.
June 2022
11/92
APPENDIX 11.2
Determination of the Deflection, Recovery

and Resistance to Cracking and Precast Units
Scope 11.2.1 This method covers the determination of the deflection

and recovery of precast units, including prestressed units,
and the resistance to cracking of prestressed units by
means of a load test.
Equipment 11.2.2 The following equipment is required:
(1) rigid supports;
(2) test loads;
(3) equipment for measuring the loads applied,

readable and accurate to 2% of the specified test
load;
(4) equipment for measuring the deflection and

recovery, readable and accurate to 0.5 mm;
(5) all equipment used in the testing shall be maintained

and calibrated to the satisfaction of the Engineer.
Procedure 11.2.3 The procedure shall be as follows:
(1) the precast unit shall be supported at the specified

points of support;
(2) the upward deflection at mid-span due to the

prestressing force in a prestressed unit and the
deflection at mid-span due to the self-weight of a
non-prestressed unit shall be measured;
(3) the specified test load shall be applied at the

specified loading points in not less than ten
approximately equal increments;
(4) the specified test load shall be maintained for 5

minutes and removed in not less than 5
approximately equal decrements;
(5) the deflection at mid-span shall be measured for

each load increment and each load decrement and
June 2022
11/93
5 minutes after the loads have been removed;
(6) steps (c) to (e) shall be repeated;
(7) Load-deflection graphs shall be plotted.
Reporting of 11.2.4 The following shall be reported:

Results
(1) details of the precast unit, including place of
manufacture;
(2) the age of the concrete in the precast unit at the

time of the test;
(3) the loads applied to the nearest 2% of the specified

test load;
(4) the deflections measured to the nearest 0.5 mm;
(5) the load-deflection graphs;
(6) details of any cracks;
(7) that the test method was in accordance with this

Specification.
June 2022
11/94
APPENDIX 11.3
Uniformity of Mixing
Mixers 11.3.1 Mixers used in the production of concrete shall comply

with section 3.4 of AS 1379 - 1991 modified as follows:
(1) Clause 3.4.1.4 add sub-clauses:
(a) Type Approval number where clause 11.3.2 of

this Appendix applies.
(b) The identification plate shall be applied to the

mixer drum unless otherwise approved by the
Engineer.
(2) References in Appendix A of AS 1379 - 1991 to AS

1012.3, 1012.4, 1012.5 and 1141.6 shall be
replaced by Section 2 of CS1, Section 6 of CS1,
Section 5 of CS1 and BS 812 respectively.
Type Approval 11.3.2 (1) Mixers may be provided with type approval where
the following information is provided :
(a) drawings showing the critical requirements

and dimensions of the mixer assembly;
(b) manufacturer's instructions for the use of the

mixer;
(c) results of uniformity tests in accordance with

Clause 11.3.1 of this Appendix for the mixes
to be produced, or results of an alternative
uniformity standard approved by the
Engineer;
(d) a maintenance schedule that ensures

continuing satisfactory performance.
(2) Mixers which are the subject of type approval shall

be given a type approval number which shall be
inscribed on the identification plate.
June 2022
11/95
APPENDIX 11.4
Sampling and Testing Concrete

for Acceptance and Compliance Purposes
General 11.4.1 (1) This procedure applies to concrete sampling,

workability determination, test cube manufacture, site
curing and transportation of test cubes together with
all records and documentation relevant to the
acceptance and compliance of fresh and hardened
concrete.
(2) Unless otherwise stated in the Contract, the

Contractor shall use the Materials Testing System
provided by the Engineer for sampling and testing of
concrete cubes. The System employs Radio
Frequency Identification (RFID) technology and
mobile application to identify cube samples and
collect sampling data. The surface of test cubes
shall be affixed with a RFID tag provided by the
Contractor. Mobile devices and Internet service
required by the System for in-situ sampling and
testing shall be provided by the Contractor.
Glossary of 11.4.2 (1) "Contractor's Site Technician" is a person proposed

Terms by the Contractor and accepted by the Engineer as
being suitably qualified and experienced to carry out
concrete sampling and testing work on behalf of the
Contractor.
(2) "Acceptance Testing of Concrete" is the sampling and

workability testing of concrete to establish that the
workability and other properties are within the agreed
limits prior to acceptance for inclusion within the
permanent works.
(3) "Compliance Testing of Concrete" is the sampling,

workability testing and test cube manufacture of
concrete to establish that the workability, strength and
other properties are within the specified limits.
(4) "CTR form" a Cube Test Request form in electronic

format on the Materials Testing System to enable the
Contractor to uniquely identify the cube samples and
give the test information required by this Specification.
June 2022
11/96
(5) "MTRCL Appointed Person" is a person appointed by

the Engineer to check and verify the Contractor's test
records and sampling procedures.
(6) "Laboratory" is the Contractor's engaged laboratory

subject to the approval of the Engineer.
Sampling and 11.4.3 Sampling and workability tests are required for each
Testing Concrete individual delivery of concrete in accordance with CS1.
for Acceptance The required information to be obtained and documented
Purposes for each workability test includes, but is not limited to the
following:
– name of Works;
– date of sampling;
– name of supplier and source of concrete;
– MTRCL assigned Plant code;
– MTRCL assigned Mix code;
– delivery note number;
– grade of concrete;
– time of adding water;
– location in works where the concrete is placed;
– time of sampling;
– ambient temperature and weather conditions;
– place and method of sampling;
– name and signature of person responsible for
sampling;
– place where workability test took place;
– time of completion of workability test;
– design workability;
– type of workability test;
– result of individual and average workability test;
– name and signature of person conducting workability
tests.
Sampling and 11.4.4 (1) Sampling, workability and 100mm cube tests are
Testing Concrete required for each individual concrete mix delivered to
for Compliance the works in accordance with Table 11.2 of this
Purposes Section and CS1. Individual mix codes shall be
assigned by the Engineer as part of the approval
process. The required information to be obtained
and documented for each cube sample includes, but
is not limited to the following:
– name of Works;
June 2022
11/97
– date of sampling;
– name of supplier and source of concrete;
– MTRCL assigned Plant code;
– MTRCL assigned Mix code;
– delivery note number;
– grade of concrete;
– time of adding water;
– location in works where the concrete is placed;
– time of sampling;
– ambient temperature and weather conditions;
– place and method of sampling;
sampling;
– place where workability test took place;
– time of completion of workability test;
– design workability;
– type of workability test;
– result of individual and average workability test;
– name and signature of person conducting
workability tests;
– unique identification number of each cube
mould;
– unique identification number of each test cube;
– time at which the cube manufacture was
completed;
– age at which to test each cube;
– date and time of cube demoulding;
– curing report for site storage;
making the cubes.
(2) Full details of the site curing of the cubes shall be

submitted if the cubes are not immediately delivered
to the laboratory after demoulding.
(3) A CTR form, similar to the example shown in Clause

11.4.10, designed to comply with the above
requirements shall be used for all cube tests. The
CTR form in electronic format on Material Testing
System. For routine compliance testing two cubes
are to be manufactured for testing at 28 days. For
trial mix compliance testing six cubes are to be
manufactured, three for testing at 7 days and three for
testing at 28 days. The testing of compliance cubes
will be conducted by the laboratory.
June 2022
11/98
(4) Additional test cubes manufactured by the Contractor,

for his own purposes will not be tested by the
laboratory and shall not be detailed on a CTR form.
The Contractor shall use his own documentation for
such cubes.
Identification 11.4.5 (1) Each cube mould shall have a unique reference
Marking of Test number attached or stamped into each component
Cubes part. This is required for initial identification of the
test cube and traceability of the individual cube mould
to any test cube exceeding the dimensional tolerance
required by CS1.
(2) No marking of test cubes shall be carried out until

after the concrete has achieved final set. The
following procedure shall be followed using a water
resistant indelible marker:
(a) after the concrete has set and prior to

de-moulding, the test cube shall be marked
with the Mould Identification Number on the
corner of the trowelled surface adjacent to the
Mould Identification Numbers, punched on the
mould;
(b) immediately prior to, or immediately after

de-moulding, each test cube shall be marked
with the unique Cube Identification Number
(the contract number, plus C, plus the number
printed on the CTR form, plus the alphabetic
suffix) on both the trowelled surface and the
adjacent cast surface of the cube. The date
cast shall also be marked on the adjacent cast
surface.
Site Storage 11.4.6 (1) All site curing shall fully comply with CS1.
and Curing of
Test Cubes (2) The test cubes shall be initially protected and stored
at the point of manufacture, in accordance with CS1,
for a period not less than 18 hours. Prior to
removing the test cubes from the mould the concrete
shall be visually checked to ensure that it has gained
sufficient maturity to enable handling without damage.
Within 30 minutes of de-moulding, the test cubes
shall be placed in a curing tank.
(3) At all times the cubes shall be cured in accordance
June 2022
11/99
with CS1 until they are transported to the laboratory.
Transportation of 11.4.7 (1) Test cubes shall be packed and transported, in

Test Cubes to the accordance with CS1 to the laboratory as directed by
Laboratory the Engineer.
(2) The test cubes shall be maintained in a saturated

condition, and protected from loss or damage at all
times, during the transportation process.
(3) The test cubes shall be transported to the laboratory

in a watertight container with sufficient water to
ensure that 100% saturation is maintained during the
journey.
(4) The test cubes shall be suitably isolated from each

other to ensure damage by cube to cube contact is
avoided.
(5) The Contractor shall propose the method of

protection and transportation for the Engineer's
Approval.
Reception of 11.4.8 (1) The laboratory staff will inspect and verify the sample
Test Cubes at and numbering against the documentation and record
the Laboratory acceptance of the cube samples by signing the CTR
form or similar request form accompanying the
samples. Any cube samples which have been
incorrectly marked or have incomplete documentation
will be rejected and the Contractor shall remove the
cubes and rectify the non-conformance.
(2) Upon completion of the reception process the

laboratory staff will return a copy of the request form
to the Contractor.
Testing and 11.4.9 The laboratory staff will test the cubes, report the test
Reporting of results and issue test certificates to the Engineer. All the
Cube Test Results test reports shall be uploaded by the laboratory to Material
Testing System directly.
June 2022
11/100
11.4.10 Format of Cube Test Request (CTR) Form

C 12345
Contract Number
MTRCL - Civil Engineering Section

Laboratory Cube Test Request (CTR) Sampling & Tests in Accordance with CS1
Note 1 Each field must contain an entry or scored out if not used SConE or AConE who is Responsible
Note 2 Blank test type to be completed if additional to Flow or Slump
Note 3 If [ ] is used please [ _ ] choice Contact Telephone Number
Mix Details Claimed by the Supplier :- Only to be contacted in the event of cube failure or any other major discrepancy
MTRCL Supplier & Plant Code Time water was added to mix :
Suppliers Ticket Number Designed Vebe Time sec ± sec
MTRCL Mix Code Designed Slump Value mm ± 25 mm
Grade of Concrete MPa Designed ±
Sample Details :- Weather and Pour Location Details :-
Date sampled / / Weather [ ] Fine [ ] Cloudy [ ] Showers [ ] Rain [ ] Storm
Time sampled : Actual location in the works where the batch sampled will be placed
Sampled from [ ] Mixer Chute [ ] Heap [ ] Skip [ ] Pump
(1)
Sampled by
Supervised by Is this location part of a BD approved Structure ? [ ] Yes [ ] No
Cube Manufacturing, Mould and Test Age Details :- Workability & Temperature Details :-
Cube marked A to test at 28 days Mould number used Location where test was conducted
Cube marked B to test at 28 days Mould number used Flow Value mm Average Flow Value
Cube marked C to test at days Mould number used Flow Value mm mm
Cube marked D to test at days Mould number used Slump Value mm Average Slump Value
Cube marked E to test at days Mould number used Slump Value mm mm
Cube marked F to test at days Mould number used Average
Time cubes manufactured :
Cubes manufactured by (1)

Ambient Temperature C
Supervised by Concrete Temperature C
Demoulding, Marking, Sample & Test Agreement Details Etc. :- Time tests were completed :
(1)
Cubes demoulded after Hours Tested by
(1)
Cubes marked by Supervised by
Marking supervised by Other Tests which are normally conducted during a Trial Mix :-
The curing regime under which the cubes were stored, while cured on site by the Fresh Density kg/m3 Average Fresh Density
Contractor, was [ ] in accordance with cl. 10.3.2 of CS1, [ ] At an incorrect high
/ low temperature, [ ] Not continuously wet Fresh Density kg/m3 kg/m3
(1)
Prepared for transport by Bleeding at 2 hours %
Preparation supervised by Transportation and Reception in the Laboratory :-
Sample & Test details shown above are Transported to Lab by

provided by the Contractor's Site
Technician Name & Signature Date received in Lab / /
Sample & Test details provided are Received in Lab by

checked and agreed by the MTRCL
Appointed Person Name & Signature Entered in Sample Register by
(1)
Must be conducted by an approved Site Technician or by a named Trainee directly supervised by an approved Site Technician
All copies are to be delivered with samples to the Laboratory. After receipt by the Laboratory distribution is Original to Laboratory, Yellow to CM, Blue to Contractor
October 2014
11/101
APPENDIX 11.5
Sampling and Testing Concrete Cores

for Compliance Purpose
General 11.5.1 (1) This procedure applies to concrete core sampling, site
curing and transportation of test cores together with all
records and documentation relevant to the compliance
of hardened concrete.
(2) Unless otherwise stated in the Contract, the

Contractor shall use the Materials Testing System
provided by the Engineer for sampling and testing of
concrete cores. The System employs Radio
Frequency Identification (RFID) technology for
testing and reporting results.
Glossary of 11.5.2 (1) "Contractor's Site Technician" is a person proposed by

terms the Contractor and accepted by the Engineer as being
suitably qualified and experienced to carry out
concrete sampling and testing work on behalf of the
Contractor.
(2) "Compliance Testing of Concrete" the sampling, curing

and testing of concrete to establish that the strength
and other properties are within the specified limits.
(3) "MTRCL Appointed Person" is a person appointed by

the Engineer to check and verify the Contractor's test
records and sampling procedures.
(4) "Laboratory" is the Contractor's engaged laboratory

subject to the approval of the Engineer.
Sampling of 11.5.3 (1) The positions from which the cores are taken shall be
Cores directed by the Engineer, and the method of drilling
shall be as CS1.
(2) A Core Test Request (ORT) form, similar to the

example shown in Clause 11.5.10 which has been
designed to comply with the above requirements shall
be used for all core tests. The OTR form is in
electronic format on Material Testing System.
Size of Cores 11.5.4 The test specimen shall be either of 150mm diameter or
100mm diameter, and in accordance with the relevant
June 2022
11/102
clauses of this Specification. The length of each core shall

be sufficient to give a length/diameter ratio of not less than
1.0 after end preparation in accordance with CS1 which will
normally require the cut length to be a minimum of three
times the diameter when cut from the structure.
Identification 11.5.5 (1) Immediately after obtaining each test core, the test
Marking of core shall be marked with the unique Sample
Cores Identification Number (the contract number plus O plus
the number printed on the OTR form plus the
alphabetic suffix on the side and cast surface of the
core.
(2) In addition to Clause 11.5.5(1) each core shall be

clearly and indelibly marked with the following
information:
(a) date of drilling;
(b) orientation within the section;
(c) direction of drilling;
(3) The direction of drilling under CS1 is to be determined

and reported in relation to the direction of casting.
Cores drilled in the same direction as the concrete was
cast shall be reported as drilled vertically.
(4) The core shall be marked to indicate the distance in

millimetres from the drilling surfaces so that the
location in the element from which the test core came
can be determined when the ends have been trimmed.
(5) The OTR form shall be marked to indicate that the

cores are to be inspected and the air void content,
density and compressive strength determined in
accordance with the procedures given in CS1.
Storage of 11.5.6 Immediately after marking, cores shall be stored in

Core Samples conditions which will prevent the loss of moisture and avoid
extremes of temperature. The location and condition of
storage and/or curing shall be in accordance with CS1 and
Transportation of 11.5.7 Test cores shall be packed and transported in accordance

Core Samples to with CS1 to the laboratory. The test cores shall be
the Laboratory maintained in a saturated condition and protected from loss
or damage at all times during the transportation process.
June 2022
11/103
Reception of Core 11.5.8 (1) The laboratory staff will inspect and verify the sample
Samples at the and numbering against the documentation and record
Engineers' acceptance of the core samples by signing the OTR
Laboratory form or similar request form accompanying the
samples. Any core samples which have been
incorrectly marked or have incomplete documentation
will be rejected and the Contractor shall remove the
core(s) and rectify the non-conformance.
(2) Upon completion of the reception process the

laboratory staff will retain a copy of the request form to
the Contractor.
Testing and 11.5.9 The laboratory staff will test and report the core test results
Reporting of to the Engineer. All the test reports shall be uploaded by
Cube Test the laboratory to Material Testing System directly.
Results
June 2022
11/104
11.5.10 Format of Core Test Request (OTR) Form
O 12345
Contract Number
MTRCL - Civil Engineering Section

Laboratory Core Test Request (OTR) Sampling & Tests in Accordance with CS1
Note 1 Each field must contain an entry or scored out if not used
SConE or AConE who is Responsible
Note 2 Circle Choice
Note 3 If [ ] is used please [ _ ] choice
Contact Telephone Number
Only to be contacted in the event of core failure or any other major discrepancy
Mix Details Claimed by the Contractor and Supplier :-
MTRCL Supplier & Plant Code Age when Sampled days hours
Date Cast / / Diameter of Cores mm
MTRCL Mix Code Orientation of member
Grade of Concrete MPa Location Represented
Date Sampled / Drilled / /
Sampled / Drilled By
(1)
Supervised By
Information and Testing Request
Identification Mark A B C D E F
Length of core as sampled mm mm mm mm mm mm
Direction of Drilling V/H V/H V/H V/H V/H V/H
Sample Contains Reinforcement Y/N Y/N Y/N Y/N Y/N Y/N
Storage conditions while the samples were on site
Indicate Tests Requested below
Distribution of Materials [ ] [ ] [ ] [ ] [ ] [ ]
Air Void Content [ ] [ ] [ ] [ ] [ ] [ ]
Density Determination [ ] [ ] [ ] [ ] [ ] [ ]
Compressive Strength [ ] [ ] [ ] [ ] [ ] [ ]
Additional comments or testing requirements
If the sample is a re-test request, please specify the previous sample identification number [ ]
(1)
Prepared for transport by
Preparation supervised by Transportation and Reception in the Laboratory :-
Sample & Test details shown above are

Transported to Lab by
provided by the Contractor's Site
Technician
Date received in Lab / /
Name & Signature
Sample & Test details provided are
Received in Lab by
checked and agreed by the
MTRCL Appointed Person
Entered in Sample Register by
Name & Signature
(1)
Must be conducted by an approved Site Technician or by a named Trainee directly supervised by an approved Site Technician
All copies are to be delivered with samples to the Laboratory. After receipt by the Laboratory distribution is Original to Laboratory, Yellow to Engineer, Blue to Contractor
June 2022
11/105
APPENDIX 11.6
Determination of the Curing Efficiency Index

of Curing Compounds
Scope 11.6.1 This method covers the determination of the curing

efficiency index of membrane forming curing compounds for
concrete.
Materials 11.6.2 (1) PC complying with BS EN 197-1, specially selected for

Required testing admixtures and identified as 'CAA/BS
5075:Part1 Reference Portland Cement'; the cement
shall be stored in airtight containers.
(2) Oven-dry natural sand with a rounded particle shape

complying with BS 1881:Part 131 and combined in the
proportions shown in Table 11.6.1.
(3) Proprietary chemical release agent.
Table 11.6.1 : Proportion by Mass of Sand Fractions
Sand Fraction Proportion by Mass
1.18 mm to 600 µm 10%

600 µm to 300 µm 60%
300 µm to 150 µm 30%
Apparatus 11.6.3 (1) Mould shall be constructed from corrosion resistant

Required metal. The mould shall be watertight, have tapered
sides, be sufficiently robust to prevent distortion and
shall have the dimensions shown in Table 11.6.2.
June 2022
11/106
Table 11.6.2 : Dimensional Tolerance of Mould
Internal size Top 100 to 105 mm x 300 to 305 mm

Internal size Bottom 95 to 100 mm x 295 to 300 mm
Internal depth 48 to 52 mm
Side and end slope 4% to 6%
Top flange width > 12 mm
(2) A balance readable and accurate to 0.1 g.
(3) A cabinet complying with BS 2648 capable of storing

specimens at a temperature of 38oC ± 1oC and at a
relative humidity of 35% ± 5%. The cabinet shall
have three perforated or mesh shelves each capable
of supporting two specimens and ensuring that a clear
space of at least 40mm on all sides of the individual
specimens is maintained. The cabinet shall be
equipped to circulate air over the specimens at rate of
0.4 to 0.6 m/s.
(4) Spray equipment recommended by the manufacturers’

literature for application of the curing compound.
(5) A "Hobart" type mortar mixer with a blade rotating

axially at 120 ± 25 rpm and in a planetary motion 60
±15 rpm, with a bowl and blade clearance of 5mm
maximum and capacity to mix at least 12 kg.
(6) A vibrating table complying with CS1.
(7) A metal screed, 148mm long, of L shaped section

50mm x 25mm with the shorter side having a
sharpened leading edge. The screed shall be
supported across the top of the mould in such a way
that it can be slid on the flanges of the mould while
holding the screed horizontally.
(8) A metal tray with sides > 3mm high and an area equal
to the surface area of the specimen.
(9) A hydrometer complying with BS 718.
(10) A steel float, 250 mm x 140 mm ± 5 mm.
June 2022
11/107
(11) A medium soft 50 mm paint brush.
Preparation of 11.6.4 (1) Three pairs of specimens shall be prepared, each pair
Specimens comprising one test and one control specimen.
(2) The mortar mix shall comprise by mass in grams:
cement 2600 g
sand 7800 g
water 1150 g
(3) Mixing of the mortar shall be carried out in a

temperature of 27oC ± 3oC for both the materials and
room temperature.
(4) The sand and cement shall be placed in the mixer and
mixed for 30 seconds, while continuing to mix the
water shall be slowly and carefully added during the
next 30 seconds, mixing shall continue for a total of 5
minutes.
(5) Two moulds for the test and control specimens shall
be cleaned and lightly coated with release agent and
weighed to the nearest 0.1 g (mT1 and mC1
respectively).
(6) The specimens shall be prepared within 20 minutes

after completion of mixing and shall be cast together in
pairs.
(7) A layer of mortar approximately 25 mm deep shall be

placed in the each mould and shall be fully compacted
on the vibrating table. A second layer sufficient to
slightly over fill the mould shall be placed in each
mould and shall be fully compacted on the vibrating
table.
(8) A uniform surface, free from undulations and surface

defects shall be produced using the minimum number
of passes of the screed working along the length of the
mould in both directions. The finished surface shall
be 7mm ± 1mm below the top of the mould and shall
be lightly brushed with the paint brush to give an even
texture.
Determination of 11.6.5 (1) A sample of curing compound shall be obtained in
June 2022
11/108
the curing accordance with the method for sampling admixtures

efficiency index given in BS EN 934-2. The sample shall be agitated
thoroughly and the relative density determined, at
room temperature, with the hydrometer.
(2) Using the measured relative density the required

quantity to cover the specimens (cr) shall be
calculated based on the manufacturers recommended
application rate. If no information is available a rate
of 0.2 L/m2 shall be used.
(3) The mould containing the test and control specimens

shall be weighed to the nearest 0.1 g (mT2 and mC2
respectively) immediately before the curing compound
is applied.
(4) The curing compound shall be applied to the test

specimens between 60 and 70 minutes after the
completion of mixing using the equipment and
methods recommended by the curing compound
manufacturer. The specimens shall be coated
uniformly by applying several layers over the complete
surface of the test sample until the specified coverage
has been reached. The specified coverage (cr) shall
be checked by repeated weighing of the test specimen
until the total mass of the test specimen and curing
compound (mT3) is equal to (mT2 + cr) ± 0.5 g.
(5) The test and control specimens shall be placed,

immediately after the application of the curing
compound to the test specimen, on the lowest shelf of
the cabinet. After the second pair of specimens have
been prepared and weighed, the first pair shall be
moved up one shelf and the second pair placed on the
lowest shelf. After the third pair of specimens have
been prepared and weighed, the first two pairs shall be
moved up one shelf and the third pair placed on the
lowest shelf.
(6) The total time for making the specimens, applying the
=curing compound and placing a pair in the cabinet
shall not exceed 2 hours.
(7) Each pair of specimens shall remain in the cabinet for

72 hours ± 15 minutes from the application of the
curing compound. Each test and control specimen
shall be weighed to the nearest 0.1 g at 24 hours ± 15
minutes, 48 hours ± 15 minutes to compare the rate of
June 2022
11/109
weight loss. Each test and control specimen shall be

weighed to the nearest 0.1 g at 72 hours ± 15 minutes
giving mT4 and mC4 respectively.
(8) The metal tray shall be weighed to the nearest 0.1 g

(m1) and be coated with the same weight ± 0.5 g of the
curing compound used on the test specimens. The
coated tray shall be weighed to the nearest 0.1 g (m2)
and placed in the cabinet for 72 hours ± 15 minutes
after the application of the curing compound at which
time the tray shall be removed from the cabinet and
weighed to the nearest 0.1 g (m3).
Calculations 11.6.6 (1) The proportion of solvent lost (V) by the curing
compound during the test period shall be calculated
from the equation:
V = (m2 - m3)/(m2 - m1)
where:
- m1 is mass of the tray

- m2 is mass of the tray after coating
- m3 is mass of the tray after 72 hours in the cabinet
(2) The loss of water from the test specimen (WT) and
loss of water from the control specimen (WC) shall be
calculated for each pair of specimens from the
equations:
WT = ((mT3 - mT4) - V(mT3 - mT2))/(mT2 - mT1) x 100%
WC = (mC2 - mC4)/(mC2 - mC1) x 100%
where:
- mT1 is mass of the test mould

- mT2 is mass of the mould and test specimen
- mT3 is mass of the mould and test specimen after
coating
- mT4 is mass of the mould and test specimen 72
hours
- mC1 is mass of the control mould
- mC2 is mass of the mould and control specimen
- mC4 is mass of the mould and control specimen
72 hours
(3) The individual curing efficiency (EI) of the curing
June 2022
11/110
compound shall be calculated for each test of the

specimen and corresponding control specimen from
the equation:
EI = (WC - WT)/WC x 100%
(4) The curing efficiency index (E) for the curing

compound shall be calculated as the average of EI for
the three test specimens.
Reporting of 11.6.7 The following shall be reported on the test certificate:

Results
(1) details of the curing compound sample including
manufacturer, identification, source, size, date
sampled and dates tested;
(2) the type of spray equipment and method used;
(3) the rate of application of the curing compound to the

nearest 0.01 L/m2;
(4) measured relative density of the curing compound;
(5) the individual curing efficiency (EI) for the three test
specimens and the curing efficiency index (E) of the
curing compound to the nearest 0.1%; and
(6) statement from the Laboratory regarding compliance

with this test method and any departures made.
June 2022
11/111
APPENDIX 11.7
Calculation of the Reactive

Alkali Content in a Concrete Mix
Calculation 11.7.1 The reactive alkali content (expressed as the equivalent

Method sodium oxide, Na2O) in the concrete mix shall not exceed
3.0 kg/m3 of concrete, and shall be the sum of the
equivalent sodium oxide in the PC, one sixth the acid
soluble alkalis (total alkalis) expressed as equivalent
sodium oxide contributed by PFA, half of the acid soluble
alkalis (total alkalis) expressed as equivalent sodium oxide
contributed by GGBS, the chloride ion in the aggregates
and the amount of equivalent sodium oxide in any
admixtures and water to be used in the mix as follows:
Equivalent Na2O in Concrete = A + B + C + D
where
A = Equivalent Acid-Soluble Na2O (PC + Admixtures +

Water)
B = Chloride Ion in Aggregates x 0.76
C = Total Acid-Soluble Equivalent Na2O in PFA x 0.167
D = Total Acid-Soluble Equivalent Na2O in GGBS x 0.5
PC 11.7.2 The acid-soluble alkali content of the PC shall be

determined in accordance with the methods detailed in BS
EN 196. The calculated acid-soluble alkali content of PC
shall be taken as the average of 25 consecutive daily
determinations of the equivalent sodium oxide (Na2O + 0.66
K2O), plus twice the standard deviation for the period in
which the PC was manufactured.
PFA and 11.7.3 The acid-soluble alkali content of PFA and GGBS shall be
GGBS determined in accordance with the methods detailed in BS
EN 196. The calculated acid-soluble alkali content of
PFA and GGBS shall be taken as the average of 25 weekly
determinations for the period immediately preceding the
certificate, plus twice the standard deviation of the results.
Where 25 consecutive weekly test figures are not available,
then 10 consecutive daily results relating to the period
immediately preceding the certificate shall be submitted.
June 2022
11/112
Aggregates 11.7.4 The chloride ion content of the coarse and fine aggregate
shall be determined in accordance with the methods
detailed in BS 812. The calculated chloride ion shall be
taken as the average of 10 consecutive weekly
determinations plus twice the standard deviation of the
results.
Admixtures 11.7.5 The total acid-soluble alkali content, expressed as

equivalent sodium oxide, content of the admixtures shall be
determined in accordance with the methods detailed in BS
1881. The calculated acid-soluble content of admixture
shall be taken as the average of 10 consecutive weekly
determinations plus twice the standard deviation for the
period. The total acid soluble alkali content contributed to
the mix shall be calculated from the maximum dosage of
the admixture proposed to be used in the mix.
Water 11.7.6 The acid-soluble alkali content of water shall be determined

in accordance with the methods detailed in APHA (17 Ed.
1989) Sections 3500-K and 3500-Na. The calculated
acid-soluble content of water shall be taken as the average
of 10 consecutive weekly determinations plus twice the
standard deviation for the period.
Submission of 11.7.7 The Contractor shall submit test certificates giving the
Certificates results of tests and calculations of the standard deviation for
each of the individual concrete constituents and the
calculated equivalent Na2O content of the Concrete.
June 2022
11/113
APPENDIX 11.8
Format of Mix Design Submittal Form
MTR CORPORATION LIMITED

CONCRETE MIX DESIGN SUBMITTAL FORM
Submission Number Supplier

Contractor Date Submitted
(*) MTRCL use only Mix Code (*)
Material Type, Source, Quantity, Volume and Alkali Content

Constituent Material Type and Source kg/m3 S.G. (3) Volume Alkali kg/m3
Materials m3 % (4) (4)
Cement
PFA
(1)
(1)
40mm Agg
20mm Agg
10mm Agg
Fine Agg
Admix 1
Admix 2
Water
Note (1) Use box for any other materials used. Tot Air (2) 0.008 Total
kg
Note (2) Use value 0.8% unless proved otherwise by previous trial Total m3
Note (3) Use S.G. from verified test results
Note (4) Calculation of Alkali content (Na2O equivalent) as percentage of material and as kg/m3.
Other Mandatory Information

Strength grade of concrete as Mpa
Aggregate/Cementitious ratio by weight Calculate value to 3
decimal places
Water/Cementitious ratio by weight
Design Workability as sec, mm , % etc.
Compliance Workability Method
Circle as appropriate or
W/C relationship attached Yes / No
remove unwanted
Individual grading details attached Yes / No choice
Combined grading details attached Yes / No
Test Reports of constituent materials attached Yes / No
Backup Compressive Strength Data attached Yes / No
Main Concrete Batching Plant which mix is applied for
Backup Concrete Batching Plant
June 2022
11/114
SECTION 12
PRESTRESSING
General
Precast 12.1 Testing of precast prestressed units shall comply with

Prestressed Section 11 of this Specification.
Units
Materials 12.2 Materials for grout for prestressing systems shall comply
for Grout with Section 11, Part 3 of this Specification, except as
stated in this Section.
Glossary of 12.3 (1) "Duct" is a void formed in the concrete to

Terms accommodate a prestressing tendon.
(2) "Prestressing components" are all the components

used in a prestressing system, including anchorages,
grips, tendon deflectors, couplers, wedges, swages,
nuts and other devices used to grip the prestressing
tendon.
(3) "Prestressing tendon" is any of the following items

used in a prestressing system:
(a) an individual steel wire, wire strand or alloy steel

bar in a duct;
(b) an individual steel wire, wire strand or alloy steel

bar not in a duct;
(c) a group of steel wires or wire strands in a duct.
(4) "Sheath" is a tube or lining which is used to form a

duct and which is left in place.
(5) "Vent" is a tube which is used to allow air and grout to

leave the duct during grouting operations.
(6) "External tendon" is a prestressing tendon which is not

contained within concrete.
(7) "Unbonded strand" is an individual wire strand

debonded from surrounding structure by grease or
similar compound and encapsulated in a protective
sheath.
June 2022
12/1
Materials
Prestressing 12.4 (1) Prestressing tendons shall comply with the following:
Tendons
High tensile steel wire
and strand for the
prestressing of
concrete : BS 5896
Hot rolled and

processed high tensile
alloy steel bars
for the prestressing
of concrete : BS 4486
(2) Steel wire and wire strand shall be in coils of

sufficiently large diameter to ensure that the steel wire
and wire strand will pay off straight.
(3) Alloy steel bars shall be straight.
(4) Grease for unbonded strand shall contain a corrosion

inhibitor.
Prestressing 12.5 (1) Prestressing components shall be a proprietary type

Components approved by the Engineer and shall comprise of a
system of sheaths, sheath connectors, grouting
connections, vents, vent connections, drains,
transitions to anchorages and caps for anchorages.
The system shall be fully compatible with the
prestressing anchorages.
(2) Prestressing anchorages shall be tested in

accordance with BS EN 13391 and shall allow a
minimum of 25 mm cover to cropped ends of
prestressing tendons.
Sheaths 12.6 (1) Sheaths shall be of a corrosion resistant, durable

material and shall be a proprietary type approved by
the Engineer. They shall form an air and water tight
protective barrier to the prestressing tendon and shall
be of an electrically non-conductive, corrosion
resistant, durable material of minimum 4mm wall
thickness. For the sheath made of steel, the sheath
shall be hot-dip galvanized to BS EN ISO 1461 for
corrosion protection purpose.
(2) The design of sheaths shall allow for grout to be

June 2022
12/2
injected from either end. There shall be no sudden

changes in the diameter of the sheath.
(3) Sheaths for external prestressing shall be continuous

between anchorages and shall be air and watertight.
(4) Results of tests on duct abrasion resistance during

tendon stressing shall be supplied to the Engineer. It
shall be demonstrated that at least 2mm thickness of
sheath will remain on completion of the stressing
operation.
(5) Deviator pipes for external prestressing sheaths shall

be of a type approved by the Engineer. If made of
steel, deviator pipes shall be galvanized in accordance
with BS EN ISO 1461. Additional protection system in
the form of the below paint system or as approved by
the Engineer shall be applied to all surfaces of the
deviator pipes.
Life to first maintenance: more than 15 years high
durability as defined in BS EN ISO 12944-5
Pretreatment: two-pack etch primer
Primer: two-pack epoxy zinc phosphate primer, 80 µm
minimum total dry-film thickness
Undercoat: two-pack micaceous iron oxide epoxy
undercoat, 140 µm minimum total dry-film thickness
Finish: two-pack polyurethane finish coat, 100 µm
minimum total dry-film thickness
Installation of 12.7 At the time of tensioning, sheaths shall be free from dents
Sheaths or other irregularities which may affect tensioning.
Joints in 12.8 (1) Joints shall be mirror heat welded or an alternative

Sheaths jointing system shall be proposed which is compatible
with the proprietary prestressing system and which
forms an air and water tight joint. Joints in adjacent
sheaths shall be staggered by at least 300mm.
(2) Use of joints shall be kept to a minimum where

practicable.
Grout Vents 12.9 Taps for grout vents in ducts shall be a proprietary type
and Taps approved by the Engineer and shall allow closure of the
vents without loss of pressure in the duct. Vents to be
used as grout entry points shall be threaded or fitted with
screw connectors or other similar devices for connection to
grout pumps. All vents and vent connections shall have an
internal diameter no less than 20mm and shall be clearly
identified by labelling.
June 2022
12/3
Grout for 12.10 (1) Grout for prestressing shall consist of ordinary
Prestressing Portland Cement (PC), admixtures and water in
Systems accordance with Section 11, Part 3 and where
modified in the following sub-clauses.
(2) Grout shall be made from a non-shrink mix. When

tested in accordance with Clauses 12.56 and 12.57
the volume change of the grout at rest for 24 hours
shall be within the range -1% to +5%. The amount of
bleeding of grout shall not exceed 0.3% of the initial
volume of the grout after 3 hours kept at rest when
tested for the average of three results. The water shall
be reabsorbed by the grout within 24 hours after
mixing.
(3) Admixtures for grout shall not contain chlorides,

thiocyanides, nitrates, formates or sulphates. The
admixtures shall not segregate and shall be uniform in
colour. They shall comply with BS EN 934-2 or BS
EN 934-4 and full account is taken of their effects on
the finished products. Grout admixtures shall not
cause the grout to promote corrosion of the
prestressing steel by rusting, pitting or stress
corrosion. The optimum dosage shall be determined
by trial mixes with the cement to be used in the grout.
This dosage shall be expressed as a percentage of
the weight of the cement. It shall be within the range
recommended by the supplier and shall not exceed
5% of the weight of the cement.
(4) Grout shall have a minimum crushing strength of

27MPa at 7 days.
(5) The maximum water/cement ratio of the grout shall be

0.40.
(6) The fluidity of the grout immediately after mixing and

30 minutes after mixing shall not be more than 25
seconds when tested in accordance with Clauses
12.63 & 12.64. The fluidity of the grout shall not
change by more than 20% for immediately after mixing
to 30 minutes after mixing.
Submissions
Particulars of 12.11 (1) The following particulars of the proposed prestressing

Prestressing system shall be submitted to the Engineer:
System
June 2022
12/4
(a) details of the prestressing system, including

prestressing tendons, prestressing components,
sheaths and tensioning apparatus;
(b) sequence of prestressing and ends of

prestressing tendons from which prestress will
be applied if not stated in the Contract;
(c) calculated values of:
(i) each type of loss of prestress;
(ii) prestressing tendon forces;
(iii) extensions of prestressing tendons and

details of the method of measuring the
extensions;
(d) a certificate showing that the tensioning

apparatus has been tested and calibrated by an
agent approved by the Engineer within a period
of six months before the apparatus is to be
used;
(e) any alterations to the reinforcement or additional

reinforcement required to allow for primary
bursting effects;
(f) details of corrosion protection required for the

prestressing system;
(g) details of the format of tensioning schedules and

of reports of tensioning operations, grouting
operations and testing of duct friction;
(h) a method statement detailing all tensioning

operations.
(2) Calculations for loss of prestress due to creep shall be

based on the information stated in the Contract.
(3) The particulars shall be submitted to the Engineer for

approval at least 8 weeks before the approval is
required.
Particulars of 12.12 (1) A certificate from the manufacturer of the proposed

Prestressing prestressing tendons shall be submitted to the
Tendons Engineer stating the manufacturer's name, the date
and place of manufacture and showing that the
June 2022
12/5
prestressing tendons comply with the requirements

stated in the Contract and including details of:
(a) cast analysis;
(b) diameter, cross-sectional area and unit mass;
(c) results of tests for mechanical properties,

including the characteristic breaking load,
characteristic 0.1% proof load, elongation at
maximum load, relaxation and modulus of
elasticity;
(d) results of tests for ductility of prestressing wires.

approval for each batch of prestressing tendons
delivered to the Site and at least 28 days before
installation of the prestressing tendons starts.
Particulars of 12.13 (1) The following particulars of the proposed grout mix
Grout Mix and and grouting procedure for prestressing systems shall
Grouting be submitted to the Engineer:
Procedure
(a) water:cement ratio by mass;
(b) details of mixing and grouting equipment;
(c) method of quality control during grout injection;
(d) details of grouting trials;
(e) Admixture: a certificate not older than 6 months

showing the manufacturer's name, the date and
place of manufacture and that the admixture
complies with the requirements stated in the
Contract and BS EN 934-2 or BS EN 934-4 as
appropriate including the manufacturer’s test
results.

approval at least 7 days before trial mixes for grout are
made.
Samples of 12.14 Samples of the following proposed materials shall be

Materials submitted to the Engineer for approval at the same time as
particulars of the prestressing systems are submitted:
(1) prestressing tendons;

June 2022
12/6
(2) prestressing components;
(3) sheaths;
(4) grout vents and taps.
Trials
Trial Mixes 12.15 (1) A trial mix for grout for prestressing systems shall be
for Grout made to demonstrate that the proposed materials,
grout mix and methods of production will produce
grout which complies with the specified requirements.
(2) The trial mixes shall be completed at least 35 days

before the grout mix is used in the Permanent Works.
(3) The Contractor shall inform the Engineer 24 hours

before making trial mixes.
(4) Trial mixes shall be made using the materials, grout

mix and methods of production submitted to the
Engineer.
Samples: 12.16 (1) One sample of grout shall be provided from the trial
Trial Mixes for mix to determine the amount of bleeding and free
Grout expansion of the grout. The method of sampling shall
be as stated in Clause 12.56(2).
(2) One sample of grout shall be provided from the trial

mix to determine the crushing strength of the grout.
The method of sampling shall be as stated in
Clause 12.59(2).
(3) One sample of grout shall be provided from the trial

mix to determine the fluidity of the grout. The sample
shall be protected from rain before the tests for fluidity
are carried out.
Testing: Trial 12.17 (1) Each sample of grout taken as stated in Clause
Mixes for 12.16(1) shall be tested to determine the amount of
Grout bleeding and volume change. The method of testing
shall be as stated in Clause 12.57.
(2) Each sample of grout taken as stated in Clause

12.16(2) shall be tested to determine the crushing
strength. The method of testing shall be as stated in
Clause 12.60.
June 2022
12/7
(3) Each sample of grout taken as stated in Clause

12.16(3) shall be tested to determine the fluidity
immediately after mixing and 30 minutes after mixing.
The method of testing shall be as stated in Clauses
12.64.
Non-compliance: 12.18 (1) If the result of any test for amount of fluidity, bleeding,
Trial Mixes for free expansion or crushing strength of trial mixes for
Grout grout does not comply with the specified requirements
for the property, particulars of proposed changes to
the materials, grout mix or methods of production shall
be submitted to the Engineer; further trial mixes shall
be made until the result of every test complies with the
specified requirements for the property.
(2) If grouting trials are carried out using the

non-complying trial mix, further grouting trials shall be
carried out unless in the opinion of the Engineer the
changes to the materials, grout mix or methods of
production will not affect the results of the previous
grouting trials.
Grouting Trials 12.19 (1) Grouting trials for grout for prestressing systems shall
be carried out to demonstrate that the proposed
materials, grout mix, methods of production and
methods of construction will produce a grouted duct
which complies with the specified requirements. A
minimum of one grouting trial shall be carried out for
each different duct geometry, unless stated otherwise
in the Contract.
(2) Grouting trials shall be completed at least 21 days

before installation of the prestressing components in
the Permanent Works.
(3) The Contractor shall inform the Engineer 24 hours

before carrying out grouting trials.
(4) Grouting trials shall be carried out using the same

materials, grout mix, methods of production and
methods of construction as will be used in the
Permanent Works.
(5) The grouting trial shall incorporate all relevant details

of sheaths, vents, sheath supports, prestressing
anchorages, prestressing strands, grout inlets and
outlets as will be used in the actual prestressing
system. The tendons shall be sufficiently tensioned
such that the strands within the duct take up a
June 2022
12/8
representative alignment. The trial shall be of similar

length to the ducts in the Permanent Works.
(6) Grouting trials shall not form part of the Permanent

Works.
(7) Prestressing for Permanent Works shall not be

permitted until a satisfactory grouting trial has been
completed to the approval of the Engineer.
Testing: 12.20 Three sections of 300mm length shall be selected by the

Grouting Trials Engineer and shall be cut from the grouted duct and
inspected not less than 2 hours after the grout used in the
grouting trial has achieved its final set. The external
sheath from these sections shall be removed for inspection.
Compliance 12.21 The sections of grouted duct cut in grouting trials shall be
Criteria: completely filled and the prestressing tendon shall be
Grouting Trials completely surrounded with grout.
Non-compliance: 12.22 (1) If the result of any test on sections of grouted duct cut
Grouting Trials in grouting trials does not comply with the specified
requirements for the test, or if in the opinion of the
Engineer any aspect of the grouting procedure as
demonstrated by the grouting trial is unsatisfactory,
particulars of proposed changes to the materials, grout
mix, methods of production or methods of construction
shall be submitted to the Engineer for approval.
(2) Further grouting trials shall be carried out until the

result of every test on sections of grouted duct
complies with the specified requirements for the test
and until in the opinion of the Engineer every aspect of
the grouting procedure is satisfactory.
(3) Further trial mixes for grout shall be made unless in

the opinion of the Engineer non-compliance of the
grouting trial was not due to the grout mix.
Approved 12.23 A grout mix which complies with the specified requirements
Grout Mix for trial mixes for grout and for grouting trials shall become
an approved grout mix.
Commencement 12.24 Grouting shall not proceed until the grout mix has been
of Grouting approved by the Engineer.
Changes in 12.25 The materials, grout mix, methods of production or methods

Materials and of construction used to produce an approved grout mix shall
June 2022
12/9
Methods of not be changed.

Construction
Handling and Storage of Materials
Handling of 12.26 Prestressing tendons shall not be subjected to rough

Prestressing handling, shock loading or dropping.
Tendons
Handling of 12.27 Prestressing components shall be handled in accordance

Prestressing with the manufacturer's recommendations.
Components
Storage of 12.28 (1) Each prestressing tendon shall be tagged with a

Materials for number to identify the coil or bundle number of the
Prestressing prestressing tendon used.
Systems
(2) Prestressing tendons and sheaths shall be stored in a
dry and weatherproof store and in a manner which will
not result in damage to or deformation of the materials
or in contamination of the materials. Damaged or
deformed materials shall not be used in the
Permanent Works.
(3) Different types and sizes of prestressing tendons,

prestressing components and sheaths shall be stored
separately.
(4) Prestressing tendons, prestressing components and

sheaths shall not be stored on or adjacent to concrete
surfaces which form part of the Permanent Works.

sheaths shall be protected from exposure to conditions
which may affect the material.
Surface Condition of Materials for Prestressing

Systems
Surface Condition 12.29 (1) Prestressing tendons, prestressing components and

of Materials for sheaths shall be clean at the time of installation and
Prestressing shall be free from loose mill scale, discolouration due
Systems to visible rust, pitting, grease or any substance which
in the opinion of the Engineer is likely to reduce the
bond or affect the prestressing tendons, prestressing
components, sheaths, concrete or grout chemically;
the prestressing tendons, prestressing components
and sheaths shall be maintained in this condition until
concrete or grout is placed around them.
June 2022
12/10
(2) If the surface condition of the prestressing tendons,

prestressing components or sheaths deteriorates such
that it does not comply with the requirements stated in
Clause 12.29(1), the prestressing tendons,
prestressing components or sheaths shall be cleaned
or dealt with by other methods approved by the
Engineer.
Installation of Prestressing Systems
Installation of 12.30 (1) Prestressing operations shall be carried out in such a

Prestressing manner that persons and property are not endangered
Systems by any sudden release of the energy stored in a
stressed prestressing tendon.

sheaths shall be accurately located and maintained in
the correct position during all operations; supports
shall be placed at a maximum spacing of 600 mm.
Joints in adjacent sheaths shall be staggered by at
least 300 mm.
(3) All prestressing tendons shall incorporate a copper

electrical connection from one prestressing strand to a
terminal which will permit connection into the stray
current control system.
(4) All prestressing tendons and metallic prestressing

components shall be electrically isolated from adjacent
reinforcement.
(5) In order to demonstrate electrical isolation an electrical

isolation test shall be carried out after tendon stressing
and before and after tendon grouting. Isolation tests
shall be carried out using a 12V supply to demonstrate
resistance between tendons and reinforcement is
greater than 200 ohms. Testing shall be carried out
using a proprietary continuity meter approved by the
Engineer.
Installation of 12.31 (1) Prestressing tendons from each batch shall not be
Prestressing installed until testing of the batch has been completed.
Tendons
(2) Steel wires, wire strands and alloy steel bars which will
be tensioned in one operation shall be taken from the
same batch.
(3) Individual steel wires and wire strands in the same

June 2022
12/11
duct shall not be twisted together. Strands which

have become unravelled shall not be used.
(4) Alloy steel bars which have become bent shall not be
straightened. Small adjustments for straightness may
be made provided that the straightening is carried out
at the ambient temperature by non-mechanical
methods and provided that no force is applied on the
threaded portion. Bars which have become bent in
the threaded portion shall not be used.
(5) Prestressing tendons which have been damaged

mechanically or by work-hardening or heating shall not
be used. After manufacture, prestressing tendons
shall not be welded and heat treatment,
work-hardening, galvanizing and other metallic
coatings shall not be applied.
Cutting 12.32 Prestressing tendons shall be cut using either a high speed
Prestressing abrasive cutting wheel or a friction saw or by other methods
Tendons approved by the Engineer; flame cutting shall not be used.
Joints in 12.33 Joints in prestressing tendons shall be made using couplers

Prestressing fixed in accordance with the manufacturer's
Tendons recommendations.
Use of 12.34 Prestressing components shall be used in accordance with

Prestressing the manufacturers' recommendations.
Components
Installation of 12.35 (1) Grout vents and taps shall be provided at the following
Grout Vents and positions:
Taps
(a) all crests of the prestressing tendon profile and
400mm on each side of each crest;
(b) all low points of the prestressing tendon profile;
(c) all anchorages;
(d) intervals not exceeding 15 m;
(e) Beyond each intermediate crest in the direction

of grout flow at the point where the duct is one
half diameter lower than the crest (but not further
than 1 m), and elsewhere as required by the
Engineer.
(2) All grout vents at the crests of the prestressing tendon

June 2022
12/12
profile and 400mm on each side of each crest shall

extend to a minimum 500mm above the highest point
of the tendon profile.
(3) Grout vents shall be placed at positions where they will

not be blocked by the prestressing tendons after
tensioning.
Tensioning of Prestressing Tendons
Tensioning of 12.36 (1) Apparatus for tensioning of prestressing tendons shall

Prestressing be a type such that a controlled total force is imposed
Tendons gradually, such that excessive secondary stresses are
not induced in the prestressing tendons and
prestressing components or in the structure or element
to which prestress is being applied.
(2) Prestressing tendons shall be securely attached to

jacks and tensioning apparatus.
(3) Steel wires or wire strands which are tensioned

simultaneously shall be approximately the same length
between anchorage points.
(4) The force in the prestressing tendons during

tensioning shall be measured by direct reading load
cells or obtained indirectly from pressure gauges fitted
in the hydraulic system. Load measuring devices
shall be accurate to within 2%.
(5) The extension of prestressing tendons and any

movement of prestressing tendons in the gripping
devices shall be measured during tensioning. The
elongation of prestressing tendons shall be measured
to an accuracy of 2% or 2 mm, whichever is the more
accurate.
(6) Tensioning apparatus and load measuring devices

shall be calibrated before tensioning starts and at
regular intervals approved by the Engineer. Calibration
certificate shall be obtained from an approved testing
laboratory once every 6 months.
(7) The force in the prestressing tendons shall not be

transferred to the concrete until it has been proven to
the satisfaction of the Engineer that the concrete has
reached the specified transfer strength. The time for
transfer shall be determined by the successful testing
of a batch of minimum 3 test cubes. If the initial batch
June 2022
12/13
of cubes test indicates that the concrete has not

attained the required strength, a further batch of cubes
shall be tested at a later date. This process shall be
repeated until a batch of cubes successfully passes
the strength test.
(8) The capacity of pressure gauges, when used together

with the load cell as a load indicator, shall be sufficient
in capacity such that the working pressure lies within
the central half of the range of the gauge.
Pretensioning 12.37 (1) The stress in prestressing tendons shall be fully

maintained during the period between pretensioning
and transfer of stress. Transfer of stress shall take
place gradually to minimise shock or damage to the
transmission length and shall be carried out in
conjunction with the release of any hold-down and
hold-up forces in tendon deflectors.
(2) In the long-line method of pretensioning, locator plates

shall be distributed throughout the length of the bed to
ensure that the steel wires or wire strands are
maintained in the correct positions during concreting.
Units which are made in line shall be free to slide in
the direction of their length to permit transfer of the
prestressing force to the concrete along the whole line.
(3) Moulds used in the individual mould system of

pretensioning shall be sufficiently rigid to provide the
reaction to the prestressing force without distortion.
(4) Tendon deflectors in contact with pretensioned

prestressing tendons of single steel wire or wire strand
shall have a radius of at least 5 times the prestressing
tendon diameter for steel wire and at least 10 times
the prestressing tendon diameter for wire strand. The
total angle of deflection shall not exceed 15. If a
system is used such that friction develops between
prestressing tendons and tendon deflectors, the
friction force shall be determined by a test procedure
approved by the Engineer and any necessary
allowance shall be made.
(5) The tendons shall be covered with sleeves of PVC or

other approved material where these materials are
specified as debonded from the concrete. Tape ends
of the sleeves to the tendon shall prevent the ingress
of grout.
June 2022
12/14
(6) When the temperature of the pretensioning steel is

below 10oC at the time of tensioning, steel elongation
computations shall allow for the increase in
temperature of the steel between the time of
tensioning and the time when the concrete takes its
initial set.
(7) The tendons shall be trimmed to flush with the face of

the concrete and apply the specified protection to their
ends.
(8) The precast prestressed members shall be indelibly

marked to show the specific information related to its
manufacturer.
Post-tensioning 12.38 (1) A tensioning schedule shall be submitted to the

Engineer for approval at least 48 hours before each
post-tensioning operation starts. The schedule shall
include the proposed sequence of tensioning the
prestressing tendons, the required prestressing loads
and the calculated extensions of the prestressing
tendons.
(2) Spacers used with post-tensioned steel wire or wire

strand which are not tensioned simultaneously shall be
sufficiently rigid to ensure that they will not be
displaced during successive tensioning operations.
(3) If both ends of the prestressing tendon are free to

move, a demonstration shall be carried out before
post-tensioning starts to show that all prestressing
tendons are free to move in the ducts.
(4) Post-tensioning shall be carried out in such a manner

that the stress in the prestressing tendons increases at
a gradual and steady rate. The sequence of
tensioning prestressing tendons and the ends of
prestressing tendons from which prestress will be
applied shall be as stated in the Contract or as
(5) For each element of a structure being stressed,

post-tensioning of the prestressing tendons shall be
carried out until the required prestress to that element
has been reached. Tensioning of each prestressing
tendon shall be carried out continuously until the
required tendon loads or extensions have been
reached. If tensioning is stopped for more than
2 days, particulars of any proposals for remedial or
June 2022
12/15
other work shall be submitted to the Engineer for

Approval and tensioning shall not recommence until
the approved work has been carried out.
(6) Measurement of extensions shall not commence until

any slack in the prestressing tendon has been taken
up. If the design permits, the draw-in of prestressing
tendons at the non-jacking end shall also be
measured. The tensioning shall be applied in
increments of load and the extensions shall be
measured at each increment. The average
measured total extension of the prestressing tendons
in each post-tensioning stage shall be within 5% of the
average calculated total extension of the
corresponding post-tensioning stage and the
measured total extension of individual prestressing
tendons in each post-tensioning stage shall be within
10% of the calculated total extension of individual
prestressing tendons of the corresponding
post-tensioning stage.
(7) If the tendon deflector in contact with a post-tensioned

prestressing tendon has a radius of less than 50 times
the diameter of the prestressing tendon or if the total
angle of deflection exceeds 15, the loss of strength of
the prestressing tendon shall be determined by a test
procedure approved by the Engineer and any
necessary allowance shall be made.
(8) Post-tensioned prestressing tendons shall be cut at a

distance from the anchorage of at least one diameter
or 10mm, whichever is the greater. Unless otherwise
permitted by the Engineer the tendons shall not be cut
until at least one day after stressing, if the tendon is to
be cut before grouting, or alternatively, at least 3 days
after grouting.
Protection of 12.39 External prestressing tendons and anchorages shall be

External protected in their permanent positions from mechanical
Prestressing damage or corrosion until the permanent protection is
Tendons and applied.
Anchorages
Records of 12.40 Records of tensioning operations shall be kept by the

Tensioning Contractor on the Site and a report shall be submitted to the
Operations Engineer within 24 hours of each tensioning operation.
The report shall contain the following details:
(1) location of tensioning operations;

June 2022
12/16
(2) coil, heat and bundle numbers of strand used;
(3) date and time of starting and completing tensioning

operations;
(4) weather conditions;
(5) technical personnel supervising or carrying out

tensioning operations;
(6) prestressing tendon reference numbers;
(7) tensioning apparatus identification;
(8) measured extensions;
(9) pressure gauge or load cell readings;
(10) amount of draw-in;
(11) load/extension graphs for each tendon as they are

being stressed.
Inspection of Prestressing Systems
Inspection of 12.41 The Contractor shall allow the Engineer to inspect the
Prestressing completed prestressing system before carrying out any
Systems work, including concreting and grouting, which will make
access to the prestressing system difficult. The Contractor
shall inform the Engineer 24 hours, or such shorter period
approved by the Engineer, before carrying out such work.
Grouting of Prestressing Systems
Grouting 12.42 (1) Grout for prestressing systems shall be mixed by a

Equipment machine capable of producing a homogeneous
colloidal grout and of keeping the grout in slow
continuous agitation after mixing and until the grouting
operation starts.
(2) Grouting equipment shall be capable of continuous

operation with little variation of pressure and shall
include a system of recirculating the grout when
grouting is not in progress.
(3) Grout pumps shall be fitted with a safety valve to

prevent pressures above 2N/mm² at any point within
the grouting system including the sheaths. All piping
June 2022
12/17
to the grout pump shall have a minimum number of

bends, valves and changes in diameter. The
connection of the pump to the sheath shall be by a
screw connector or other positive method. Baffles to
the pump shall be fitted with 1.18mm sieve strainers.
Suction circuits shall be airtight.
(4) Grouting equipment shall be thoroughly washed

through with clean water after every series of grouting
operations and at the end of use each day.
(5) Not used.
Grouting 12.43 Grouting of prestressing tendons shall be effective such that

Effectiveness the duct is completely filled, and the prestressing tendon is
completely surrounded, with grout.
Grout Injection 12.44 (1) The permission of the Engineer shall be obtained
before prestressing tendons are grouted. If grouting
is not started within 24 hours of permission having
been given, permission shall again be obtained from
the Engineer.
(2) Grouting of the prestressing tendons shall be carried

out as soon as practicable, and not more than 5 days
after tensioning of the tendons.
(3) Immediately before grouting starts, the ducts shall be

thoroughly washed by pumping clean water through
the ducts. The water shall flow through all grout
vents. Partial or complete blockage of grout vents
shall be cleared before grouting starts. After washing,
the ducts shall be blown dry with oil-free compressed
air. As soon as the drying is complete each duct,
vent, inlet and outlet shall be checked to ensure that
they are capable of accepting the injection of grout by
blowing the compressed air through the system.
Each vent shall be checked in turn.
(4) Grout shall be used within 30 minutes of mixing unless

a retarder is incorporated in the grout. If a retarder is
used, the time shall be determined by a test procedure
(5) Grouting shall be undertaken by vacuum assistance.

Prior to grout injection a vacuum pump shall be
connected to the higher end of the duct to be grouted.
The grout injection shall be from the lower ends of
ducts. With all vents closed the vacuum pump shall
June 2022
12/18
be activated and run for not less than 10 minutes prior

to grout injection. A negative pressure of 750 millibar
shall be maintained throughout the grouting. While
maintaining the vacuum, the grout shall be pumped in
to the lower end of the duct. The grout pressure
applied shall be as low as practicable and shall not
exceed 1 MPa. Grout injection shall be continuous
and steady and shall be at a rate which will avoid grout
segregation and the trapping of air in the duct. The
vacuum shall be maintained until grout is observed at
the higher end of the duct. Grouting shall be
maintained until grout of an equivalent consistency to
the grout injected is observed flowing out of the higher
end of the duct. After closing the higher end, grout
shall be allowed to flow from each of the grout vents
until its consistency is equivalent to that of the grout
injected. Following this, a further 5 litres at each vent
shall be vented into a clean receptacle.
Representative samples as indicated by the Engineer
shall be tested in accordance with Clause 12.56 and
discarded. All vents shall be closed one after another
in the direction of flow except that at intermediate
crests the vents 400mm downstream shall be closed
before their associated crest vent. After the last grout
vent has been closed, the pressure shall be
maintained at 0.5 MPa for 5 minutes. The injection
vent shall then be closed under pressure. 10 minutes
after the injection vent is closed the vents at all crests
in the duct profiles shall be reopened and any escape
of air, water or grout shall be recorded and
immediately reported to the Engineer to agree any
further action which may be necessary.
(6) If there is any blockage or breakdown or if the grout

injection is interrupted, the duct shall immediately be
thoroughly washed with clean water and blown dry
with oil-free compressed air; regrouting shall start as
soon as practicable.
(7) Grouted ducts shall not be subjected to shock or

vibration within 24 hours of grouting.
(8) The level of grout in grout vents shall be inspected and

made good as approved by the Engineer. Making
good shall not be carried out until at least 2 days after
grouting.
Records of 12.45 Records of grouting operations for prestressing systems

Grouting shall be kept by the Contractor on the Site and a report shall
June 2022
12/19
Operations be submitted to the Engineer within 3 days of each grouting

operation. The report shall contain the following details:
(1) location of grouting operations;
(2) date and time of starting and completing grouting

operations;
(3) weather conditions;
(4) technical personnel supervising or carrying out

grouting operations;
(6) grout mix, including any admixtures;
(7) grout injection pressure;
(8) volume of grout used;
(9) details of any interruptions and topping up.
Tolerances
Tolerances: 12.46 The line of sheaths shall be within 5 mm of the specified

Sheaths line.
Testing : Prestressed Units / Prestressing Tendons
Batch: 12.47 (1) Testing of prestressed units shall comply with Clauses
Prestressed Units 11.124 to 11.126, Section 11 Part 4 of this
& Prestressing Specification.
Tendons
(2) A batch of prestressing tendons is any quantity of
prestressing tendons of the same type, size and
grade, manufactured by the same manufacturer,
covered by the same certificates and delivered to the
Site at any one time.
Samples: 12.48 (1) Samples of prestressing tendons shall be provided

Prestressing from each batch of prestressing tendons delivered to
Tendons the Site and at least 28 days before installation of the
prestressing tendons starts. The number of samples
to be provided from each batch shall be as stated in
Table 12.1.
(2) The number of specimens in each sample shall be 15.
June 2022
12/20
(3) Each specimen shall be 1.5 metre long and straight.
(4) Each specimen shall be taken from different coils or

bars in the batch. The ends of specimens shall be
cut square without unravelling of wires and loose mill
scale and loose rust shall be removed by wire
brushing before delivery to the laboratory.
prob
Table 12.1 : Rate of sampling prestressing tendons
Description Size of batch No. of samples per batch
0 - 50 tonnes 1
steel wire exceeding 50 tonnes 1 for each 50 tonnes
or part thereof
0 - 100 tonnes 1
Wire strand and
alloy steel bar exceeding 100 tonnes 1 for each 100 tonnes
or part thereof
Testing: 12.49 (1) Each specimen of prestressing tendon shall be tested

Prestressing to determine the characteristic breaking load,
Tendons characteristic 0.1% proof load, elongation at maximum
load, diameter, cross-sectional area, unit mass and
modulus of elasticity. Each specimen of prestressing
wire shall also be tested to determine the ductility.
(2) Except that tests shall be carried out on specimens

having a temperature of between 5C and 30C, the
method of testing shall be in accordance with the
following:
High tensile steel wire

and strand for the
prestressing
of concrete : BS 5896
Hot rolled and hot rolled

and processed high
tensile alloy steel
bars for the
prestressing of
concrete : BS 4486
(3) Not used.

June 2022
12/21
Compliance 12.50 (1) The standard deviations of the results of tests for
Criteria: characteristic breaking load and characteristic 0.1%
Characteristic proof load, expressed as equivalent stress values, of
Breaking Load, prestressing tendons shall not exceed the following:-
Characteristic 0.1%
Proof Load –tensile strength : 55 MPa
–0.1% proof stress : 60 MPa
(2) The statistical interpretation of the steel results shall

be in accordance with BS ISO 16269-6, Form A of
Annex B and BS 2846: Part 4, Table E, both for a
one-sided tolerance interval of 0.95 and for a
confidence level of 0.95.
Non-compliance: 12.51 (1) If the result of any test for elongation at maximum
Elongation, load, diameter, cross-sectional area, unit mass,
Diameter, modulus of elasticity or ductility of prestressing
Cross-sectional tendons does not comply with the specified
Area, Unit Mass, requirements for the property, one additional sample
Modulus of shall be provided from the same batch and additional
Elasticity, Ductility tests for the property shall be carried out.
(2) The number of specimens in the additional sample

shall be 15.
(3) The batch shall be considered as not complying with

the specified requirements for the property if the result
of any additional test does not comply with the
specified requirements for the property.
Testing : Duct Friction
Testing: Duct 12.52 (1) The number and details of tests to determine the duct
Friction friction in prestressing systems shall be as stated in
the Contract. The method of testing shall be as
stated in Clause 12.52 (2) to (4).
(2) Prestressing tendons shall be tensioned from one end

and the tendon force shall be measured at both the
jacking and non-jacking ends.
(3) The tendon force at the non-jacking end shall be

measured by direct-reading load cells or by a dummy
jack of a type approved by the Engineer. The load
measuring device shall be sufficiently rigid to ensure
that the movement of the prestressing tendon at the
non-jacking end under the specified tendon force is not
June 2022
12/22
excessive. The load measuring device shall be

readable and accurate to 0.5mm. Load measuring
devices with a deflection under the maximum load
exceeding 10mm shall not be used.
(4) The prestressing tendon shall be tensioned to the

specified tendon force in equal increments and the
tendon extensions at the jacking end and the tendon
force and tendon movement at the non-jacking end
shall be measured to within 5 mm. The number of
load increments shall be suited to the tensioning
operation but shall be at least 5.
Compliance 12.53 The force at the non-jacking end of the prestressing tendon
Criteria: determined in the duct friction test shall be within
Duct Friction +10% and -5% of the calculated value.
Records of Duct 12.54 Reports of duct friction tests shall be submitted to the
Friction Tests Engineer within 3 days of each test. The report shall
contain the following details:
(1) details stated in Clauses 12.11(1) and 12.12(1);
(3) graph showing tendon forces at jacking end against

tendon forces at non-jacking end;
(4) comparison between the calculated tendon forces at

the non-jacking end and the measured values.
Testing : Grout - General Requirements
Batch: Grout for 12.55 A batch of grout for prestressing systems is any quantity of
Prestressing grout produced in one cycle of operations of a mixer.
Systems
Testing : Grout - Bleeding and Free Expansion
Samples: 12.56 (1) For each grout mix one sample of grout shall be
Bleeding and provided from each 25 batches of grout, or from the
Volume Change of amount of grout produced in one day, whichever is the
Grout lesser, to determine the amount of bleeding and
volume change of the grout.
(2) Samples shall be provided and testing immediately

after the grout has been mixed. Samples shall be
protected from rain before the tests for amount of
bleeding and volume change are carried out.
June 2022
12/23
Testing: 12.57 (1) Each sample of grout taken as stated in Clause 12.56
Bleeding and shall be divided into 3 specimens; each specimen shall
Volume Change of be tested to determine the amount of bleeding and
Grout volume change.
(2) The amount of bleeding and volume change of the

grout shall be determined by the wick-induced method
in accordance with BS EN 445.
Non-compliance: 12.58 If the result of any test for amount of bleeding or volume
Bleeding and change of grout for prestressing systems does not comply
Volume Change of with the specified requirements for the property, particulars
Grout of proposed changes to the materials, grout mix or methods
of production shall be submitted to the Engineer; further trial
mixes shall be made and further grouting trials shall be
carried out.
Testing : Grout - Crushing Strength
Samples: 12.59 (1) For each grout mix one sample of grout shall be
Crushing Strength provided from each 25 batches of grout, or from the
of Grout amount of grout produced in a day, whichever is the
lesser, to determine the crushing strength of the grout.
(2) Samples shall be provided not more than one hour

after the grout has been mixed and shall be protected
from rain before test cubes are made.
Testing: 12.60 (1) Two 100 mm test cubes shall be made from each
Crushing Strength sample of grout taken as stated in Clause 12.59.
of Grout Each test cube shall be tested to determine the
crushing strength at 7 days.
(2) The method of making, curing and testing the test

cubes, and the calculation of the test results, shall be
as stated in Section 11, except that compaction of the
grout is not required.
Non-compliance: 12.61 If the result of any test for crushing strength of grout for
Crushing Strength prestressing systems does not comply with the specified
of Grout requirements for crushing strength, particulars of
proposed changes to the materials, grout mix or methods
of production shall be submitted to the Engineer; further
trial mixes shall be made and further grouting trials shall
be carried out.
Supervision
June 2022
12/24
Supervision of 12.62 All prestressing and grouting operations are to be carried

Prestressing out under the supervision of a named person with
Operations appropriate knowledge, training and experience in carrying
out similar operations. That named person shall be
present during all procedures and shall be responsible for
all safety precautions relating to the operations. The
appointment of the named person shall be subject to the
Testing: Grout – Fluidity
Samples: fluidity of 12.63 (1) For each grout mix one sample of grout shall be
grout provided from each 25 batches of grout, or from the
amount of grout produced in a day, whichever is the
lesser, to determine the fluidity of the grout.
(2) Samples shall be provided and tested immediately

after the grout has been mixed. Samples shall be
protected from rain before the tests for fluidity are
carried out.
Testing: fluidity of 12.64 Each sample of grout taken as stated in Clause 12.63
grout shall be tested to determine the fluidity of the grout by the
cone method in accordance with BS EN 445
Non-compliance: 12.65 If the result of any test for fluidity of grout for prestressing
fluidity of grout systems does not comply with the specified requirements
for the property, particulars of proposed changes to the
materials, grout mix or methods of production shall be
submitted to the Engineer. Further trial mixes shall be
made and further grouting trials shall be carried out unless
otherwise permitted by the Engineer.
June 2022
12/25
SECTION 14
WATERPROOFING
General
Preamble 14.1 (1) In all cases where waterproofing is required the

Contractor shall submit a method statement for the
approval of the Engineer at least 4 weeks before the
work commences. The method statement shall
include full material and workmanship details and
samples of the materials to be employed.
(2) The Contractor shall carry out trials, on a minimum

area of 10m², to demonstrate that the materials and
proposed methods of working comply with the
specified requirements.
(3) The trials shall be carried out on areas with an

equivalent surface finish and geometry.
(4) No material shall be used which is beyond its

manufacturer's expiry date.
(5) All waterproofing materials are to be stored in a cool

place.
(6) Materials which are subsequently exposed to sunlight

shall not be affected by atmospheric conditions or ultra
violet light.
(7) All materials shall be suitably resistant to all chemicals

with which they are likely to come into contact.
(8) The approved materials and the approved method

statement shall not be varied without the written
Approval of the Engineer.
(9) All waterproofing membranes shall be applied in

Application of waterproofing systems shall be by a
sub-Contractor chosen from the manufacturer’s list of
approved applicators.
(10) A liquid polymer waterproofing system will be

acceptable only if the Contractor can demonstrate to
the satisfaction of the Engineer that the transportation,
June 2022
14/1
storage and application of the materials will not cause

an environmental hazard to either the workers or the
general public.
(11) Wherever possible, self-healing waterproofing systems

shall be applied.
Waterproofing of 14.2 (1) All underground structural elements in contact with the
Structures ground in their final conditions shall be waterproofed
with a 2 coat, high quality, spray applied, liquid,
polymer, jointless system, unless otherwise stated in
the Contract. The waterproofing system shall be
applied directly to the reinforced concrete element
before the laying of any screed or other protective
surfacing. Base slabs shall be waterproofed with a
keyed preformed membrane.
(2) Warranty period of not less than 15 years shall be

provided for the waterproofing system. The warranty
certificate shall refer to Clause 14.29 of this Section.
Preparation of 14.3 (1) Defects in the concrete surface shall be repaired in

Surfaces accordance with Section 11, Part 7. All surfaces shall
be free from loose particles, dirt, oil, laitance, bentonite
and curing membrane unless specifically agreed with
the waterproofing manufacturer.
(2) All surfaces shall be fully cured and prepared in

Where appropriate, all the solvent constituent of
primers must be allowed to evaporate before placing
of subsequent elements.
Traffic 14.4 No vehicle or items of plant shall be permitted to travel on

any membrane or coating unless approved by the Engineer.
Membrane Under 14.5 Membranes under base slabs shall be laid directly on top of
Base Slabs a 75mm thick blinding layer finished to a U3 standard. The
joints of the membrane shall be sealed in accordance with
Membrane: 14.6 Where non self-healing membrane systems are specified in

Protection the Contract:
- on roofs membranes shall be protected by a minimum

of 75mm thick concrete screed as described for base
slabs;
- on walls membranes shall be protected by 75mm

June 2022
14/2
minimum blockwork unless otherwise recommended

by the manufacturer.
Waterstops 14.7 Except in structural elements that are wholly internal,

waterstops shall be inserted in all external below ground
and water excluding/retaining concrete joints irrespective of
the provision of any waterproof membrane, in accordance
with the manufacturer's recommendations and Section 8.
Non Hydrophilic Membranes
Membranes 14.8 Waterproof membranes shall be as BS 8102, sections 8, 9

and 10. All edges shall be sealed in accordance with the
manufacturer's recommendation at the end of each working
day and all penetrations must be properly treated in
accordance with the manufacturer's recommendation.
Membranes shall be fully bonded to the surface of the
underlay/overlay materials before any loads are allowed to
be imposed on the structure.
Liquid Polymer 14.9 (1) Liquid polymer membranes shall be a spray applied,
Membrane fast cure, 2 part, proprietary, waterproofing system.
(2) The liquid polymer membrane shall be not less than

2mm thick and sprayed in a minimum of two coats.
(3) The cured, liquid, polymer membrane shall be

chemically resistant, particularly to the effects of
seawater, hydraulic fluids, diesel fuel and diluted
mineral acids.
(4) The liquid polymer membrane shall be suitable for use

in an ambient temperature range of 0oC to 40oC.
(5) The polymer membrane shall allow the diffusion of

water vapour to prevent build up of pressure between
the membrane and substrate. It shall be resistant to
puncture after application.
(6) The specified properties of the polymer membrane

shall be maintained for a period of not less than 15
years.
(7) The tensile strength in any of the three orthogonal

planes of the waterproofing membrane shall be not
less than 4MPa, when tested in accordance with a
recognised international standard approved by the
Engineer.
June 2022
14/3
(8) Bond to concrete substrate shall not be less than 1

MPa when using the pull off test method in
accordance with BS EN ISO 4624 or BS EN 1542.
(9) Adhesion between coats shall be not less than 2MPa.
(10) The cured liquid waterproofing membrane of specified

membrane thickness shall have an elongation at break
of not less than 300% and capable of bridging a 2mm
gap without diminishment of resistance to water
permeation when tested in accordance with BS EN
1062-7.
(11) Spray applied polymer membrane shall achieve a

Shore A Hardness of >70 on curing.
Liquid Polymer 14.10 (1) The membrane thickness shall be checked every
Membrane: 10m2 during spraying using a gauge pin or standard
Installation comb type thickness gauge, making allowance for
membrane reduction during curing. In addition the
weight of materials used shall be monitored against
area covered. Destructive testing, to measure Dry
Film Thickness, shall be carried out on the cured
membrane at every 100m² or at every working shift
which ever occurs sooner.
(2) Holiday Tests shall be carried out on the cured

membrane to prove the integrity of the membrane.
(3) Backfill or protection block work to the membrane shall

not be placed until the membrane has cured.
(4) Damaged or non-compliant sections of membrane

shall be repaired in accordance with manufacturer's
recommendations and as approved by the Engineer.
Keyed Preformed 14.11 Keyed preformed membranes (KPM) shall be equipped with
Membrane: 'T-Grip' continuous key, homogeneously welded on to a
General preformed sheet membrane at regular intervals not
exceeding 75mm centres, to form an integral bond when
cast into concrete.
Keyed Preformed 14.12 (1) Keyed membrane shall be manufactured from a

Membrane: polymer, shall be chemical resistant and shall have the
Material minimum specified mechanical and physical properties
as stated in Table 14.1.
(2) Keyed membrane sheets shall be manufactured free

from pin-holes, cracks or other defects which may
June 2022
14/4
affect the quality and durability of the membrane.

Defective sheets shall be replaced or repaired in
(3) The thickness of the keyed membrane shall be not

less than 2mm.
(4) All joints between sheet panels shall be continuously

extrusion welded. The resulting strength of the joint
shall be at least equal to the strength of the parent
material. All keys at joints shall be aligned and all
joints shall be tested non-destructively using a spark
testing device at a voltage of approximately 20,000
volts. Weld seams shall have a width of not less than
30mm.
Keyed Preformed 14.13 Where the keyed membrane is to be used under a slab, the
Membrane: membrane shall be placed on blinding which has an U3
Installation finish. The liner sheets shall not be nailed on to the form.
Table 14.1: Keyed Preformed Membrane Sheet Physical

Properties (Tested at Temperature of 25C)
Property Test Method Unit Value

Density BS EN ISO g/cm² > 0.90
1183
Tensile Strength BS EN ISO N/mm² > 20
527
Elongation at Tensile BS EN ISO % 75 - 500
Strength 527
Pull-out Strength of - N/cm 100

Keys
Preformed 14.14 (1) Preformed Polymer Membrane (PPM) shall consist of

Polymer heat welded sheets of soft polyvinylchloride (PPVC)
Membrane:
Material PPM shall have the following specified mechanical and
physical properties specified in Table 14.2 in both the
longitudinal and transverse directions when tested in
accordance with the appropriate standards as stated in
Table 14.2.
(2) Where reinforced concrete and/or embedded

steelwork is to be placed against the waterproofing
June 2022
14/5
membrane a signalling layer, to give a visual indication

of any mechanical damage, shall be provided on the
exposed surface of the waterproofing membrane.
The signalling layer shall be such that it does not
adversely affect the seam welds.
(3) Evidence shall be obtained from the manufacturer that

no components of a PPM leach out in the long term
such that the durability of any of the following
components is adversely affected:
(a) the waterproofing membrane;
(b) the geotextile drainage/protective layer;
(c) other plastic materials or PVC materials such as

waterstops.
(4) PPM shall be self extinguishing. The Contractor shall

submit details of the membrane combustibility and
smoke emission class to the Engineer for approval.
(5) Other types of bonded sheet waterproof membrane

may be used subject to Approval by the Engineer. The
membrane shall consist of one of the following
materials:
- flexible polyolefin (FPO/TPO) unreinforced;

- high-density polyethylene (HDPE) in accordance
with DIN 16776 Parts 1 and 2;
- ethylene copolymerical bitumen (ECB);
The membrane shall conform to the performance

requirements as stated in Table 14.3.
June 2022
14/6
Table 14.2: PPM Material Mechanical and Physical Properties
Property Minimum Requirement Test Standard

Thickness 2mm ± 10% BS EN 1849-2
Tensile strength > 16 MPa BS EN 12311-2
Elongation at break > 300% BS EN 12311-2
State during and following BS EN 1107-2

storage at 80C:
BS EN 1107-2
• General No blister inclusion
• Change in dimension < 3% BS EN 12311-2
• Change in tensile strength < ± 10%
• Change in elongation < ± 10% BS EN 12311-2
Behaviour when subjected to No leaking at 10 bar BS EN 1928

hydrostatic pressure Method B
Puncture resistance No perforation for BS EN 12691 /

750mm drop of test tool EN ISO 12236
Behaviour after storage in BS EN 1847 /

aqueous solution: BS EN 14414
• Change in tensile < ± 10% BS EN 12311-2
• Cold bend behaviour No cracking BS EN 495-5
Fire Rating Self-extinguishing BS EN ISO
11925-2
Smoke Class Class E BS EN ISO
11925
June 2022
14/7
Table 14.3: Performance Requirements of Other Types of Sheet

Waterproof Membrane
Property Minimum Requirement Test Standard

Thickness 2mm ± 10% BS EN 1849-2
Tensile strength > 16 MPa BS EN 12311-2
Elongation at break > 300% BS EN 12311-2

Bond to substrate > 0.5 MPa BS EN 1542
Behaviour when subjected to No leaking at 10 bar BS EN 1928

hydrostatic pressure Method B
Puncture resistance No perforation for BS EN 12691 /

750mm drop of test tool EN ISO 12236
Behaviour after storage in BS EN 1847 /

aqueous solution: BS EN 14414
• Change in tensile < ± 10% BS EN 12311-2
• Cold bend behaviour No cracking BS EN 495-5
Fire Rating Self-extinguishing BS EN ISO
11925-2
Smoke Class Class E BS EN ISO
11925
PPM: Fixing of 14.15 (1) The waterproofing membrane shall be installed closely
Membrane to a against the geotextile drainage (if appropriate) and
Rock Surface protective layer.
(2) The membrane sheets shall be fixed at all the nailing

discs around the nails by spot heat welding, or by
bitumen adhesive in the case of ECB sheets.
Alternative methods of fixing the waterproofing
membrane may be used subject to approval by the
Engineer.
(3) Nails, welding tools or any other object shall not

penetrate the membrane except in accordance with
approved fixing details.
(4) Welding of the membrane sheet edges shall be carried

out by experienced personnel and with purpose made
June 2022
14/8
equipment to form a flat double weld seam. Each

weld shall be at least 6mm wide and the space
between the two welds shall not exceed 20mm.
Repairs and T-joints may have solid weld up to 30mm
wide, and shall be as recommended by the
manufacturer.
(5) Upright double seams shall not be used.
(6) The connections between the nailing discs and the

membrane shall be weaker than the membrane itself.
(7) The membrane at the ends of each waterproofed

section shall be sealed against the surface as stated in
the Contract to prevent ingress of concrete or grout
between the membrane and the surface.
(8) The method of fixing the membrane to a base slab

shall be such as to preclude the ingress of grout during
concreting and any backgrouting operations. Fixing
methods shall be as stated in the Contract.
(9) The installation of the waterproofing membrane shall

be carried out only when the atmospheric temperature
in the area of installation is higher than 5C and in
PPM Testing 14.16 (1) All completed double seam welds shall be tested by
the application of air pressure to the space between
the two seams. The test pressure shall be applied in
the presence of the Engineer at one end of the seams
and measured at the other end to test the integrity of
the whole joint. The Contractor shall give at least 24
hours notice to the Engineer of his intention to
undertake seam testing.
(2) The test pressure shall be not less than 2 bar and
reduction of pressure after 10 minutes shall not
exceed 20%.
(3) Vacuum testing to 0.2 bar shall be carried out on solid

welds with no loss of vacuum.
(4) Testing pressures and results shall be marked on the

membrane.
(5) Any areas failing to achieve the specified requirements

shall be repaired in accordance with the
manufacturer's recommendations or replaced. Any
June 2022
14/9
areas which have been repaired shall be recorded and

details submitted to the Engineer.
PPM: Protection 14.17 (1) The membrane shall be protected carefully until
concrete is placed against it.
(2) Any reinforcement in the area where the waterproofing

membrane is used shall be provided with plastic caps
over cut ends and PVC tubing shall be used as
spacers. These spacers shall be of sufficient
diameter and of sufficiently short length that they will
be filled with concrete.
(3) Any burning, drilling or welding of steel within the

tunnel shall only be carried out where the membrane
has been protected as approved by the Engineer.
(4) Water percolating outside the membrane shall be led

away so that formation of water-filled blisters is
avoided. Pipes for disposal of water shall be "lay-flat"
type as shown on the drawings suitable for
subsequent grouting once the final concrete is placed.
(5) Strips of membrane at least 0.5 m wide shall be spot

welded to the waterproofing membrane at the
formwork stop ends to protect the installed membrane
from being damaged.
(6) The Contractor shall supply and maintain such

additional fire fighting equipment in the tunnel as may
be deemed necessary by the Engineer for the whole
period that membrane material is exposed in the
tunnel.
Polymer Modified 14.18 The PMCC shall consist of a polymer modified thixotropic
Cementitious cementitious coating of a type approved by the Engineer.
Coating (PMCC): The material shall meet or exceed the following technical
Material requirements:
(1) minimum 28 day compressive strength of 30 MPa;
(2) minimum 28 day flexural strength of 10 MPa;
(3) minimum adhesive strength to sound concrete of

2MPa;
(4) water permeability coefficient of 6x10-16 m/sec;
(5) oxygen diffusion coefficient of 5x10-5 cm²/sec.

June 2022
14/10
PMCC: 14.19 (1) The surface to be waterproofed shall be free from

Application loose particles, dirt, oil, laitance, bentonite and curing
Requirements membrane, and shall be prepared in accordance with
(2) The prepared substrate shall be pre-wetted until fully

saturated (without standing water) with potable water
for a minimum of 12 hours before applying the PMCC.
(3) The PMCC shall be mixed and applied strictly in

Two coats of similar thickness shall be applied to
provide a minimum overall thickness of 2mm at every
location. The second coat shall be applied in a timely
manner to ensure proper bond to the first coat.
(4) The PMCC shall be properly and fully cured in order to

ensure a dense, crack-free waterproof coating is
achieved.
(5) In all cases the PMCC shall be returned not less than
100mm up the sides of the adjacent vertical or inclined
concrete surfaces, such as at parapet stitches,
trackslabs and track plinths.
(6) Where applicable the PMCC shall be applied after

track laying in that vicinity has been completed to
minimise the risk of mechanical damage to the PMCC.
PMCC: Quality 14.20 (1) The thickness of the PMCC as laid shall be verified at
Control a minimum frequency of 1 measurement per 200m2 of
laid PMCC or 1 measurement per shift that the
material is laid, whichever is greater. The locations
for samples and method of verification shall be
approved by the Engineer. The Contractor shall
restore the integrity of the PMCC membrane at each
measurement point to the approval of the Engineer.
(2) The 28 day compressive strength of the PMCC shall

be verified using three 40mm grout cubes prepared on
each day that material is mixed and used. Cubes
shall be stored, delivered to the laboratory and
crushed in accordance with Section 11.
(3) Areas of PMCC membrane that exhibit signs of

cracking due to improper curing, non compliance with
the manufacturer's application instructions or any other
reason shall be replaced or repaired in accordance
June 2022
14/11
with the manufacturer's recommendations and to the

satisfaction of the Engineer. Areas where inadequate
bond is present shall be treated in the same way.
Reactive 14.21 (1) RCC shall be a proprietary product and shall be

Cementitious cementitious waterproofing materials consisting of
Coating (RCC): cement, quartzite sands of optional grain size, and
General multiple activating chemicals.
(2) The activating chemicals contained in RCC shall be

able to penetrate the capillary system of the concrete
and seal the capillaries and spaces to prevent water
penetration. The chemical complexes shall lie
dormant in the absence of moisture or water but
reactivate whenever re-exposed to moisture or water.
RCC: 14.22 (1) RCC shall be non-toxic and shall not have any
Requirements detrimental effect on the properties of either concrete
or reinforcement. The material shall be suitable for
application to internal faces of diaphragm walls and
similar elements.
(2) RCC shall have the following properties :
(a) minimum water pressure resistance of 1.5 MPa;
(b) reduces the chloride ion penetration rate into

concrete;
(c) resists sulphate attack;
(d) achieves in-depth waterproofing effect in

concrete.
RCC: Application 14.23 (1) The surface to be waterproofed shall be free from
Requirements loose particles, dirt, oil, laitance, bentonite and curing
membrane, and shall be prepared in accordance with
(2) The prepared substrate shall be pre-wetted with

potable water until fully saturated (without standing
water) for a minimum of 12 hours before applying the
RCC.
(3) The RCC shall be mixed and applied strictly in

Two coats of similar thickness shall be applied to
provide a minimum overall thickness of 2mm at every
location. The second coat shall be applied in a timely
June 2022
14/12
manner to ensure proper bond to the first coat.
(4) The waterproofing shall be moisture cured for at least

three days.
RCC: Quality 14.24 The thickness of the RCC as laid shall be verified at a
Control minimum frequency of 1 measurement per 100m2 of laid
RCC or 1 measurement per shift that the material is laid,
whichever is greater. The locations for samples and
method of verification shall be approved by the Engineer.
The Contractor shall restore the integrity of the RCC
membrane at each measurement point to the approval of
the Engineer.
RCC: Traffic 14.25 During the curing period the treated area shall not be
subject to construction traffic load or abrasive loadings.
Once fully cured, the waterproofing material shall have
similar properties as the concrete substrate.
Bitumen 14.26 Bitumen shall comply with BS EN 12591 of viscosity grade

within the range of 25 - 50 seconds and with a coverage of
at least 0.5 l/m2. Primers shall be a proprietary type
recommended by the bitumen manufacturer and approved
by the Engineer.
Mastic Asphalt 14.27 Mastic Asphalts shall comply with BS EN 12970.

Proposed methods of placement shall be in accordance
with the recommendations of BS 8102. The mastic asphalt
is to be compatible with the underlying material.
Membranes at 14.28 At movement joints in structures the manufacturer's

Movement Joints recommended details shall be adopted and shall be subject
to the approval of the Engineer.
Warranty 14.29 (1) The Contractor and the membrane manufacturer shall
jointly provide a not less than 15 years warranty
certificate for the waterproofing system which is to be
free of defects in material and workmanship upon
completion of works.
(2) The warranty certificate shall be provided in

accordance with Conditions of Contract for Civil
Engineering and Building Works Construction.
June 2022
14/13
SECTION 15
CARRIAGEWAYS : SUB-BASE MATERIALS AND

BITUMINOUS MATERIALS
Materials
Sub-base Materials 15.1 (1) Sub-base material shall be crushed rock and shall
using Virgin have the properties stated in Table 15.1. Sub-base
Materials material passing the 425 μm BS test sieve, when
tested in accordance with Clause 15.46 (5) shall be
non-plastic.
(2) If more than 10% of sub-base material Type 1 is

retained on 20 mm BS test sieve, the whole material
shall be assumed to have a CBR value of 30% or
more. If 10% or less is retained on 20 mm BS test
sieve, the fraction that passes the sieve shall satisfy
the CBR requirements stated in Table 15.1 and shall
be tested in accordance with Clause 15.46(4).
Table 15.1 : Properties of Sub-base Materials
Properties BS Test Sieves Percentage by Mass Passing
Particle Size 75 mm 100

Distribution 37.5 mm 85 - 100
20 mm 60 - 85
10 mm 40 - 70
5 mm 25 - 45
600 μm 8 - 22
75 μm 0 - 10
10% fines crushing value > 50 kN
CBR value > 30.0%
Plasticity index 0
Recycled Sub-base 15.2 (1) Recycled sub-base material shall be crushed rock,
Materials in lieu of crushed concrete or clean crushed inert demolition
Virgin Materials material and may contain up to 12.5 % by mass of
natural sand which passes the 5mm BS test sieve.
The material shall lie within the grading limits of
Table 15.1, and not be gap graded.
(2) The material shall have a 10 % fines value of 50 kN

or more when tested in accordance with Clause
June 2022
15/1
15.47(3).
(3) The material passing the 425μm BS test sieve shall

be non-plastic when tested in accordance with
Clause 15.47(4).
(4) The aggregate shall be considered suitable if it has a

soundness value greater than 65.
(5) The material shall have a water-soluble sulphate

content of less than 1.9g of sulphate (expressed as
SO3) per litre, if used within 500mm of cement-bound
material, concrete pavements, concrete structures or
concrete products.
(6) The material shall have a minimum laboratory

California Bearing Ratio (CBR) value of 30% or such
other higher value as specified by the Engineer.
(7) The material shall not contain quantities of

contaminants in excess of the percentages given in
Table 15.2 unless otherwise approved by the
Engineer.
(8) Notwithstanding the above sub-clauses, the

Contractor may propose for the Engineer’s approval
the use of virgin aggregates in lieu of recycled
aggregates in the sub-base material when there is a
shortage of supply of recycled aggregates.
Table 15.2 : Allowable Contamination of Recycled Sub-base Material
Type of contamination
Maximum Maximum Maximum foreign Maximum
Sub-base sulphate metals material content organic
type content content e.g. glass, soft material
By mass By mass material etc. content
By mass By mass
Recycled 1% 1% 1% 0.5%
sub-base
Aggregates for 15.3 (1) Coarse aggregate for bituminous materials shall be
Bituminous crushed rock all retained on a 5 mm BS test sieve and
Materials shall have the properties stated in Table 15.3.
June 2022
15/2
(2) Fine aggregate for bituminous materials shall be

crushed rock, river sand or a mixture of crushed rock
and river sand all passing 5 mm BS test sieve. The
water absorption of fine aggregate shall not exceed
2.0%.
(3) For the purpose of mix design, the combined grading

of aggregates for bituminous materials shall be such
that the particle size distribution shall be within the
limits stated in Table 15.4 for the relevant bituminous
material.
Table 15.3 : Properties of Coarse Aggregates for Bituminous

Materials
Property Value
Flakiness index 37.5 mm  25.0 %

for aggregate 28 mm  26.0%
with nominal 20 mm  27.0%
maximum aggregate size 10 mm  30.0%
10% fines crushing value > 100 kN
Water absorption  2.0%
Filler for 15.4 (1) Filler for bituminous materials shall be crushed rock
Bituminous filler, PC, PFAC, PFA or hydrated lime. Fillers shall
Materials be free-flowing and dry before addition to the
bituminous mixture.
(2) Filler for polymer modified friction course material shall

contain hydrated lime; the amount of hydrated lime,
expressed as a percentage by mass of the total
aggregates, shall be at least 1.5%.
(3) PC and PFAC shall comply with BS EN 197-1.
(4) PFA shall comply with BS EN 450:Part 1 except that

the criterion for maximum water requirement shall not
apply.
(5) Crushed rock filler and hydrated lime shall comply with
ASTM D 242.
Bitumen 15.5 (1) Bitumen for bituminous materials other than polymer
modified friction course material shall comply with
ASTM D 946, Grade 60-70 and shall have a softening
June 2022
15/3
point exceeding 44C and less than 55C. The wax

content of the bitumen shall comply with requirements
for Grade A specified in JTG F40-2004. Unless
otherwise permitted by the Engineer, bitumen shall be
blended or mixed at a refinery Approved by the
Engineer.
(2) Bitumen for polymer modified friction course material
shall be polymer modified bitumen that shall be a
pre-blended type bitumen with
Styrene-Butadiene-Styrene (SBS) polymer
manufactured by the wet mix method unless otherwise
approved by the Engineer. Dry mix method for mixing
the bitumen and polymer in the batching plant shall not
be allowed. The polymer modified bitumen shall have
a performance grade not lower than PG 76 of the
Performance Graded Asphalt Binder Specification
specified by the AASHTO Designation M320.
Bituminous 15.6 Bituminous emulsion shall be cationic bituminous emulsion

Emulsion complying with BS EN 13808, Class C40B4.
Bituminous 15.7 Bituminous priming material shall be medium curing grade

Priming Material cutback bitumen complying with ASTM D 2027, Table 1,
Class MC-30.
Design of Sub-base Materials and Bituminous Materials
Design Procedure 15.8 (1) Sub-base materials and bituminous roadbase

for Sub-base materials shall be recipe mixes. Laboratory design
Materials and mixes other than those for sub-base materials and
Bituminous bituminous roadbase materials shall be made and
Materials tested as part of the design procedure at a laboratory
(2) Unless otherwise permitted by the Engineer, mix

designs and associated tests shall be carried out by
the Contractor in the presence of the Engineer. The
Contractor shall notify the Engineer at least 7 days, or
such shorter period approved by the Engineer, before
carrying out the mix designs.
(3) The Contractor shall use bituminous roadbase

material incorporating reclaimed asphalt pavement
(RAP) for carriageway works. The specific
requirements are as follows: -
(a) Roadbase incorporating RAP shall be designed,

manufactured, laid and tested in accordance with
June 2022
15/4
the requirements for roadbase using

non-recycled materials or otherwise specified by
the Engineer. Failure in designing and
manufacturing a mix satisfying such requirements
shall not be accepted as a valid reason for not
incorporating RAP in bituminous roadbase
material.
(b) The RAP shall comply with the following:
(i) RAP shall be obtained from milling or excavation

of existing bituminous pavements, and return
loads from site and offcuts from bituminous layer
joint preparation. Return loads can include
bituminous materials rejected from site. RAP
shall be crushed and screened as necessary
such that the maximum particle size is not
greater than the nominal maximum aggregate
size of the type of bituminous materials being
produced and a reasonably well-graded and
consistent mixture can be produced.
(ii) RAP shall be free of foreign materials such as

unbound granular sub-base, broken concrete, or
other contaminants.
(iii) RAP shall be stored in separate stockpiles before

use. RAP that has been stockpiled for some
time shall be reprocessed, where necessary, to
ensure that it is in a free-flowing state at the time
of use.
(iv) The amount of RAP allowable in the bituminous

roadbase material shall be in the range of 10% to
15% by mass of the total mix. Separate mix
designs shall be required for roadbase materials
incorporating RAP.
(c) Notwithstanding the above clauses, the

Contractor may propose for the Engineer’s
approval for using bituminous roadbase material
without RAP when there is a shortage of supply
of RAP in the market.
(4) The Contractor shall appoint a Production Manager

employed by the supplier as approved by the
Engineer, certifying that the specified amount of RAP
is added to the bituminous material according to the
June 2022
15/5
mix design. All certified documents shall be submitted

bi-weekly to the Engineer for verification and record.
The Production Manager shall be personally
responsible to certify that RAP is added for the
production of the recycled bituminous materials. He
shall be an experienced person with at least seven
years of experience in bituminous material production
or having a recognized professional qualification such
as MHKIE or equivalent. The bituminous materials
incorporating RAP supplied by the supplier shall not be
used if the Contractor fails to appoint the Production
Manager.
(5) The Contractor shall work out and submit to the

Engineer for approval a method statement to ensure
that the RAP generated from existing pavements are
delivered, stored and used with no contamination and
minimum wastage in order to produce the bituminous
materials incorporated with RAP as specified. The
Contractor shall at all times facilitate the inspection by
the Engineer on the production of recycled bituminous
materials, storage and sorting facilities for RAP.
Design of 15.9 (1) Bituminous materials shall consist of coarse and fine
Bituminous aggregates complying with Clause 15.3, filler
Materials complying with Clause 15.4 and bitumen complying
with Clause 15.5. The different types of bituminous
materials shall have particle size distributions and
bitumen contents within the limits stated in Table 15.4.
(2) The Contractor shall use bituminous wearing course

and base course materials incorporating reclaimed
asphalt pavement (RAP) for carriageway works.
The RAP and production of bituminous materials
incorporating RAP shall comply with the requirements
specified in Clause 15.8(4) & (5). The specific
requirements are as follows:
(a) Wearing course and base course materials

incorporating RAP shall be designed,
manufactured, laid and tested in accordance with
the requirements for these materials using
non-recycled materials or otherwise specified by
the Engineer. Failure in designing and
manufacturing a mix satisfying such requirements
shall not be accepted as a valid reason for not
incorporating RAP in bituminous wearing course
June 2022
15/6
and base course materials.

(b) The RAP shall comply with the following:
(i) RAP shall be obtained from milling or excavation

of existing bituminous pavements, and return
loads from site and offcuts from bituminous layer
joint preparation. Return load can include
bituminous materials rejected from site. RAP
shall be crushed and screened as necessary
such that the maximum particle size is not
greater than the nominal maximum aggregate
size of the type of bituminous materials being
produced and a reasonably well-graded and
consistent mixture can be produced.
(ii) RAP shall be free of foreign materials such as

unbound granular sub-base, broken concrete, or
other contaminants.
(iii) RAP shall be stored in separate stockpiles before

use. RAP that has been stockpiled for some time
shall be reprocessed, where necessary, to
ensure that it is in a free-flowing state at the time
of use.
(iv) The amount of RAP allowable in the bituminous

wearing course or base course materials shall be
in the range of 20% to 30% by mass of the total
mix. Separate mix designs shall be required for
these materials incorporating RAP.
(c) Notwithstanding the above clauses, the

Contractor may propose for the Engineer’s
approval for using bituminous wearing course or
base course materials without RAP when there is
a shortage of supply of RAP in the market.
(3) The properties of the different types of bituminous

materials shall be as stated in Table 15.5.
(4) Bituminous materials of all aggregate sizes other than

bituminous roadbase material shall be designed in
accordance with the Marshall Method of Mix Design
stated in The Asphalt Institute Handbook `MS-2 Mix
June 2022
15/7
Design Methods for Asphalt Concrete and other

Hot-mix Types' Sixth Edition (1997) with modifications
only if agreed by the Engineer. The compaction
standard shall be 75 blows per side. For design of
polymer modified friction course materials, the
compaction standard shall be 50 blows per side unless
otherwise agreed by the Engineer. The mixing and
compaction temperatures for the mixes shall follow the
recommendations of the manufacturer of the polymer
modified bitumen.
June 2022
15/8
Table 15.4 : Particle Size Distribution, Bitumen Content and

Temperature Requirements for Bituminous Materials
Properties of bituminous Type of bituminous material

material
Roadbase Base Wearing Course Polymer
(recipe course modified
mix) Friction
course
Nominal maximum aggregate size (mm)
37.5 37.5 28 20 10 10
Particle BS test
size sieve size
distribu- 50 mm 100 100 - - - -
tion as 37.5 mm 90 - 100 91-100 100 - - -
percentage 28 mm 70 - 94 70-94 91-100 100 - -
by mass of 20 mm 62 - 84 62-84 85-95 91 - 100 - -
total 14 mm - 55-76 72-87 78 - 90 100 100
aggregate 10 mm 49 - 67 49-67 55-75 68 - 84 87 - 100 85 - 100
and filler, 5 mm 37 - 55 37-55 35-53 54 - 72 62 - 80 20 - 40
excluding 2.36 mm 27 - 43 27-43 25-40 42 - 58 42 - 58 5 - 15
binder, 1.18 mm - 20-35 15-30 34 - 48 34 - 48 -
passing BS 600 μm 13 - 28 13-28 12-24 24 - 38 24 - 38 -
test sieve 300 μm 7 - 21 7-21 8-18 16 - 28 16 - 28 -
150 μm - 4-14 5-12 8 - 18 8 - 18 -
75 μm 2-8 2-8 3-6 4-8 4-8 2-6
Bitumen content min 3.0 4.0 4.5 5.0 6.0 5.5

as percentage
of total mass max 4.0 4.5 5.0 5.5 7.0 7.0
including binder
As
Aggregate min 130
recommend
temperature at
ed by the
mixing (oC) max 175
supplier of
the polymer
Binder min 135
modified
temperature at
bitumen
mixing (oC) max 165
Bituminous min 130

materials
temperature max 165
after mixing
(oC)
Mixture min -
temperature at
laying (oC) max -
Mixture min -
temperature at
start of
compaction (oC)
June 2022
15/9
(5) For polymer modified friction course material, binder

drainage tests in accordance with BS 594987, Annex
K shall be carried out on the proposed
aggregate/modified binder combination to determine
the maximum target binder content (Tmax) of the mix.
The proposed mix will be acceptable if the maximum
target binder content (Tmax) is equal to or greater than
the proposed binder content.
Table 15.5 : Properties of Designed Bituminous Materials
Properties Type of bituminous material
Base course Wearing Polymer

course Modified
friction
course
37.5 28 20 10 10
Minimum Marshall 10.0 10.0 -

stability (kN)
Maximum flow value (mm) 4.0 4.0 -
Air voids in mix as

percentage of total bulk 3.0 - 5.0 3.0 - 5.0 min. 20.0
volume
Minimum voids in mineral

aggregate as a percentage 12.5 13.0 14.0 16.0 -
of total bulk volume
Submissions
Particulars of 15.10 (1) The following particulars of the proposed aggregate,

aggregate, filler, bitumen, bituminous emulsion and bituminous
filler, Bitumen, priming material for bituminous materials shall be
bituminous submitted to the Engineer:
emulsion and
bituminous priming (a) a certificate from the manufacturer for each type
material for of filler showing the manufacturer's name, the
Bituminous date and place of manufacture and showing that
June 2022
15/10
Materials the filler complies with the requirements stated in

the Contract and including results of tests for:
– particle size distribution

– relative density
– plasticity index;
(b) a certificate from the manufacturer for bitumen

other than polymer modified bitumen showing
the manufacturer's name, the date and place of
manufacture and showing that the bitumen
Contract, including a temperature- viscosity
relationship for the bitumen, and including
results of tests for:
– relative density
– softening point
– penetration
– ductility
– retained penetration after thin film oven test
– solubility
– viscosity
– loss on heating
– wax.
(c) a certificate from the manufacturer for each type

of aggregates showing the manufacturer’s name
and place of manufacture and showing the
aggregate complies with the requirements stated
in the Contract,
(d) a certificate from the manufacturer for polymer

modified bitumen showing the manufacturer’s
name, the date and place of manufacture and
showing that the polymer modified bitumen
complies with the requirements in Clause
9.06(2),
(e) a certificate from the manufacturer for

bituminous emulsion showing the
manufacturer’s name, the date and place of
manufacture and showing the bituminous
emulsion complies with the requirements stated
in the Contract, and
June 2022
15/11
(f) a certificate from the manufacturer for

bituminous priming material showing the
manufacture and showing the bituminous
priming material complies with the requirements
(2) The particulars, including certificates, shall be

submitted to the Engineer at the time stated in
Clause 15.11(3).
(3) Further certificates showing that the materials comply

with the specification shall be submitted at intervals
Particulars of 15.11 (1) The following particulars of each recipe mix for
Mixes for Sub-base sub-base materials and bituminous roadbase
Materials and materials, shall be submitted to the Engineer:
Bituminous
Materials (a) source and type of aggregates;
(b) grading details in tabular and graphical form;
(c) details of each mixing plant proposed.
(2) The following particulars of bituminous materials shall

also be submitted to the Engineer:
For bituminous materials other than polymer modified

friction course material:
(a) certified copies of work sheets for mix designs,

which shall include the relative density of mixed
aggregates;
(b) source of bitumen;
(c) if requested by the Engineer, past test records of

the same mix produced in the same plant.
For polymer modified friction course material:
(a) polymer modified binder content % by weight of

total mass,
June 2022
15/12
(b) source and type of aggregates,
(c) certified copies of work sheets for mix designs,

which shall include the relative density of the mix
aggregates,
(d) mixing temperature during production,
(e) grading details in tabular and graphical form,
(f) source of polymer modified bitumen,
(g) details of each mixing plant proposed, and
(h) if requested by the Engineer, past test records of

the same plant.
(3) The particulars required in Sub-clauses (1) and (2)

shall be submitted to the Engineer at least 21 days
before:
(a) trial areas are constructed; or
(b) the mix is placed in the Permanent Works if trial

areas are not required.
Particulars of 15.12 The name of the supplier and the location of each plant
Supplier of from which the Contractor proposes to obtain sub-base
Sub-base Materials materials and bituminous materials shall be submitted to the
and Bituminous Engineer by the time stated in Clause 15.11(3).
Materials
Particulars of 15.13 (1) The following particulars of recycled sub-base

virgin sub-base material if used in lieu of virgin material shall be
material and submitted to the Engineer:
recycled sub-base
material Details of the recycling plant, and test results for:
- Ten percent fines value

- Soundness value
- CBR value
- Content of contaminant in percentage by mass
- Water-soluble sulphate content
- Organic material content, and
(2) The following particulars of virgin sub-base material

and recycled sub-base material if used in lieu of
June 2022
15/13
virgin material shall be submitted to the Engineer for

approval:
(a) Details of the test results for:

- Ten per cent fines value
- Grading details in tabular and graphical form,
and
(b) A certificate from the manufacturer for each

type of aggregates showing the
manufacturer’s name and place of
manufacture and showing the aggregate
Contract.
Particulars of 15.14 (1) The following particulars of the proposed methods of

Methods of laying and compacting of sub-base materials and
Laying and bituminous materials shall be submitted to the
Compacting Engineer:
Sub-base Materials
and Bituminous (a) details of constructional plant;
Materials
(b) programme and rate of working.
(2) The particulars shall be submitted to the Engineer at

the time stated in Clause 15.11(3).
Samples of 15.15 One sample of each type of sub-base material, and one
Sub-base Material, sample of each type of aggregate, filler and bitumen for
Aggregate, Filler bituminous material shall be submitted to the Engineer at
and Bitumen the same time as the particulars specified in Clauses 15.10
to 15.14 are submitted.
Trials
Trial Areas 15.16 (1) Trial areas of each type and layer of bituminous
materials shall be constructed to demonstrate that the
proposed materials, mixes, methods of production and
methods of construction are capable of producing a
carriageway which complies with the specified
requirements. Unless otherwise stated in the
Contract trial areas shall be constructed in the
permanent carriageway at locations approved by the
Engineer. The width of each trial area shall be at
least one lane of the carriageway and the length shall
be at least 60m. The trials shall be carried out at
least 28 days before further material of the same type
is placed in the permanent carriageway.
June 2022
15/14
(2) Trial areas shall be constructed using the same

materials, mixes, methods of production and methods
of construction as those submitted to the Engineer.
Materials shall be delivered in not less than two loads.
(3) The Contractor shall inform the Engineer 48 hours, or

constructing trial areas.
(4) The permission of the Engineer shall be obtained

before each layer of material is placed in the trial area.
(5) The Engineer shall be given sufficient time to

determine whether the specified requirements have
been produced in the trial area before further
material of the same type is placed in the permanent
carriageway.
(6) Trial areas shall be protected from damage and shall

be left in position until the Engineer instructs their
removal. Trial areas which form part of the
permanent carriageway and which comply with the
specified requirements shall not be removed.
Samples: 15.17 (1) One sample of bituminous materials, excluding

Trial Areas bituminous roadbase materials, shall be provided from
each mix used in trial areas. The method of sampling
shall be as stated in Clauses 15.54 to 15.66.
(2) Ten cores shall be cut from each layer of base course
and wearing course in trial areas. The method of
taking cores shall be as stated in Clause 15.63.
Testing: 15.18 (1) Each sample of bituminous material taken as stated in

Trial Areas Clause 15.17, shall be tested to determine the
properties stated in Clause 15.54 to 15.66.
(2) If the layer is to form part of the Permanent Works,

each layer of bituminous material in trial areas,
excluding bituminous roadbase material, shall be
tested as stated in Clause 15.40 to determine the level
of the surface.
(3) The layer which is to be the final layer of carriageway

in each trial areas shall be tested as stated in
Clauses 15.42 and 15.43 to determine the surface
regularity if the layer is to form part of the Permanent
June 2022
15/15
Works.
(4) The layer of polymer modified friction course in each

trial area shall be tested as stated in Clause 15.67 to
15.69, to determine the texture depth and permeability.
(5) Cores shall be tested as stated in Clause 15.63 to

15.66 determine the compacted layer thickness and
air void content.
Compliance 15.19 The properties of the materials, the levels of the surface,
Criteria: compaction, surface regularity, texture depth and
Trial Areas permeability of bituminous materials laid in the trial areas
shall comply with the specified requirements for the
permanent carriageway.
Non-compliance: 15.20 (1) If the result of any test on trial areas does not comply
Trial Areas with the specified requirements for trial areas,
particulars of proposed changes to the materials,
mixes, methods of production or methods of
construction shall be submitted to the Engineer; further
trial areas shall be constructed until the result of every
test on trial areas complies with the specified
requirements for the trial areas.
(2) Trial areas, or parts of trial areas, which do not comply

with the specified requirements for the trial area shall
be removed.
Approved mix for 15.21 (1) A mix for bituminous materials other than bituminous
Bituminous roadbase material which complies with the specified
Materials Other requirements for design mixes and for trial areas shall
than Bituminous become an approved mix.
Roadbase Material
(2) The approved gradation envelope for bituminous
materials other than bituminous roadbase material
shall be the gradation envelope found by applying the
tolerances stated in Table 15.6 to the particle size
distribution of the approved mix.
(3) The approved bitumen content range for bituminous

materials other than bituminous roadbase material
shall be the bitumen content range formed by applying
the tolerances of ±0.5% to the bitumen content of the
approved mix.
Commencement 15.22 Bituminous materials shall not be placed in the Permanent
June 2022
15/16
of Placing Works until the mix has been approved by the Engineer.
Bituminous
Materials
Changes in 15.23 The materials, mix, methods of production used in

Materials and producing the approved mixes and the methods of
Methods of construction used in the trial areas shall not be changed.
Construction
June 2022
15/17
Table 15.6 : Tolerances for Particle Size Distribution from Approved

Mix
Tolerance of particle size distribution in

percentage by mass of total mix passing BS
test sieve
37.5 28 20 10 10
(for mix (for
BS test sieve other than polymer
polymer modified
modified friction
friction course
course material)
material)
50 mm 0 - - - -
37.5 mm ±4 0 - - -
28 mm ±7 ±4 0 - -
20 mm ±7 ±7 ±4 - -
14 mm ±7 ±7 ±7 0 0
10 mm ±7 ±7 ±7 ±4 ±4
5 mm ±7 ±7 ±7 ±7 ±7
2.36 mm ±7 ±7 ±7 ±7 ±7
1.18 mm ±7 ±7 ±7 ±7 -
600 μm ±5 ±5 ±5 ±5 -
300 μm ±5 ±5 ±5 ±5 -
150 μm ±3 ±3 ±3 ±3 -
75 μm ±2 ±2 ±2 ±2 ±2
June 2022
15/18
Handling, Storage and Transport of Materials
Handling and 15.24 (1) Cement and PFA shall be stored as stated in Section
Storage of 11.
Sub-base Materials
and Bituminous (2) Material handling and storage areas shall be levelled
Materials and well drained. Sub-base materials and bituminous
materials shall not be handled or stored in a manner
which will result in mixing of the different types and
sizes or in segregation or contamination of the
materials. Measures to protect the materials from the
effects of weather shall be submitted to the Engineer
for approval.
(3) Different types and sizes of sub-base materials shall

be stored in separate stockpiles. The stockpiles shall
be placed on well-drained, prepared areas and shall
be separated by dividing walls of sufficient height to
keep the different materials separate.
(4) Bituminous materials shall not be stored in heated

surge bins for more than 12 hours or in transport
vehicles for more than 3 hours.
Transport of 15.25 (1) Sub-base materials and bituminous materials shall be

Sub-base Materials transported directly to the location in which they will be
and Bituminous laid. The materials shall be protected by covers while
Materials being transported and before laying. Covers for
bituminous materials shall be heavy canvas or a
similar insulating material; the covers shall completely
cover the material and shall be securely fixed to
minimise loss of heat and to protect the materials from
contamination by dust or other deleterious material.
(2) Sub-base materials and bituminous materials shall be

transported in clean vehicles with smooth trays and
sides.
(3) The tray and sides of vehicles transporting bituminous

materials may be lubricated with soap solution or light
oil sprayed on the trays.
June 2022
15/19
Mixing of Sub-base Materials and Bituminous Materials
Mixing of 15.26 Sub-base materials and bituminous materials shall be

Sub-base mixed before delivery to the Site at a mixing plant approved
Materials and by the Engineer. The plant shall be designed and
Bituminous operated to produce a uniform mix which will comply with
Materials the specified requirements.
Mixing Plant for 15.27 (1) The mixing plant for bituminous materials shall have at
Bituminous least 4 separate cold feed bins for preliminary cold
Materials batching of the coarse and fine aggregates, and a
rotary drum dryer which will continuously agitate the
aggregates during the heating and drying processes.
After passing through the dryer, the aggregates shall
be screened into at least 4 hot storage bins before
mixing.
(2) Bitumen heating and storage tanks shall be fitted with

circulating pumps to ensure an even temperature
throughout the tanks.
(3) The mixing plant shall be fitted with extractors to

remove excess filler before mixing and shall be
provided with sampling devices to take samples of hot
aggregates, filler and bitumen before mixing.
(4) Insulated surge bins, if fitted to the mixing plant, shall

be designed and operated to prevent segregation
occurring in the mix. Heating devices fitted to surge
bins shall be capable of maintaining the temperature of
the mix to within the specified limits.
(5) Measuring and weighing equipment shall be

maintained in a clean, serviceable condition. The
equipment shall be zeroed daily and calibrated before
mixes for the Permanent Works are produced and at
regular intervals not exceed 6 months.
(6) Alternative methods of mixing bituminous materials

may be used with the approval of the Engineer.
Mixing 15.28 (1) Aggregates and filler for bituminous materials shall be
Bituminous measured to an accuracy of ± 3.0% by mass. The
Materials aggregate moisture content after drying shall not
exceed 0.4% by mass.
(2) Bituminous materials other than polymer modified

friction course material shall comply with the
June 2022
15/20
temperature requirements as stated in Table 15.4

during and after mixing.
(3) Mixing of bituminous materials shall continue for at

least 30 seconds after the addition of all constituents
or for such longer period as may be necessary to
ensure that the aggregates and filler are uniformly
coated with bitumen.
(4) The polymer modified friction course material shall

comply with the temperature requirements as
recommended by the supplier of the polymer modified
bitumen during and after mixing.
(5) The particulars of temperature requirements for the

polymer modified friction course material shall be
submitted to the Engineer at the time stated in Clause
9.12(3).
(6) If instructed by the Engineer, the Contractor shall

measure in the presence of the Engineer’s
Representative the following temperaturs:
(a) Temperature after mixing,

(b) Temperature at laying, and
(c) Temperature at start of compaction.
Preliminary Work
Installation 15.29 (1) Pipes, cables, manholes, chambers, gullies and other
of Utilities utilities below carriageways shall be completed and fill
material shall be deposited and compacted in trenches
before the carriageway is constructed. Openings to
manholes, chambers and gullies shall be protected by
temporary covers or by other methods approved by
the Engineer.
(2) Covers, frames and other hardware which will prevent

continuous laying of bituminous materials for roadbase
and base course shall not be fixed in position until
such work is complete.
(3) After the penultimate layer of bituminous material has

been laid and compacted, the roadbase and base
course shall be cut out, temporary covers shall be
removed and the permanent covers, frames and other
hardware shall be installed.
June 2022
15/21
(4) Finishing around covers, frames and other hardware

shall be carried out using bituminous material of the
same type as that in the adjacent surface. The
material shall be compacted in layers not exceeding
50 mm thick using handrammers or mechanical
equipment up to the underside of the wearing course if
the top surfacing is wearing course, or up to underside
of the polymer modified friction course if the top
surfacing is polymer modified friction course.
Preparation of 15.30 Construction of carriageways shall start as soon as

Formation practicable after the formation has been completed. The
formation shall be protected as stated in Section 6 until
construction of the carriageway starts.
Laying and Compaction of Sub-base Materials
Laying and 15.31 (1) Sub-base materials shall be laid and compacted in a
Compaction of manner which will not result in segregation of the
Sub-base materials and at a moisture content which allows the
Materials compaction stated in Clause 15.31(6) to be achieved.
The moisture content shall not be less than 2%.
(2) Sub-base materials shall be laid in layers in such a

manner that the compacted thickness of each layer will
not exceed 225 mm. If the specified final compacted
thickness of the sub-base exceeds 225 mm, the
material shall be laid in two or more layers; the
minimum thickness of each layer shall be 100 mm
and, if the layers are of unequal thickness, the lowest
layer shall be the thickest.
(3) Each layer of sub-base materials shall be evenly

spread immediately after placing in position and shall
be compacted immediately after spreading.
(4) The minimum compaction plant to be used for

compaction of sub-base materials shall be of the type
as stated in Clause 15.36(1).

before the next layer is placed on each layer of
compacted sub-base material.
(6) Sub-base materials shall be compacted to obtain a

relative compaction of at least 95% maximum dry
density throughout.
June 2022
15/22
(7) The surface of each layer of sub-base shall be

maintained in a compacted condition until the next
layer of sub-base material or roadbase material is laid;
the surface shall not be disturbed by constructional
plant or other vehicles and shall be free from ridges,
cracks, loose material, pot-holes, ruts or other defects.
Laying and 15.32 (1) Recycled sub-base material shall be laid and
Compaction of compacted in a manner which will not result in
Recycled segregation of the material and at a moisture content
Sub-base Material which allows the compaction stated in Clause
in 15.32(7) to be achieved. The moisture content shall
lieu of Virgin not be less than 2%.
Material
(2) The recycled sub-base shall consist of an upper layer
of virgin sub-base material overlying a layer of
recycled sub-base material. The ratio of the
thickness of the recycled sub-base layer to that of the
virgin sub-base layer shall be approximately 6 to 4.
During laying and compaction, the thickness of each
of these two layers shall take into account the layer
thickness requirements given in sub-clause (3)
below.
(3) Recycled sub-base material shall be laid in layers in

such a manner that the compacted thickness of each
layer will not exceed 225 mm. If the specified final
compacted thickness of the sub-base exceeds 225
mm, the material shall be laid in two or more layers.
The minimum thickness of each layer shall be 100
mm and, if the layers are of unequal thickness, the
lowest layer shall be the thickest.
(4) Each layer of recycled sub-base material shall be

evenly spread immediately after placing in position
and shall be compacted immediately after spreading.
(5) The minimum compaction plant to be used for

compaction of recycled sub-base material shall be as
stated in Clause 15.36(1).

before the next layer is placed on each layer of
compacted recycled sub-base material.
(7) Recycled sub-base material shall be compacted to

obtain a relative compaction of at least 95%
maximum dry density throughout.
June 2022
15/23
(8) The surface of each layer of recycled sub-base shall

be maintained in a compacted condition until the next
layer of sub-base material or roadbase material is
laid. The surface shall not be disturbed by
construction plant or other vehicles, and shall be free
of ridges, cracks, loose material, pot-holes, ruts or
other defects.
Laying and Compaction of Bituminous Materials
Laying and 15.33 (1) Bituminous materials shall not be laid during periods of
Compaction of wet weather or when ponded water is present on the
Bituminous underlying surface unless in the opinion of the
Materials Engineer the works will not be adversely affected.
(2) Bituminous wearing course material shall not be laid

when the ambient air temperature is expected to fall
below 8C or when winds cool the material to such an
extent that in the opinion of the Engineer laying and
compaction may be adversely affected. Polymer
modified friction course material shall not be laid when
the ambient air temperature is expected to fall below
10C. Temperatures shall be measured in the shade
near to the surface on which laying is to be carried out.
(3) Surfaces on which bituminous materials are laid shall

be clean and free from mud, grit and other deleterious
material.
(4) A tack coat of bituminous emulsion shall be applied to

surfaces on or against which bituminous materials will
be laid. The tack coat shall be evenly applied at a
rate of between 0.4 L/sq m and 0.6 L/sq m using a
spray machine. Other application procedures shall
comply with BS 434:Part 2. Bituminous materials
shall not be laid until the tack coat has cured.
Constructional Plant and other vehicles shall only be
allowed to run on the tack coat as necessary to lay the
bituminous materials.
(5) If approved by the Engineer, surfaces of existing

carriageways may be regulated before the overlying
bituminous material is laid; bituminous regulating
course material shall be a material approved by the
Engineer complying with the requirements for the 10
mm nominal maximum aggregate size wearing course
material as specified in Table 15.4. Regulating
June 2022
15/24
course material shall be laid by paving machines

unless laying by manual methods is instructed by the
Engineer.
(6) Bituminous materials shall be laid in layers in such a

manner that each layer will be within the specified
tolerances.
(7) Bituminous materials other than polymer modified

friction course material shall comply with the
temperature requirements as stated in Table 15.4
during laying and compaction. Bituminous materials
including polymer modified friction course with a
temperature exceeding 145C shall not be laid on
waterproofing systems unless precautions approved
by the Engineer have been taken to prevent heat
damage to the waterproofing system.
(8) Without prejudice to Clause 15.33(2) above, polymer

modified friction course material shall comply with the
temperature requirements as recommended by the
manufacturer of the polymer modified bitumen during
laying and compaction.
Laying 15.34 (1) Bituminous materials shall be placed and spread using
Bituminous a self-propelled paving machine with a screw auger
Materials by and attached screed capable of spreading and laying
Paving Machine the material to the full width required. The paving
machine shall be capable of giving initial compaction
to the material and finishing it to a level suitable for
subsequent compaction.
(2) Paving machines may be fitted with cut-off shoes or

extensions to limit or extend the width of the screed;
screed extensions shall not be used unless the screw
auger is extended in accordance with the
manufacturer's recommendations. The surface
texture produced by paving machines shall be free
from segregation and from pushing or dragging marks.
(3) Bituminous materials laid by paving machines shall be

placed directly from the vehicles transporting the
material into the hopper of the paving machine.
Delivery of materials to the paving machine and laying
of the materials shall be at a uniform rate appropriate
to the capacity of the paving machine and compaction
plant.
June 2022
15/25
(4) If any delay in laying operations occurs, the paving

machine shall be removed, the uncompacted cold
material shall be removed and a transverse joint shall
be formed as stated in Clause 15.37.
(5) Paving machines working in echelon shall be as close

as practicable; the machines shall be not more than
30 m apart unless a longitudinal joint is formed as
(6) Manual placing of materials on freshly laid surfaces

shall only be used for the purpose of locally correcting
levels as paving operations proceed, before
compaction by rolling is commenced.
Laying Bituminous 15.35 Bituminous materials shall be laid by manual methods only
Materials by if in the opinion of the Engineer the use of a paving machine
Manual Methods is impracticable. If approved by the Engineer, bituminous
materials may be laid by manual methods:
(a) in courses of irregular shape and varying thickness;
(b) in confined locations;
(c) adjacent to expansion joints, covers, frames and other

hardware; and
(d) in reinstatements to trenches.
Compaction of 15.36 (1) The minimum compaction plant to be used to compact

Bituminous bituminous roadbase, base course, regulating course,
Materials and wearing course, and sub-base material shall be:
Sub-base Material
(a) a smooth three-wheeled steel-wheeled roller
with a mass of between 6 t and 12 t, or a
vibratory tandem steel-wheeled roller with an
effective mass of between 6 t and 12 t, and a
smooth pneumatic-tyred roller with a mass of
between 12 t and 25 t, and with not less than
seven overlapping wheels which have tyres that
are capable of having pressures varying
between 300 MPa and 800 MPa, and suitable
mechanical rammers and hand-tools; and
(b) other types of rollers, vibrating plates and

rammers approved by the Engineer, or other
similar plant approved by the Engineer,
necessary to produce the required degree of
June 2022
15/26
compaction.
(2) Bituminous roadbase, base course, regulating course

and wearing course materials shall be initially rolled
using a steel-wheeled roller operated in a longitudinal
direction along the carriageway with the driving wheels
nearest the paving machine.
(3) All roller marks shall be removed from the surface of

bituminous roadbase, base course and wearing
course materials using either a smooth-wheeled
dead-weight roller or a smooth-wheeled vibratory roller
in non-vibrating mode.
(4) To ensure continuity of voids in polymer modified

friction course, pneumatic-tyre roller shall not be used
for compacting polymer modified friction course.
(5) Rollers shall be not parked on newly laid or compacted

bituminous materials.
(6) Bituminous materials immediately adjacent to kerbs,

covers, frames and other hardware where rollers
cannot operate effectively shall be compacted using
hand-operated mechanical compaction plant.
Joints in 15.37 (1) The screed of the paving machine shall overlap
Bituminous previously laid strips of bituminous material by at least
Materials 50 mm and shall be sufficiently high that compaction
will produce a smooth dense flush joint. Bituminous
materials overlapped the previously laid strip shall be
pushed back to the edge of the previously laid strip;
the excess material shall be removed.
(2) Longitudinal joints in polymer modified friction course

or wearing course shall be formed coincident with the
specified position of the lane-markings unless
otherwise permitted by the Engineer.
(3) A prepared joint shall be formed between hot

bituminous material and cold material or existing
bituminous material which is at a temperature below
the minimum specified laying temperature.
(4) The distance between prepared longitudinal joints in

different layers shall be at least 150 mm and the
distance between prepared transverse joints in
different layers shall be at least 500 mm.
June 2022
15/27
(5) Prepared joints in base course and wearing course

shall be formed by cutting back the face of the cold
material or existing bituminous material for a minimum
distance of twice the depth of the layer or 100 mm,
whichever is greater; a vertical face shall be cut for the
full depth of the layer. All loosened materials shall be
removed and the face shall be coated with bituminous
emulsion; the bituminous emulsion shall not be applied
beyond the edges of the joint. The hot bituminous
materials shall be laid and compacted against the
coated face with a joint formed as stated in this
Clause.
(6) Polymer modified friction course joints shall not be

coated with bituminous emulsion.
Protection of Surfaces of Sub-base Materials and

Bituminous Materials
Protection of 15.38 (1) The surface of each layer of sub-base materials and
Surfaces of bituminous materials shall be kept clean and free from
Sub-base Materials deleterious material. Bituminous priming coat shall
and Bituminous be applied to the final surface of the sub-base layer at
Materials a rate of between 0.9 L/sq m and 1.1 L/sq m.
(2) Layers of carriageways under construction shall not be

used by Constructional Plant or vehicles other than
those which in the opinion of the Engineer are
essential to construct the work.
(3) Polymer modified friction course shall not be used by

Constructional Plant or other vehicles until at least
24 hours after the material has been laid and
compacted. Other bituminous courses shall not be
used by Constructional Plant or other vehicles until at
least 6 hours after the material has been laid and
compacted.
Tolerances
Tolerances: 15.39 The line of the edges of carriageways shall be within 25 mm

Alignment of of the specified line except at the edges of structures where
Carriageway it shall be within 6 mm.
June 2022
15/28
Tolerances: 15.40 (1) The levels of the surface of each layer of sub-base,
Level of roadbase, base course, wearing course and polymer
Carriageway modified friction course shall be determined on a grid
at 10 m centres in the longitudinal direction and at 2 m
centres in the transverse direction.
(2) The level of the surface of each layer of sub-base,

roadbase, base course, wearing course and polymer
modified friction course shall be within the tolerances
stated in Table 15.7.
(3) The difference in level of the surface of wearing course

and polymer modified friction course across joints shall
not exceed 3 mm.
(4) The combination of permitted tolerances in levels shall

not result in a reduction in the thickness of the
pavement, excluding the sub-base, of more than
15 mm from the specified thickness nor a reduction in
the thickness of the bituminous wearing course or
polymer modified friction course of more than 5 mm
from the specified thickness.
Table 15.7 : Tolerances in Level
Polymer
Modified
Type of Roadbase Base Wearing Friction
surface Sub-base course course course course
Permitted +10 +8 ±6
tolerance in -20 - 15
level (mm)
Tolerances: 15.41 The level of covers, frames and other hardware shall be not
Covers, Frames lower than, and shall be not be more than 5 mm higher than
and other surface of the carriageway. The level of gully gratings shall
Hardware not be higher than, and shall not be more than 5 mm lower
than, the surface of the carriageway.
Testing : Surface Regularity
Testing: 15.42 The surface regularity of the final layer of the pavement shall
Surface be determined as stated in Section 16 of this Specification.
Regularity
Compliance 15.43 The results of tests for surface regularity shall comply with
June 2022
15/29
Criteria: Surface Section 16 of this Specification.

Regularity
Testing : Sub-base Materials
Batch: 15.44 A batch of sub-base material is a quantity not exceeding 250

Sub-base m3 of sub-base material of the same type and same mix
Materials produced at the same mixing plant, and delivered to the Site
at any one time.
Samples: 15.45 (1) One sample of each type of sub-base material shall be
Sub-base provided at the same time as particulars of the material
Materials are submitted to the Engineer. One sample of each
type of material shall be provided from each batch of
sub-base material delivered to the Site.
(2) The size of each sample shall be at least 50 kg. The

method of sampling shall be in accordance with CS3.
Testing: 15.46 (1) Each sample of sub-base material shall be tested to

Sub-base determine the particle size distribution, 10% fines
Materials crushing value, maximum dry density, optimum moisture
content and plasticity index of the portion passing a
425μm BS test sieve. The tests shall be carried out at
such intervals approved by the Engineer.
(2) The method of testing for particle size distribution shall

be in accordance with CS3.
(3) The method of testing for 10% fines value shall be in

accordance with CS3 under a soaked condition.
(4) Not used
(5) The method of testing for plasticity index shall be in

accordance with Geospec 3, Test Method 6.1, except
that sample preparation shall be by wet sieving the
material over a 425 μm BS test sieve.
(6) The method of testing for maximum dry density and

optimum moisture content shall be in accordance with
Geospec 3, Test Method 10.1, 10.2, 10.3, 10.4, 10.5,
10.6, 10.7 or 10.8, and Appendix 6.5 of Section 6 of the
Specification, whichever as instructed by the Engineer.
Testing: Recycled 15.47 (1) Each sample of recycled sub-base material shall be
June 2022
15/30
Sub-base Material tested to determine the particle size distribution, 10 %

in lieu of Virign fines value, maximum dry density, optimum moisture
Material content, plasticity index of the portion passing a 425μm
BS test sieve, CBR value, soundness value,
water-soluble sulphate content and percentage of
contaminants as defined in Table 15.2.
(2) The method of testing for particle size distribution shall

be in accordance with CS3.
(3) The method of testing for 10 % fines value shall be in

accordance with CS3 under a soaked condition.
(4) The method of testing for plasticity index shall be in

accordance with Geospec 3, Test Method 6.1, except
that sample preparation shall be by wet sieving the
material over a 425 μm BS test sieve.
(5) The method for testing for maximum dry density and
optimum moisture content shall be in accordance with
Geospec 3, Test Method 10.1, 10.2, 10.3, 10.4, 10.5,
10.6, 10.7 or 10.8, and Appendix 6.4 of this
Specification, whichever as instructed by the Engineer.
(6) Soundness value shall be determined in accordance

with CS3.
(7) Water-soluble sulphate content shall be determined in

accordance with BS 1377: Part 3.
(8) The maximum organic material content shall be

determined in accordance with BS1377: Part 3.
(9) The maximum metals and foreign material content shall

be determined in accordance with the following
procedure:
By means of the sampling procedure detailed in BS EN

932:Part 6, a sample shall be obtained of the aggregate
containing at least 500 particles. The particles shall then be
sorted manually into the following separate fractions:
(i) Concrete and dense or normal weight aggregates.

(ii) Brick, mortar, lightweight block and lightweight
aggregate.
(iii) Asphalt, bitumen, tar and mixtures of these
materials with aggregate.
(iv) Wood.
June 2022
15/31
(v) Glass.
(vi) Metal.
(vii) Other foreign material such as clay lumps and
plastics.
Because of the adherence of dust, it may be necessary to

wash or break some particles to make a positive
identification. The resulting fractions shall be weighed and
expressed as a percentage of the total weight of material.
Notes:
(a) Lightweight block material - This should be noted

as a separate category if more than 1% by volume
(approx. 5 pieces in 500).
(b) Ultra-lightweight material (e.g. insulation) - This

should be noted if more than 1% by volume (5
pieces in 500).
(10) CBR value shall be determined in accordance with

BS1377: Part 4 with surcharge discs. The material
shall be tested at the density and moisture content
likely to develop in equilibrium pavement conditions,
which shall be taken as being the density relating to a
uniform air voids content of 5% and the optimum
moisture content determined in compliance with BS
5835:Part 1:1980.
Testing : Relative Compaction of Sub-base
Testing: 15.48 (1) Each area of sub-base which contains sub-base material
Relative of the same type and same mix produced at the same
Compaction of mixing plant and which is laid and compacted in a single
Sub-base layer in one day shall be tested to determine the relative
compaction. Tests shall be carried out after the
sub-base material has been laid and compacted in the
final position.
(2) Two tests shall be carried out on each area of 1000 m²

or part thereof laid and compacted each day.
(3) Tests shall be carried out at positions which in the

opinion of the Engineer are representative of the area of
compacted sub-base as a whole.
(4) The method of testing for relative compaction and

determination of maximum dry density shall be in
June 2022
15/32
accordance with Section 6.
Compliance 15.49 The results of tests for relative compaction of sub-base shall
Criteria: Relative comply with the requirements stated in Clause 15.31(6).
Compaction of
Sub-base
Non-compliance: 15.50 If the result of any test for relative compaction of sub-base
Relative does not comply with the specified requirements for relative
Compaction of compaction of sub-base, the area shall be recompacted and
Sub-base 2 additional tests for relative compaction of sub-base shall be
carried out on the area.
Testing : Aggregates, Filler and Bitumen for

Batch: 15.51 A batch of aggregates, filler or bitumen for bituminous

Aggregates, materials is any quantity of aggregates, filler or bitumen for
Filler and Bitumen bituminous materials of the same type, manufactured or
for Bituminous produced in the same place and covered by the same
Materials certificates delivered to the Site at any one time.
Samples: 15.52 (1) One sample of each type of aggregates, filler and
Aggregates, Filler bitumen for bituminous materials shall be provided from
and Bitumen for each batch.
Bituminous
Materials (2) The size of each sample and the method of sampling
shall be as stated in Table 15.8.
Table 15.8 : Size of Samples and Method of Sampling for

Aggregates, Filler and Bitumen
Material Minimum size Method of

of sample sampling
Aggregate CS3 CS3

Filler 5 kg ASTM D 242
Bitumen 2 litres ASTM D 140
Testing: 15.53 Each sample of aggregate, filler and bitumen for bituminous
Aggregates, materials shall be tested to determine the properties stated in
Filler and Bitumen Table 15.9. The method of testing shall be as stated in
for Bituminous Table 15.9.
Materials
June 2022
15/33
Table 15.9 : Testing Aggregates, Filler and Bitumen for

Material Property Method of testing
Coarse aggregate Relative density CS3

Water absorption
10% fines value CS3
Particle size distribution CS3
Flakiness index CS3
Fine aggregate Relative density CS3

Water absorption
Particle size distribution Geospec 3, Test Method
8.2
Filler Relative density BS EN 196:Part 6

Particle size distribution ASTM D 546 with BS
Sieves
Bitumen for Relative density ASTM D 3289

bituminous Softening point BS EN 1427
materials other Penetration ASTM D 5
than polymer Ductility ASTM D 113
modified friction Retained penetration ASTM D 1754
course material after thin film oven test
Solubility ASTM D 2042
Viscosity ASTM D 2171
Loss on heating BS EN 13303
Bitumen for Viscosity AASHTO Designation

polymer modified T316
friction course
material
Dynamic Shear AASHTO Designation
T315
Dynamic Shear after AASHTO Designation

Rolling Thin-Film Oven T315 and
AASHTO Designation
T240
Flash Point AASHTO Designation T48
Testing : Bituminous Materials other than Polymer

Modified Friction Course Material
Batch: 15.54 A batch of bituminous materials other than polymer

Bituminous modified friction course material is a quantity, not exceeding
Materials other the limit stated in Table 15.10 of bituminous materials of the
than Polymer same type and same mix produced at the same mixing
Modified Friction plant in one day or one shift.
June 2022
15/34
Course Material
Table 15.10 : Maximum Size of Batch for Bituminous Materials
Other than Polymer Modified Friction Course
Material
Material Maximum batch size
Wearing Course 100t
Base Course 150t
Roadbase 200t
Samples: 15.55 (1) One sample of bituminous materials other than

Bituminous polymer modified friction course material shall be
Materials other provided from each batch.
than Polymer
Modified Friction (2) The size of each sample shall be as stated in Table
Course Material 15.11.
(3) Samples shall be taken at the mixing plant or at the

location where the bituminous material will be laid as
instructed by the Engineer. Samples taken at the
mixing plant shall be taken from the delivery vehicle
immediately after loading from the plant or from the
surge bin. Samples taken at the location where the
bituminous materials will be laid shall be taken from
the delivery vehicle.
(4) The method of sampling shall be in accordance with

ASTM D 979.
Table 15.11 : Size of Samples for Bituminous Materials Other than

Bituminous Friction Course Material
Material Minimum Size of

Sample (kg)
Wearing Course 10
(10mm nominal maximum aggregate size)
Wearing Course 16
(20mm nominal maximum aggregate size)
Base Course 24
Road Base 24
June 2022
15/35
Testing: 15.56 (1) Each sample of bituminous materials taken as stated

Bituminous in Clause 15.55(1) shall be tested to determine the
Materials other particle size distribution, bitumen content and Rice's
than Polymer specific gravity.
Modified Friction
Course Material (2) The method of testing shall be in accordance with the
following:
Particle size distribution : ASTM C 136 with

modifications and
ASTM C 117, Method B
Bitumen content : ASTM D6307 or ASTM D

2172, Method A
Rice's specific gravity : ASTM D 2041,

Weighing – in - water
method
Bulk specific gravity : ASTM D 2726
ASTM D 2172, Method A, shall be used to determine

bitumen content unless otherwise approved by the
Engineer.
(3) For particle size distribution tests in accordance with

ASTM C 136, the modifications are:
(a) Sieves to BS ISO 3310:Part 1 and Part 2 instead

of sieves to ASTM E 11 shall be used.
(b) Each sample of bituminous materials taken as

stated in Clause 15.55 shall be reduced to a test
specimen of suitable size as follows:
Nominal Maximum Aggregate Minimum Sample

Size (kg) Size (mm)
37.5 2.5
28.0 2.0
20.0 1.5
10.0 1.0
(4) The residual pressure manometer specified in ASTM

D 2041 may be replaced by a vacuum gauge.
Records of Tests: 15.57 Records of tests carried out on bituminous materials other
June 2022
15/36
Bituminous than polymer modified friction course material shall be

Materials Other submitted to the Engineer within 7 days of the tests on each
than Polymer batch. The records shall contain the following details:
Modified Friction
Course Material – location of mixing plant;
– date and time of sampling;
– weather conditions;
– name and address of laboratory;
– date of testing;
– type of bituminous material;
– results of tests.
Compliance 15.58 (1) The results of tests on bituminous materials other than
Criteria: polymer modified friction course material and
Bituminous bituminous roadbase material shall comply with the
Materials other following requirements:
than Polymer
Modified Friction (a) the particle size distribution shall be such that not
Course Material more than 2 points on the particle size distribution
curve are outside the approved gradation
envelope as stated in Clause 15.21(2). The
percentage passing the 75μm BS test sieve shall
not exceed the approved design value by more
than 3%;
(b) the bitumen content shall be within the approved

bitumen content range determined as stated in
Clause 15.21(3).
(2) The results of tests on bituminous roadbase material

shall comply with the following requirements:
(a) The particle size distribution shall be such that

not more than two points on the particle size
distribution curve are outside the design limit as
stated in Table 15.4. Notwithstanding the
above distribution, the percentage passing the
75 μm BS test sieve shall not exceed 8 % as
specified in Table 15.4.
(b) The bitumen content shall be within the

allowable bitumen content range as specified in
Table 15.4.
Testing : Polymer Modified Friction Course Material
June 2022
15/37
Batch: 15.59 A batch of polymer modified friction course material is a

Polymer Modified quantity not exceeding 100 t of polymer modified friction
Friction Course course material of the same mix produced at the same
Material mixing plant in one day.
Samples: 15.60 (1) One sample of bituminous friction course material shall
Polymer Modified be provided from each batch of bituminous friction
Friction Course course material.
Material
(2) The size of each sample shall be at least 15 kg.
(3) Samples shall be taken at from roadway prior to

compaction at locations where the polymer modified
friction course material will be laid or from other
locations as instructed by the Engineer prior to
compaction.
(4) The method of sampling shall be in accordance with

ASTM D 979.
Testing: 15.61 (1) Each sample of polymer modified friction course

Polymer Modified material shall be tested to determine the particle size
Friction Course distribution and bitumen content.
Material
(2) The method of testing shall be in accordance with the
following:
Particle size distribution : Appendix 15.2
Bitumen content : Appendix 15.2

(3) For particle size distribution tests in accordance with
ASTM C 136, the modifications are:
(a) Sieves to BS ISO 3310:Part 1 and BS ISO

3310:Part 2 instead of sieves to ASTM E 11 shall
be used.
(b) Each sample of bituminous materials taken as

stated in Clause 15.60 shall be reduced to a test
specimen of suitable size as follows:
Nominal Maximum Aggregate Minimum Sample

Size (kg) Size (mm)
37.5 2.5
28.0 2.0
20.0 1.5
10.0 1.0
June 2022
15/38
Compliance 15.62 The results of tests on polymer modified friction course

Criteria: material shall comply with the following requirements:
Polymer Modified
Friction Course (a) the particle size distribution shall be such that not more
Material than one point on the particle size distribution curve is
outside the approved gradation envelope as
determined in Clause 15.21(2). Notwithstanding the
above distribution, the percentage passing the 75μm
BS test sieve shall not exceed the approved design
value by more than 3%.
(b) the bitumen content shall be within the approved

bitumen content range as determined in Clause
15.21(3).
Testing : Bituminous Material Cores
Samples: 15.63 (1) Each area of roadbase, base course and wearing
Bituminous course which contains bituminous material of the same
Material Cores type and same mix produced at the same mixing plant
and which is laid and compacted in a single layer in
one day shall be tested to determine the compacted
layer thickness.
(2) Each area of bituminous material to be tested shall be

divided into approximately equal sub-areas as stated
in Table 15.12. One core shall be taken at random
from each sub-area.
(3) Cores shall not be taken from within 300 mm of

covers, frames and other hardware, or construction
joints in the bituminous material.
(4) Cores shall be taken by a mechanically operated

coring machine.
(5) Cores shall be 150 mm diameter for bituminous

material with a designed layer thickness of 40 mm or
greater and shall be 100 mm diameter for bituminous
material with a designed layer thickness of less than
40 mm.
(6) Cores shall be taken as soon as practicable but not

later than 48 hours after completion of the paving
operation.
(7) If agreed by the Engineer, the sampling rate for
June 2022
15/39
roadbase may be applied to wearing course and base

course.
(8) Holes formed by taking cores shall be filled with

compatible bituminous material as soon as practicable
after the core has been taken.
Table 15.12 : Rate of Sampling for Bituminous Material Cores
Area of bituminous No. of sub-areas/ cores

material laid and Wearing Course
compacted in one day Roadbase
and Base Course
< 5000 m² 4 10
5000 - 10000 m² 10 15
> 10000 m² 20 20
Testing: 15.64 (1) Each bituminous material core shall be measured to

Bituminous determine the compacted layer thickness of the
Material Cores bituminous material and tested to determine the air
void content.
(2) The method of testing for air void content shall be in

accordance with ASTM D 3203.
Compliance 15.65 The results of tests on bituminous material cores shall

Criteria: comply with the following requirements:-
Bituminous
Material Cores (a) The average air void content of the cores taken from
an area of bituminous base course or wearing course
material shall be within the range 3.0% to 6.0%.
(b) The air void content of each core taken from an area
of bituminous base course or wearing course material
shall be within the range 2.5% to 7.5%.
(c) The air void content of each core taken from an area
of bituminous roadbase material shall be within the
range 3.0% to 9.0%.
(d) The compacted layer thickness of each core shall

comply with the thickness requirements stated in
June 2022
15/40
Clause 15.40(4) and shall be compatible with the level

tolerances stated in Table 15.7.
Non-compliance: 15.66 (1) If the result of any test for air void content of cores
Bituminous does not comply with the specified requirements for air
Material Cores void content, the following procedure shall apply:
(a) Four additional cores shall be taken from each

sub-area for which the original core did not
comply with the specified requirements for air
void content. The cores shall be taken at
locations evenly spaced throughout the
sub-area such that in the opinion of the
Engineer they are representative of the
sub-area as a whole.
(b) Each additional core shall be tested to

determine the air void content and the test
results of the additional cores from the same
sub-area shall be averaged.
(c) The average air void content of the sub-area

thus obtained shall replace the original air void
content of the respective sub-area. The new
average air void content of the area of
bituminous material tested shall then be
calculated for compliance checking.
(2) If the air void content of any of the additional cores

determined as stated in Clause 15.64(2) is not within
the range 2.5% to 7.5% for bituminous base course
material and bituminous wearing course material, or
3.0% to 9.0% for bituminous roadbase material, the
sub-area from which the cores were taken shall be
requirements.
(3) The area of bituminous material tested shall be

requirements for average air void content if the
average air void content of the cores taken from the
area does not comply with the specified requirements
for average air void content.
(4) If the result of any test for compacted layer thickness

of cores is not compatible with the requirements of
Table 15.7 and Clause 15.40(4), four additional cores
shall be taken from the same sub-area and the
June 2022
15/41
average compacted layer thickness determined. The

cores shall be taken at locations evenly spaced
throughout the sub-area such that in the opinion of the
Engineer they are representative of the sub-area as a
whole.
(5) If the average compacted layer thickness determined

as stated in Clause 15.66(4) is not within the permitted
tolerance stated in Clause 15.65(d), the sub-area from
which the cores were taken shall be considered as not
complying with the specified requirements and shall be
rejected and removed from the Works.
Testing : Texture Depth and Permeability
Testing: 15.67 (1) Each area of polymer modified friction course to be

Texture tested shall be divided into approximately equal
Depth and sub-areas as stated in Table 15.13. The sand patch
Permeability test and the permeability test shall be carried out on
each sub-area at positions which in the opinion of the
Engineer are representative of the sub-area of polymer
modified friction course as a whole. No measurement
shall be taken within 300 mm of the longitudinal edge
of the carriageway.
(2) If agreed by the Engineer the number of tests for

texture depth and permeability may be reduced to the
minimum stated in Table 15.13.
(3) Tests shall be carried out before the area of polymer

modified friction course is used by Constructional Plant
and other vehicles.
(4) Testing to determine the texture depth shall be carried

out by the Engineer. The method of testing shall be
by the sand patch test in accordance with Appendix
16.1.
(5) Testing to determine the permeability shall be carried

out by the Engineer. The method of testing shall be
in accordance with Appendix 15.1.
Table 15.13 : Rates of Testing for Texture Depth and Permeability
June 2022
15/42
Area of bituminous No. of sub-areas/ cores

material laid and
compacted in one day Minimum Normal
< 5000 m² 4 10
5000 - 10000 m² 10 15
> 10000 m² 20 20
Compliance 15.68 The results of tests for texture depth on an area of polymer
Criteria: modified friction course shall comply with the following
Texture requirements:
Depth
(a) the average texture depth shall be not less than
1.5 mm;
(b) not more than one of the tests for texture depth shall
give a result of less than 1.2mm.
Compliance 15.69 The time for 150 mL of water to drain into the polymer
Criteria: modified friction course in the permeability test stated in
Permeability Clause 15.67(5) shall not exceed 30 seconds.
June 2022
15/43
APPENDIX 15.1
Determination of the Permeability of Polymer Modified Friction Course Material
Scope 15.1.1 This method covers the determination of the permeability of

polymer modified friction course material by measuring the
time taken for 150 mL of water to drain into the material.
Apparatus 15.1.2 The following apparatus is required:
(a) a non-porous ring with an internal diameter of 150

mm ± 2 mm, and a minimum height of 20mm;
(b) suitable sealant for sealing one face of the ring onto
the friction course surface;
(c) a measuring cylinder for measuring 150 mL of water

to an accuracy of 1 mL;
(d) two containers, each suitable for containing and

pouring 150 mL of water;
(e) a stop watch.
(a) carefully inspect the specified test location and record

any unusual features;
(b) place one face of the ring on the friction course at the
location to be tested and seal the interface with
sealant to prevent any leakage of water;
(c) prepare two volumes of water, 150 mL each using the

measuring cylinder and the two containers;
(d) pour the 150 mL volume of water into the ring quickly
and steadily without spillage;
(e) as soon as all of the water has drained into the friction
course, pour the second 150 mL volume of water into
the ring quickly and steadily without spillage, and at
the same time start the stop watch;
(f) Record the time taken for the second 150 mL volume
of water to drain into the polymer modified friction
course surface.
June 2022
15/44

Results
(a) the test location;
(b) the time taken for the second 150 mL volume of water
to drain into the polymer modified friction course
surface, to the nearest one second;
(c) that the test was carried out in accordance with this
Specification.
June 2022
15/45
APPENDIX 15.2
Determination of binder content and particle size distribution of polymer modified

friction course material
Scope 15.2.1 This method covers the determination of the polymer

modified binder content (i.e. the total binder and polymer
content) and particle size distribution of polymer modified
friction course material by making use of a combination of
two tests in accordance with ASTM D 2172, Method A and
ASTM D 6307, ASTM C 136 with modifications and ASTM
C 117, Method B.
Calibration 15.2.2 Testing on laboratory mix to determine the calibration factor

procedure shall be required. The procedure shall be as follows:
(a) For a particular mix, prepare a laboratory mix of

known particle size distribution and bitumen content
(A).
(b) Test the trial samples of the laboratory mix in

accordance with ASTM D 2172, Method A
(Centrifugal Method) to determine the polymer
modified binder content (B) of the trial samples.
(c) Test the residual of the trial samples that have been
tested by ASTM D 2172, Method A in accordance
with ASTM D 6307 (Ignition Method) to determine the
polymer modified binder content (C) of the residual.
(d) Calculate the calibration factor for that particular mix

(Z) by the following formula:
Calibration Factor (for a particular mix), Z=C – (A – B)
(e) Repeat the above steps from (a) to (d) for two
additional calibration samples.
(f) Calculate the average calibration factor (Z) by

averaging the three values obtained in step (d) above.
Testing 15.2.3 The procedure for testing polymer modified friction course
material shall be as follows:
(a) Test the samples in accordance with ASTM D 2172,

Method A (Centrifugal Method) to obtain the polymer
June 2022
15/46
modified binder content (X) of the test samples.
(b) Keep the residual (Residual 1) of the test samples

that have been tested in sub-clause (a) above.
(c) With the average value of the calibration factor (Z)

entered into the NCAT Tester for correction purpose,
test Residual 1 obtained from sub-clause (b) above
in accordance with ASTM D 6307 (Ignition Method)
to obtain the residual polymer modified binder
content (Y) of Residual 1.
(d) Keep the residual (Residual 2) of Residual 1 that has

been tested in sub-clause (c) above.
(e) Determine the particle size distribution of Residual 2

in accordance with ASTM C 136 with modifications
and ASTM C 117, Method B.
Calculation 15.2.4 (1) The polymer modified binder content of the test
samples shall be calculated as follows:
Polymer modified binder content = X + Y
(2) The particle size distribution of the test samples shall

be the particle size distribution of Residual 2.

results
(a) Polymer modified binder content (X).
(b) Polymer modified binder content (Y)
(c) Polymer modified binder content (total binder and

polymer content).
(d) Particle size distribution.
June 2022
15/47
SECTION 16
CONCRETE CARRIAGEWAYS
General
General 16.1 (1) The works and materials specified in Clauses 16.2 to
Requirements 16.6 shall comply with the sections stated, unless
otherwise stated in this Section.
(2) All adhesive and sealants shall contain not more than
0.01% and 0.5% by wet weight of formaldehyde and
total aromatic compounds (including benzene, toluene,
xylenes, ethylbenzene, etc.) respectively.
Formwork and 16.2 Formwork and finishes to concrete for concrete

Finishes carriageways shall comply with Section 9 of this
Specification except as stated in this Section.
Reinforcement 16.3 Steel reinforcement for concrete carriageways shall comply

with Section 10 of this Specification except as stated in this
Section.
Concrete 16.4 Concrete for concrete carriageways shall comply with

Section 11 of this Specification except as stated in this
Section. The abrasion resistance in Los Angeles value for
coarse aggregates in concrete shall not exceed 30% loss in
accordance with CS3.
Curing Compound 16.5 Curing compound for concrete carriageways shall comply
with Section 11 of this Specification except as stated in this
Section.
Earthworks 16.6 Earthworks for concrete carriageways shall comply with

Section.
Materials
Reinforcement 16.7 Dowel bars, tie bars, cradles and tie bars for cradles shall
be Grade 250 plain round steel bars complying with Section
10. Dowel bars and tie bars shall be straight; both ends of
dowel bars and one end of tie bars shall be sawn square
with all burrs removed.
Cement 16.8 Cement mortar for supporting cradles shall consist of 1 part
Mortar for of cement to 3 parts of fine aggregate together with the
June 2022
16/1
Cradles minimum amount of water necessary to achieve a

consistency suitable for the required work. Fine
aggregates shall be sand or crushed rock to BS EN 13139
and shall be less than or equal to 4mm.
Fine 16.9 Fine aggregate for concrete shall be clean, hard and
Aggregates durable crushed rock in accordance with Section 11.
Polythene 16.10 Polyethylene sheeting shall be impermeable and shall have

Sheeting a nominal thickness of 0.125 mm.
Joint Filler 16.11 Joint filler shall be a proprietary type approved by the
Engineer and shall be a firm, compressible, single
thickness, non-rotting filler.
Joint Sealant 16.12 (1) Joint sealant shall be a grade suited to the climatic
conditions of Hong Kong and shall perform effectively
over a temperature range of 0C to 60C.
(2) Joint sealant shall be a cold poured two-part

polymer-based sealant complying with BS EN
14188:Part 2, Class A.
(3) Primers and caulking material for use with joint sealant
shall be a proprietary type recommended by the joint
sealant manufacturer and approved by the Engineer.
Bond 16.13 Bond breaker tape shall be a proprietary type

Breaker recommended by the joint sealant manufacturer and
Tape approved by the Engineer. The tape shall be a
polyethylene film with adhesive applied on one side and
shall be the full width of the groove.
Groove 16.14 (1) Groove forming strip shall be a proprietary type

Forming approved by the Engineer. The strip shall be a firm
Strip compressible strip of either ethylene vinyl acetate
foam with a density of at least 90 kg/cu m or synthetic
rubber. The strip shall be 25 mm deep and 5 mm
thick and shall be sufficiently rigid to remain in position
during concreting without deforming or stretching.
(2) Adhesive for groove forming strip shall be a proprietary

type recommended by the groove forming strip
manufacturer and approved by the Engineer.
Sleeves for 16.15 Sleeves for dowel bars and tie bars shall be uPVC and shall
Dowel Bars have a nominal wall thickness not exceeding 1.5 mm; the
and Tie Bars sleeves shall fit tightly to the bars.
June 2022
16/2
Epoxy 16.16 Epoxy resin grout shall be a proprietary type approved by

Resin the Engineer.
Grout
Concrete
Concrete Mix 16.17 Concrete for concrete carriageways shall comply with the
following requirements:
(1) concrete shall be Grade 40/20 and shall be a designed

mix;
(2) the concrete mix shall contain either PFAC or a

minimum of 265 kg of PC plus a minimum of 85 kg of
PFA per cu m of compacted concrete;
(3) the percentage by mass of fine aggregate to total

aggregate shall be at least 30%;
(4) the workability in terms of designed slump value shall

not exceed 75 mm.
Cementitious 16.18 The minimum cementitious content of concrete for concrete

Content of carriageways shall be 350 kg/cu m.
Concrete
Submissions
Particulars of 16.19 (1) The following particulars of the proposed materials for
Materials for joints in concrete carriageways shall be submitted to
Joints the Engineer for Approval:
(a) manufacturer's literature and a certificate for

joint filler showing the manufacturer's name, the
date and place of manufacture and showing
that the joint filler complies with the
requirements stated in the Contract and
– disintegration and shrinkage;

– recovery value and reduction in mass;
– extrusion.
(b) manufacturer's literature for joint sealant,

including details of the method and time
required for mixing the different components,
and a certificate showing the manufacturer's
June 2022
16/3
showing that the sealant complies with the

– application life;
– tack-free time;
– resistance to flow;
– recovery;
– adhesion and cohesion in tension and
compression;
– resistance to heat ageing.
(c) manufacturer's literature and a certificate for

groove forming strip showing the
manufacturer's name, the date and place of
manufacture and showing that the groove
forming strip complies with the requirements
stated in the Contract and including results of
tests for density; and
(d) particulars of primers and caulking material for

joint sealant, adhesive for groove forming strip,
bond breaker tape and sleeves for dowel bars
and tie bars.

first delivery of the material to the Site. Certificates
shall be submitted for each batch of the material
delivered to the Site.
Particulars of 16.20 Particulars of proposed methods of construction for

Methods of concrete carriageways shall be submitted to the Engineer at
Construction least 7 days before the trial length is constructed.
Samples of 16.21 Unless otherwise permitted by the Engineer, one samples

Materials of the following proposed materials shall be submitted to the
Engineer at the same time as particulars of the material are
submitted:
– polyethylene sheeting;
– joint filler;
– bond breaker tape;
– groove forming strip;
– sleeves for dowel bars, including compressible filler,
and for tie bars.
June 2022
16/4
Pavement Joint 16.22 Not less than 42 days before the commencement of the
Layout concrete pavement construction, the Contractor shall
submit the proposed pavement joint layout which shall take
into account manholes, gullies, utility pits and all other
matters that may affect the pavement joint layout.
Trials
Compliance 16.23 The results of the tests on trial mix concrete for concrete
Criteria: Trial Mix carriageways shall comply with the following requirements:
Concrete
– each of the 6 slump values shall not exceed 85 mm;
– the average of the 6 slump values shall not exceed
80 mm.
Trial Length 16.24 (1) A trial length of concrete carriageway shall be

constructed to demonstrate that the proposed
materials, mix design, methods of production and
methods of construction will produce a concrete
carriageway which complies with the specified
requirements.
(2) The trial length shall be completed in sufficient time

before the permanent carriageway is constructed to
allow the Engineer a period of at least 7 days to
determine if the specified requirements have been
complied with in the trial length.
(3) The Contractor shall inform the Engineer 48 hours, or

constructing the trial length.
(4) The trial length shall be constructed using the

methods of construction submitted to the Engineer.
(5) Unless otherwise stated in the Contract the trial length

shall be the first 30 m of the permanent carriageway,
or such other length approved by the Engineer. The
trial length shall be constructed over a width of two
bays and shall include one expansion joint, one
contraction joint and the longitudinal joint between the
bays.
(6) The trial length shall be protected from damage and

shall be left in position until the Engineer instructs its
removal. A trial length which forms part of the
permanent carriageway and which complies with the
June 2022
16/5
specified requirements shall not be removed.
Testing: 16.25 (1) The trial length shall be tested to determine the
Trial Length accuracy of the alignment and level, the surface
regularity and the texture depth. The method of
testing the surface regularity shall be as stated in
Clause 16.56. The method of testing the texture
depth shall be as stated in Clause 16.58.
(2) Concrete cores shall be cut from the trial length to

determine the thickness of the slab, the positions of
the reinforcement and joint components, the amount of
segregation of the constituents, the presence of voids.
The method of taking, preparing, inspecting and
testing concrete cores shall be as stated in
Clauses 16.63 and 16.64.
Compliance 16.26 The results of tests on trial lengths shall comply with the
Criteria: following requirements:
Trial Length
(1) the alignment, levels and thickness of the carriageway
shall comply with Clauses 16.54 and 16.55;
(2) the surface regularity shall comply with Clause 16.57;
(3) the texture depth shall comply with Clause 16.59
(4) the positions of the reinforcement and joint

components shall comply with Clauses 16.50, 16.51,
16.52 and 16.53;
(5) the amount of segregation of the constituents, the

presence of voids shall comply with Clause 16.65.
Non-compliance: 16.27 (1) If the result of any test on the trial length does not
Trial Length comply with the specified requirements for the trial
length, particulars of proposed changes to the
materials, mix design, methods of production or
methods of construction shall be submitted to the
Engineer; further trial lengths shall be constructed until
the result of every test on the trial length complies with
the specified requirements for the trial length. Further
trial mixes shall be made unless in the opinion of the
Engineer non-compliance of the trial length was not
due to the concrete mix.
(2) Unless otherwise permitted by the Engineer, trial

areas, or parts of trial areas, which do not comply with
June 2022
16/6
the specified requirements for the trial area shall be

removed.
Commencement 16.28 (1) Concrete shall not be placed in the permanent

of Concreting carriageway other than in a trial length until the result
of every test on the trial length complies with the
specified requirements for the trial length.
(2) Concrete may be placed in the permanent

carriageway before the results of tests for compressive
strength of the trial mix are available provided that the
result of every other test on the trial mix and trial length
complies with the specified requirements for trial mix
concrete and for the trial length.
Changes in 16.29 Unless otherwise permitted by the Engineer, the materials,

Materials and mix design, methods of production and methods of
Methods of construction used to produce a trial length which complies
Construction with the specified requirements shall not be changed.
Storage of Materials
Storage of 16.30 (1) Joint sealant, primer for joint sealant and adhesive for
Materials for Joints groove forming strip shall be stored in sealed
and Polythene containers marked to identify the contents and
Sheeting protected from exposure to conditions which may
adversely affect the material. The materials shall be
stored in accordance with the manufacturer's
recommendations and shall not be used after the
recommended shelf life has been exceeded.
(2) Polyethylene sheeting, joint filler, bond breaker tape,

groove forming strip and sleeves for dowel bars and tie
bars shall be stored in accordance with the
manufacturer's recommendations in a dry,
weatherproof store with a raised floor. Joint filler shall
be stored in sealed plastic bags and shall not be
exposed to moisture or air.
Preliminary Work
Installation of 16.31 (1) Pipes, cables, manholes, chambers, gullies and other
Utilities utilities below concrete carriageways shall be
completed and fill material shall be deposited and
compacted in trenches before the carriageway is
constructed. Openings to manholes, chambers and
gullies shall be protected by temporary covers or by
other methods agreed by the Engineer.
June 2022
16/7
(2) Box-outs shall be formed in concrete carriageways for

covers, frames and other hardware; the covers, frames
and other hardware shall be fixed in position after the
main slab has been concreted and before the infill slab
is concreted.
Preparation of 16.32 Construction of concrete carriageways shall start as soon

Formation and as practicable after the formation or sub-base has been
Sub-base completed. The formation shall be protected as stated in
Section 6 and the sub-base shall be protected as stated in
Section 15 until construction of the carriageway starts.
Laying 16.33 Polythene sheeting below concrete carriageways shall be

Polyethylene laid flat without creases. Laps shall be at least 300 mm
Sheeting and there shall be no gaps at the edges of bays.
Formwork
Formwork 16.34 (1) Formwork for concrete carriageways shall be steel.

The finish to concrete surfaces for transverse and
longitudinal joints shall be Class F3; the finish to
concrete surfaces for other edges of the carriageway
shall be Class F2.
(2) Concrete shall not be placed against excavated

surfaces or against kerbs.
(3) Formwork shall not be loosened or removed until at

least 7 hours after concreting has been completed.
(4) Care shall be taken in the striking of steel forms to

avoid damage to the concrete and to any protruding tie
bars or dowel bars.
Forming Joints
Forming Joints 16.35 (1) Materials for joints in concrete carriageways shall be
used in accordance with the manufacturer's
recommendations or as otherwise stated in the
Contract.
(2) Dowel bars, tie bars and their sleeves shall be

securely fixed in position through holes in the
formwork before concreting. The bars shall be
parallel to the top surface of the slab and to each
other. Bars at transverse joints shall be parallel to the
adjacent longitudinal joint or to the longitudinal axis of
June 2022
16/8
the carriageway if there is no longitudinal joint or to

other lines instructed by the Engineer.
(3) Joint filler shall be cut to size before fixing and shall be
securely fixed in position to the existing concrete
surface before concreting. There shall be no gaps
between the joint filler and formation. Holes in joint
filler for dowel bars shall be cut to form a sliding fit to
the sleeved bar.
(4) Joints shall be formed perpendicular to the top surface

of the slab.
Transverse Joints 16.36 (1) Unless otherwise permitted by the Engineer,

transverse joints in concrete carriageways shall be
straight and perpendicular to the longitudinal axis of
the carriageway.
(2) Transverse expansion joints and transverse

contraction joints shall be formed only at the specified
positions. The joints shall be continued across
longitudinal joints and shall be in line and of the same
type on both sides of the longitudinal joint. The joints
shall be continued through kerbs, edgings and
quadrants and their foundation and backing; the joint
dimensions and materials shall be the same as the
transverse joints with the omission of dowel bars.
The location of additional contraction joints shall be in
accordance with Section 17.
(3) The joint filler and groove for joint sealant at transverse
expansion joints shall provide complete separation of
adjacent slabs.
Longitudinal 16.37 Longitudinal joints in concrete carriageways shall be formed

Joints only at the specified positions.
Isolation Joints at 16.38 Isolation joints shall be formed in concrete carriageways at

Manholes and manholes and chambers.
Chambers
Forming 16.39 (1) Grooves in concrete carriageways for joint sealant

Grooves shall be straight, shall have parallel sides and shall be
perpendicular to the top surface of the slab. The
bottom of the groove shall be flat and shall be parallel
to the top surface of the slab.
(2) Grooves at transverse expansion joints and at isolation
June 2022
16/9
joints at manholes and chambers shall be formed by

sawing the groove to the specified width and depth not
less than 7 days after concreting. The grooves shall
be located over the joint filler such that the upper
surface of the joint filler is entirely contained in the
groove.
(3) Grooves at transverse contraction joints shall be

formed using one of the following methods:
(a) An initial groove shall be sawn as soon as

practicable after concreting without causing
spalling of the edges. The width of the initial
groove shall be less than the specified width of
the final groove and the depth of the initial
groove shall be between 1/4 and 1/3 of the
thickness of the slab. The final groove shall be
sawn to the specified width and depth not less
than 7 days after concreting. The centre lines
of the initial and final grooves shall coincide.
(b) The final groove shall be sawn to the specified

width and depth as soon as practicable after
concreting without causing spalling of the edges.
(4) Grooves at transverse construction joints shall be

formed by fixing groove forming strip with adhesive to
the concrete already placed before concreting the
adjacent slab.
Protection of 16.40 Before permanent sealing, grooves in concrete

Grooves carriageways for joint sealant shall be protected from
contamination by a temporary sealing strip or by other
methods approved by the Engineer.
Sealing Joints 16.41 (1) The permanent sealing of joints in concrete

carriageways shall be carried out at least 7 days after
concreting.
(2) Immediately before permanent sealing, groove forming

strips, temporary seals, dirt and loose material shall be
removed from the groove and the sides of the groove
shall be cleaned and roughened by water jetting, sand
blasting or by other methods approved by the
Engineer.
(3) Caulking material shall be firmly packed in the bottom

of the groove if the joint sealant is not required to
June 2022
16/10
extend to the bottom of the groove.
(4) Bond breaker tape shall be fixed continuously and

evenly along the bottom of the groove for the full width
and length of the groove.
(5) Primer for the joint sealant shall be applied to the sides
of the groove in accordance with the manufacturer's
recommendations.
(6) Joint sealant shall be applied between the minimum

and maximum drying times of the primer
recommended by the manufacturer. The
components of the sealant shall be thoroughly mixed
in accordance with the manufacturer's
recommendations using a power operated paddle
mixer for sufficient time to produce a homogeneous
mass without entrapped air. The sealant shall be
dispensed into the groove as soon as practicable after
mixing and within the time recommended by the
manufacturer.
(7) The groove shall be clean and dry at the time of

applying the primer and joint sealant.
(8) Excess joint sealant shall be removed by using a

purpose made finishing tool such that the finished
surface of the sealant is between 4 mm and 6 mm
below the surface of the slab.
Placing and Compacting Concrete
Placing and 16.42 (1) Concrete shall be placed continuously between the
Compacting joints in concrete carriageways.
Concrete
(2) Concrete in unreinforced slabs shall be placed and
compacted to the full thickness of the slab in one
operation.
(3) Unless otherwise permitted by the Engineer, concrete

in reinforced slabs shall be placed and compacted to
the specified level of the fabric reinforcement; the
fabric reinforcement shall be placed in position and
concrete shall be placed and compacted to the
remaining thickness of the slab. The time between
compaction of the first layer and placing of the
remaining layer shall not exceed 30 minutes unless in
the opinion of the Engineer the concrete already
June 2022
16/11
placed is sufficiently workable and the permission of

the Engineer has been obtained. If permission is not
obtained, a construction joint shall be formed in
accordance with Section 8 of this Specification.
Concrete shall not be placed against the concrete
already placed for at least 24 hours unless permitted
by the Engineer.
(4) Concrete in infill slabs at covers, frames and other

hardware shall be placed and compacted after the
covers, frames and hardware have been fixed in
position and shall not be placed at the same time as
the concrete in the main slab.
(5) Unless otherwise permitted by the Engineer, the

temperature of fresh concrete when placed in
position shall not exceed 30oC for mixes of grade
strength greater than 20MPa. The Contractor shall
submit for approval details of the proposal to ensure
that this temperature will not be exceeded
Construction Joints
Construction 16.43 (1) Construction joints shall be formed in concrete

Joints carriageways only where approved by the Engineer or
in cases of emergency if concreting is interrupted by
adverse weather, plant breakdown or similar
circumstances. Construction joints shall not be
formed within 2.5 m of an existing or planned
expansion or contraction joint.
(2) Transverse construction joints shall be formed by

either:
(a) using formwork and cast-in tie bars; or
(b) breaking back from an unformed edge and

fixing the tie bars and sleeves with epoxy resin
grout in drilled holes.
Surface Finish
Surface 16.44 (1) Unless combined double beam compactor-levellers

Regulation are being used, then after compaction, the concrete in
concrete carriageways shall be struck off to slightly
above the levels of the formwork and the surface shall
be regulated by a regulating machine or a vibrating
beam.
June 2022
16/12
(2) Regulating machines shall be purpose made and shall

span the full width of the slab either transversely or
obliquely. The machine shall be equipped with at
least two oscillating-type transverse screed and shall
be supported on a carriage.
(3) Vibrating beams shall have a steel or aluminium

surface and shall be mounted on a separate carriage.
The beam shall be driven by a motor to provide a
vibration frequency of at least 3,500 cycles per minute.
(4) Wooden floats may be used to tamp and regulate

small areas of the carriageway as approved by the
Engineer; steel floats or trowels shall not be used.
(5) After regulation by the regulating machine or vibrating

beam, the surface of the carriageway shall be
regulated by at least two passes of a scraping
straight-edge with a blade length of at least 1.8 m.
Scraping straight-edges which operate in conjunction
with regulating machines shall pass across the surface
at right angles to the longitudinal axis of the
carriageway. If the surface is torn by the
straight-edge, the surface shall be regulated again by
the regulating machine or vibrating beam and by the
scraping straight-edge.
Surface 16.45 (1) After the surface of the concrete carriageway has been
Texturing regulated and before the curing compound is applied,
the surface, other than the surface of channels and
edges of slabs which do not require to be textured,
shall be textured by brushing with a wire broom.
(2) The wire broom shall be at least 450 mm wide and

shall have two rows of tufts. The rows shall be
20 mm apart and the tufts in each row shall be at
10 mm centres and in line with the centre of the gaps
between the tufts in the other row. The tufts shall
contain an average of 14 wires, each of 32 gauge and
initially 100 mm long. The broom shall be replaced if
any tuft wears down to a length of 90 mm.
(3) The surface texture shall be produced by brushing

evenly across the slab in one direction at right angles
to the longitudinal axis of the carriageway. Brushing
shall be carried out after the moisture film has
June 2022
16/13
disappeared from the concrete surface and before the

initial set is complete.
Curing Concrete
Curing 16.46 The surface and edges of concrete carriageways shall be

Concrete protected in accordance with Section 11. Covering with
hessian, sacking, canvas or other absorbent material shall
not be permitted. A liquid curing compound shall be used
and shall be applied to the concrete surface by a
low-pressure spray until a continuous visible covering is
achieved. The curing compound shall be applied to the
surface immediately after the surface has been textured
and shall be applied to the edges immediately after the
formwork has been removed.
Protection of Concrete Carriageway
Protection of 16.47 (1) Immediately after the curing compound has been
Concrete applied, the concrete carriageway shall be fenced off
Carriageway from pedestrian traffic and covered with protective
sheeting for at least 24 hours. The sheeting shall be
lapped and securely held in position in such a manner
that the surface of the carriageway will not be
damaged.
(2) Loads from materials not forming part of the

Permanent Works or from Constructional Plant or
other vehicles shall not be applied to the concrete
carriageway until at least 7 days after concreting has
been completed and until all grooves at joints have
been temporarily or permanently sealed or protected.
(3) When construction plant or other vehicles will turn on

the concrete carriageway the contractor shall lay a 100
mm thick protection layer of mesh reinforced 30/20
concrete over the turning area. The protection
concrete shall be separated from the concrete
carriageway by a layer of polyethylene and it shall be
removed by the Contractor without damage to the
concrete carriageway when construction traffic ceases.
Tolerances
Tolerances: 16.48 The level of the sub-base below concrete carriageways

Sub-base shall not be more than 10 mm higher, and shall not be more
than 20 mm lower, than the specified level.
June 2022
16/14
Tolerances: 16.49 (1) The line of formwork for concrete carriageways shall
Formwork be within 10 mm of the specified line of the concrete
carriageway.
(2) The level of the top of the formwork shall be within

3 mm of the specified level of the concrete
carriageway.
(3) Abrupt irregularities in the line of the formwork and in

the level of the top of formwork shall not exceed 3 mm.
Tolerances: 16.50 The cover to fabric reinforcement in concrete carriageways

Reinforcement shall be within 10 mm of the specified cover.
Tolerances: 16.51 (1) Dowel bars at joints in concrete carriageways shall be

Dowel Bars within 20 mm of the mid-depth of the slab.
and Tie Bars
(2) Dowel bars shall be parallel to within 3 mm in half the
length of the bar to:
(a) the longitudinal joint or the longitudinal axis of

the concrete carriageway if there is no
longitudinal joint;
(b) the top surface of the slab;
(c) adjacent dowel bars.
Tolerances: 16.52 Unless otherwise recommended by the manufacturer of the

Grooves joint sealant the depth of grooves for joint sealant in
concrete carriageways shall be within 3 mm of the specified
depth.
Tolerances: 16.53 The level of covers, frames and other hardware shall not be
Covers, Frames higher than, and shall not be more than 3 mm lower than,
and Other the surface of the adjacent carriageway.
Hardware
Tolerances: 16.54 (1) The best fit straight line of straight joints and of straight
Alignment of edges of concrete carriageways shall be within 25 mm
Concrete of the specified line. The line of straight joints and of
Carriageway straight edges of concrete carriageways shall be within
10 mm of the best fit straight line.
(2) The best fit curved line of curved joints and of curved
edges of concrete carriageways shall be as approved
by the Engineer and shall be within 25 mm of the
specified line. The line of curved joints and of curved
June 2022
16/15
edges of concrete carriageways shall be within 10 mm

of the best fit curved line.
(3) Joints in concrete carriageways shall be continuous

across intersections of joints to within 5 mm of the best
fit straight lines or best fit curved lines of each joint.
Tolerances: 16.55 (1) The levels of the surface of concrete carriageways

Level of shall be determined 200 mm from the edges of each
Concrete bay at 10 m centres in the longitudinal direction and at
Carriageway 2 m centres in the transverse direction.
(2) The level of the surface of concrete carriageways shall

be within 6 mm of the specified level. In low lying and
flat areas the Contractor shall pay special attention to
level control to ensure that falls on the surface of the
carriageway are in the specified direction.
(3) The difference in level of the surface of concrete

carriageways across joints shall not exceed 3 mm.
(4) The thickness of concrete carriageway slabs shall not

be less than the specified thickness minus 10 mm.
Testing: Surface Regularity
Testing: 16.56 (1) The surface regularity of concrete carriageways shall

Surface be determined by measuring the number of
Regularity irregularities in the surface. An irregularity means
that the gap between the surface of the carriageway,
and a 3 m straight-edge placed on the surface of the
carriageway, exceeds the specified amount.
Irregularities shall be measured in millimetres
perpendicular to the straight-edge.
(2) The longitudinal surface regularity of carriageways

with a total length of 75 m or more shall be measured
using a rolling straight-edge of the type designed by
the U.K. Transport and Road Research Laboratory.
The longitudinal surface regularity of carriageways
with a total length of less than 75 m and the transverse
surface regularity of carriageways shall be measured
using a 3m straight edge.
(3) The longitudinal surface regularity shall be measured

along lines parallel to the longitudinal axis of the
carriageway and approximately 1 m from the nearside
edge of each carriageway lane. The transverse
June 2022
16/16
surface regularity shall be measured along lines at

right angles to the longitudinal axis of the carriageway
at 10 m intervals along the length of the carriageway.
(4) Testing to determine the surface regularity will be

carried out by the Engineer and shall be attended by
the Contractor.
Compliance 16.57 The results of tests for surface regularity of carriageways

Criteria: Surface shall comply with the following requirements:
Regularity
(1) the size and number of irregularities in the longitudinal
direction shall not exceed the size and permitted
number of irregularities stated in Table 16.1;
(2) there shall be no irregularity exceeding 4 mm in a 3 m

length in the transverse direction for Category A roads
and there shall be no irregularity exceeding 7 mm in a
3 m length in the transverse direction for Category B
roads.
Table 16.1 : Permitted Irregularities in Longitudinal Direction
Total length Permitted number of Permitted number of

of Size of irregularities irregularities
carriageway irregularity (Category A road) (Category B road)
< 75m > 4 mm (9 x total length)/75 (18 x total length)/75

> 7 mm 1 2
75 m - 300 m > 4 mm 9 in any 75 m length 18 in any 75 m length

> 7 mm 1 in any 75 m length 2 in any 75 m length
> 300 m > 4 mm 20 in any 300 m length 40 in any 300 m length

9 in any 75 m length 18 in any 75 m length
> 7 mm 2 in any 300 m length 4 in any 300 m length
1 in any 75 m length 2 in any 75 m length
Category A roads are roads with a legal speed limit greater than 70
kilometres per hour; all other roads are Category B roads.
No irregularity greater than 10 mm shall be permitted.
Irregularities greater than 7 mm shall also be counted as greater than 4

mm.
Testing : Texture Depth
Testing: 16.58 (1) The texture depth of concrete carriageways shall be
June 2022
16/17
Texture determined by the sand patch test. Tests shall be

Depth carried out at least 2 days after the surface texturing
has been carried out and before the area is used by
Constructional Plant or other vehicles.
(2) Each carriageway lane shall be divided into sections of

equal length not exceeding 150 m. Tests shall be
carried out at 10 locations on each section at
approximately equal spacings as instructed by the
Engineer. Tests shall not be carried out within
300 mm of the longitudinal edge of the sections.
(3) Testing to determine the texture depth will be carried

out by the Engineer and shall be attended by the
Contractor. The method of testing shall be in
accordance with Appendix 16.1.
Compliance 16.59 The results of tests for texture depth of each section of
Criteria: concrete carriageway lane shall comply with the following
Texture Depth requirements:
(1) The average texture depth in the tests shall be not less
than 0.70 mm; and
(2) Not more than one out of the 10 measured texture

depths shall be less than 0.6 mm.
Testing: Concrete
Testing: 16.60 Testing to determine the workability and compressive

Workability and strength of concrete in concrete carriageways shall be as
Compressive stated in Section 11 except as stated in Clauses 16.61 and
Strength of 16.62.
Concrete
Compliance 16.61 The average slump value of the 2 specimens taken from
Criteria: one sample of concrete shall not exceed the approved
Workability of slump value by more than 10 mm.
Concrete
Samples: 16.62 One sample of concrete shall be provided from each 25m3
Compressive or 25 batches of concrete or from the amount of concrete
Strength of produced each day, whichever is less.
Concrete
Testing : Concrete Cores From Trial Lengths
Samples: 16.63 (1) Two concrete cores shall be provided from each bay,
June 2022
16/18
Concrete and one core shall be provided from each joint, of

Cores from concrete carriageway in the trial length. The positions
Trial from which the cores are taken shall be as instructed
Lengths by the Engineer.
(2) Concrete cores shall be 150 mm diameter unless

otherwise permitted by the Engineer and shall be the
full depth of the slab. Cores shall be taken as soon
as the concrete has hardened sufficiently for the core
to be taken.
(3) The method of taking concrete cores shall be in

accordance with CS 1.
(4) Holes formed by taking concrete cores from trial

lengths which form part of the permanent carriageway
shall be reinstated using the approved concrete mix;
joints shall be repaired as instructed by the Engineer.
Testing: 16.64 (1) Each concrete core from trial lengths in concrete
Concrete carriageways shall be inspected to determine the
Cores from thickness of the slab and the positions of the
Trial Lengths reinforcement and joint components. Each core shall
be inspected for evidence of segregation of the
constituents and for the presence of voids.
(2) The method of preparing and inspecting concrete

cores shall be in accordance with CS 1
Compliance 16.65 Concrete cores from trial lengths in concrete carriageways

Criteria: Concrete shall not show evidence of segregation which in the opinion
Cores from Trial of the Engineer is excessive and there shall be no
Lengths honeycombing In the concrete core.
Testing: Materials for Joints
Batch: Joint Filler, 16.66 A batch of joint filler and joint sealant for joints in concrete
Joint Sealant carriageways shall be as stated in Section 8.
Samples: 16.67 Samples of joint filler and joint sealant for joints in concrete
Joint Filler, carriageways shall be as stated in Section 8.
Joint Sealant
Testing : 16.68 Testing of joint filler and joint sealant for joints in concrete
Joint Filler, carriageways shall be as stated in Section 8 except as
Joint Sealant stated in Clause 16.69.
June 2022
16/19
Testing: 16.69 Manufacturer’s literature and certificates for the tests in

Joint Sealant accordance with BS EN 14188:Part 2 shall be provided
unless otherwise requested by the Engineer that each
sample of joint sealant shall be tested in BS EN 14188:Part
2.
June 2022
16/20
APPENDIX 16.1
Determination of the Texture Depth of Carriageways
Scope 16.1.1 This method covers the determination of the texture depth
of carriageways by the sand patch test.
Materials 16.1.2 The following material is required:
Dry natural sand with a rounded particle shape which has

been washed and then screened such that it meets the
grading stated in Table 16.1.1.
Table 16.1.1 : Grading of sand
BS test sieve Percentage by mass pass
600 μm 100
300 μm 95-10
150 μm 0-6
(1) A soft brush.
(2) A robust measuring cylinder having an internal

diameter of 20 ± 2 mm and a flat top surface such
that its internal volume is 25 ± 0.1 mL.
(3) A flat wooden disc of 65 ± 2 mm diameter with a

1.5 mm thick hard rubber disc attached to one face
and a handle fixed to the other face.
(4) A steel rule calibrated to 1 mm.
(5) A suitable wind shield.
(6) A funnel with an outlet tube at least 100 mm long with

a bore of between 4 mm and 6 mm, and capable of
accepting a volume of at least 200 ml.
(7) A steel straight edge for screeding off the measuring

cylinder.
June 2022
16/21
(8) A steel-wire brush.
(1) The test location shall be at least 300 mm square and

shall be vigorously brushed ten times in two directions
at right angles using the steel-wire brush and then
dried and swept clean with the soft brush.
(2) Sand shall be poured into the measuring cylinder

filling it to overflowing, and any excess sand shall be
screeded off using the straight edge. All sand on the
outside of the cylinder shall be removed, taking care
not to drop any sand onto the test location.
Alternatively, this step in the procedure may be
carried out in a laboratory, and the sand transferred to
a suitable container ready for pouring.
(3) The measured volume of sand shall be poured onto

the centre of the test location through the funnel to
form a heap. The wind shield shall be used to
protect the test location if required.
(4) The sand shall be spread outwards with a circular

motion over the test location using the rubber-faced
disc with its face parallel to the surface of the
carriageway. This shall be continued until the patch
of sand is approximately circular and will spread
outwards no more.
(5) The size of the patch of sand shall be measured to

the nearest 1 mm along 3 diameters which are
aligned at approximately 120 degrees to each other.
(6) If the difference between the maximum and minimum

of the 3 measurements exceeds 20% of the average
of the 3 measurements, then all the measurements
shall be discarded and the test repeated at an
adjacent location.
(7) The test shall be repeated for all the ten test locations
for each section of carriageway lane.
Calculation 16.1.5 (1) The texture depth (T) for each test shall be calculated
from the equation:
T = 31000 / D² mm
June 2022
16/22
where:
- D is the average of the 3 diameter measurements

of the sand patch calculated to the nearest 1 mm.
(2) The average texture depth for the 10 tests shall be

calculated.

Results
(1) the test location;
(2) the average diameter of the sand patch for each test
to the nearest 1 mm;
(3) the texture depth for each test to the nearest 0.1 mm;
(4) the average texture depth to the nearest 0.1 mm;
(5) that the test was carried out in accordance with this
Specification.
June 2022
16/23
SECTION 17
MISCELLANEOUS ROADWORKS
Part 1, General Requirements. Clause 17.1 to 17.10
Part 2, Concrete Profile Barriers. Clause 17.11 to 17.26
Part 3, Pedestrian Guard-railing. Clause 17.27 to 17.38
Part 4, Untensioned Beam Barriers. Clause 17.39 to 17.50
Part 5, Kerbs, Edgings and Quadrants. Clause 17.51 to 17.55
Part 6, Footways, Cycletracks and Paved Areas. Clause

17.56 to 17.59
Part 7, Precast Concrete Paving Slabs and Paving Blocks.

Clause 17.60 to 17.88
PART 1 : GENERAL REQUIREMENTS
General
General 17.1 The works and materials specified in Clauses 17.2 to 17.8
Requirements shall comply with the sections stated, unless otherwise
stated in this Section.
Earthworks 17.2 Earthworks shall comply with Section 6 of this Specification

except as stated in this Section.
Sub-base 17.3 Sub-base materials and bituminous materials shall comply

Materials and with Section 15 of this Specification except as stated in this
Bituminous Section.
Materials
Joints in 17.4 Joints in concrete shall comply with Section 8 of this

Concrete Specification except as stated in this Section.
Formwork 17.5 Formwork and finishes to concrete shall comply with

Section.
Reinforcement 17.6 Steel reinforcement shall comply with Section 10 of this

June 2022
17/1
Concrete 17.7 Concrete shall comply with Section 11 of this Specification

Steelwork 17.8 Steelwork shall comply with Section 7 of this Specification

Materials
Cement Mortar 17.9 Cement mortar shall consist of one part of cement to three
parts of fine aggregate by volume together with the
minimum amount of water necessary to achieve a
consistency suitable for the required work. Fine
aggregates shall be sand or crushed rock to BS EN 13139
and shall be less than or equal to 4mm.
Polyethylene 17.10 Polyethylene sheeting shall be impermeable and shall have

Sheeting a nominal thickness of 0.125 mm.
June 2022
17/2
PART 2: CONCRETE PROFILE BARRIERS
Materials
Concrete Mix 17.11 Concrete for concrete profile barriers shall be Grade 30/20.
Submissions
Particulars of 17.12 (1) The following particulars of the proposed methods of

Concrete Profile construction for concrete profile barriers shall be
Barriers submitted to the Engineer:
(a) particulars of formwork as stated in Section 9 for

in-situ construction using fixed forms;
(b) details of slip-form machine for in-situ

construction between sliding forms;
(c) methods of manufacture, handling, transport,

storage and fixing in position of precast units.

information at least 14 days before construction of
concrete profile barriers starts.
Trials
Trial Length 17.13 (1) A trial length of concrete profile barrier shall be
constructed to demonstrate that the proposed
methods of construction will produce a concrete profile
barrier which complies with the specified requirements.
If it is not stated in the Contract that the trial length is
to be constructed in a location separate from the
permanent concrete profile barrier, the trial length shall
be the first 25 m of the permanent barrier.
(2) The trial length shall be constructed in sufficient time

before the permanent barrier is constructed to allow
the Engineer a period of at least 7 days to determine if
the specified requirements have been produced in the
trial length.
(3) The Contractor shall inform the Engineer at least

24 hours, or such shorter period approved by the
Engineer, before constructing the trial length.
(4) The trial length shall be constructed using the
June 2022
17/3

methods of construction submitted to the Engineer.
(5) The trial length shall be used as a means of

comparison against which the Engineer shall
determine the compliance or otherwise of the
permanent concrete profile barrier. The trial length
shall be protected from damage and shall be left in
position until the Engineer instructs its removal. A
trial length which forms part of the permanent barrier
and which complies with the special requirements shall
not be removed.
Testing: 17.14 (1) The trial length shall be tested to determine the
Trial Length accuracy of the alignment and level and the finish of
the concrete surface.
(2) Concrete cores shall be cut from the trial length to

determine the amount of segregation of the
constituents, the presence of voids. The method of
taking, preparing, inspecting and testing concrete
cores shall be as stated in Clause 17.26.
Compliance 17.15 The results of tests on trial lengths shall comply with the
Criteria: following requirements:
Trial Length
(1) The alignment and levels of the barrier shall comply
with Clause 17.25.
(2) The finish of concrete surfaces shall comply with the

requirements of Section 9 of this Specification.
(3) The amount of segregation of the constituents, the

presence of voids and the air void content of the
concrete shall comply with Section 16 of this
Specification for concrete carriageways.
Non-compliance: 17.16 (1) If the result of any test on the trial length does not
Trial Length comply with the specified requirements for the trial
length, particulars of proposed changes to the
materials, mix design, methods of production or
methods of construction shall be submitted to the
Engineer; further trial lengths shall be constructed until
the result of every test on the trial length complies with
the specified requirements for the trial length. Further
trial mixes shall be made unless in the opinion of the
Engineer non-compliance of the trial length was not
due to the concrete mix.
June 2022
17/4
(2) Unless otherwise permitted by the Engineer, trial

lengths, or parts of trial lengths, which do not comply
with the specified requirements for the trial length shall
be removed.
Commencement of 17.17 (1) Except as stated in Clause 17.17(2) concrete shall not
Concreting be placed in the permanent barriers until the result of
every test on the trial length complies with the
specified requirements for the trial length.
(2) Concrete may be placed in the permanent barriers

before the results of tests for compressive strength of
the trial mix are available provided that the result of
every other test on the trial mix and trial length
complies with the specified requirements for trial mix
concrete and for the trial length.
Changes in 17.18 Unless otherwise permitted by the Engineer, the materials,

Materials and mix design, methods of production and methods of
Methods of construction used to produce a trial length which complies
Construction with the specified requirements shall not be changed.
Further trial lengths shall be constructed to demonstrate any
proposed changes unless otherwise permitted by the
Engineer.
Formwork and Finishes to Concrete
Formwork 17.19 (1) Formwork for concrete profile barriers shall be steel
unless otherwise permitted by the Engineer.
(2) Formwork shall not be loosened or removed until at

least 7 hours after concreting has been completed.
Finishes to 17.20 (1) The finish to unformed concrete surfaces of concrete

Concrete profile barriers shall be Class U5.
(2) The finish to concrete surfaces for transverse joints

shall be Class F3 and the finish to exposed concrete
surfaces shall be Class F5.
Joints in Concrete Profile Barriers
Joints in Concrete 17.21 (1) Joints shall be formed in concrete profile barriers at
profile Barriers locations which coincide with expansion or
construction joints in the adjoining structure or
carriageway or at intervals not exceeding 12 m,
whichever is less.
June 2022
17/5
(2) Joints in concrete profile barriers shall comply with

Section 8 of this Specification.
Construction of Concrete Profile Barriers
Construction by 17.22 Construction of concrete profile barriers by slip-form

Slip-form Machine machine between sliding forms shall be carried out in
accordance with BS 5931. Slip-form machines shall
comply with BS 5931, Appendix A.
Construction 17.23 Precast concrete profile barriers shall be laid on a cement

Using Precast mortar regulating layer of between 10 mm and 40 mm thick.
Units
Protection of Concrete Profile Barriers
Protection of 17.24 Immediately after the formwork has been removed the
Concrete Profile curing compound shall be applied and the concrete profile
Barriers barriers shall be protected by polythene sheeting for at least
24 hours from exposure to conditions which may affect the
concrete. The sheeting shall be lapped and securely held
in position in such a manner that the surface of the concrete
will not be damaged.
Tolerances
Tolerances: 17.25 Concrete profile barriers shall comply with the following
Concrete Profile requirements:
Barriers
(1) the horizontal dimensions of cross-sections shall be
within 5 mm of the specified dimensions;
(2) the vertical dimensions of cross-sections shall be

within 10 mm of the specified dimensions;
(3) the alignment along the centreline shall be within

10 mm of the specified centreline;
(4) the level of the formation shall be within 10 mm of the

specified level;
(5) the level of the top of the barriers shall be within 10

mm of the specified level;
(6) the barriers shall form a smooth alignment.
Testing : Concrete Cores from Trial Lengths
June 2022
17/6
Testing: 17.26 (1) Two concrete cores shall be provided from each trial
Concrete Cores length of concrete profile barriers. The positions from
from Trial Lengths which the cores are taken shall be as instructed by the
Engineer.
(2) Samples, testing and compliance criteria for concrete

cores from trial lengths shall be as stated in Section 16
of this Specification.
June 2022
17/7
PART 3 : PEDESTRIAN GUARD-RAILING
General
Design of 17.27 Pedestrian guard-railing which is proposed by the

Pedestrian Contractor as an alternative to that stated in the Contract or
Guard-railing which is erected as Temporary Works shall be designed in
accordance with the design loads as given in Table 1..
Table 1 : Design Loads for pedestrian guard-railing

Minimum design loads
Rails End and 90o corner posts Other posts Infilling
Transverse Longitudinal Transverse Longitudinal
load load load load
N/m N N N N N
1400 1400 1400 2800 1400 1000
Materials
Steel 17.28 Steel for pedestrian guard-railing shall comply with the
following:
Hot finished seamless tubes : BS EN 10297-1
Steel tubes and tubulars suitable

for screwing to BS EN 10226
pipe threads : BS EN 10255
Hot rolled sections : BS EN 10365
Hot rolled structural steel sections

- equal and unequal Angles : BS EN 10056
Weldable structural steels : BS EN 10025

Stainless Steel 17.29 Stainless steel for pedestrian guard-railing shall be
Grade 1.4401 and shall comply with the following:
Technical delivery conditions

For sheet/plate and strip of
corrosion resisting steels
for general purposes : BS EN 10088-2
Stainless steel tubes suitable for

threading in accordance
with BS EN 10226 : BS 6362
Aluminium 17.30 (1) Aluminium for pedestrian guard-railing shall be

H 30 TF and shall comply with the following:
June 2022
17/8
Wrought aluminium and aluminium

alloys for general engineering
purposes:
– plate, sheet and strip : BS EN 485, Parts 1 to 4

BS EN 573, Parts 1 to 4
BS EN 515
– drawn tube : BS EN 754-7 and 754-8
– bars, extruded round
tubes and sections : BS EN 515,
BS EN 573-3 and 4
BS EN 755-1 to 9
BS EN 12020-1 and 2
(2) Aluminium shall be anodised to Grade AA 25 in

accordance with BS EN 12373-1.
Bolts, Nuts, 17.31 (1) Bolts, nuts, screws, washers and rivets for pedestrian
Screws, Washers guard-railing shall comply with the following:
and Rivets
ISO metric black hexagon bolts,
screws and nuts : BS 4190
ISO metric black cup and countersunk

head bolts and screws
with hexagon nuts : BS 4933
Metal washers for general engineering

purposes : BS 4320
Rivets for general engineering

purposes : BS ISO
1051
Wrought aluminium and aluminium

alloys for general engineering
purposes:
– rivet, bolt and screw stock : BS 1473
(2) The length of bolts shall be such that the threaded

portion of each bolt projects through the nut by at least
one thread and by not more than 4 threads.
(3) Rag, indented, expansion and resin bonded bolts shall

be a proprietary type approved by the Engineer and
shall be capable of withstanding the design working
June 2022
17/9
load.
(4) Galvanised bolts, nuts, screws, washers and rivets

shall be used with galvanised pedestrian guard-railing.
Aluminium materials shall be insulated from ferrous
materials by a non-conductive insulator at least 2 mm
thick of a type approved by the Engineer.
Mesh Infill 17.32 Mesh infill for pedestrian guard-railing shall comply with
BS 4483. The mesh infill shall be free from surface
defects, surface irregularities and mesh misalignment.
Fabrication of Pedestrian Guard-railing
Galvanizing to 17.33 (1) Steel components forming pedestrian guard-railing

Steel shall be hot-dip galvanized in accordance with BS EN
ISO 1461 to a coating thickness of at least 500 g/sq m.
(2) Galvanizing to steel shall be applied after welding,

drilling and cutting are complete.
Welding Steel 17.34 (1) Welding for fabrication of pedestrian guard-railing shall
be full depth fillet welds. Welded surfaces shall be
clean and flush before application of the protective
coating.
(2) Steel shall not be welded after galvanizing unless

permitted by the Engineer. If permitted, the welded
areas shall be free of scale and slag and shall be
treated with an alternative zinc-coating system
Submissions
Particulars of 17.35 (1) The following particulars of the proposed pedestrian

Pedestrian guard-railing shall be submitted to the Engineer:
Guard-railing
(a) a certificate from the manufacturer showing the
manufacture and showing that the materials
comply with the requirements stated in the
Contract;
(b) details of alternative designs proposed by the

Contractor, including drawings, showing the
proposals and that the pedestrian guard-railing
has been designed in accordance with Clause
17.27.
June 2022
17/10

least 28 days before fabrication of the pedestrian
guard-railing starts.

Materials submitted to the Engineer for Approval of the source and
type of each material at the same time as particulars of the
pedestrian guard-railing are submitted:
(1) each type of pedestrian guard-railing;
(2) mesh infill;
(3) each type of bolt, nut, and washer.
Storage of 17.37 Pedestrian guard-railing shall be stored on a levelled, well

Pedestrian drained and maintained hard-standing ground on level
Guard-railing supports and in a manner which will not result in damage or
deformation to the guard-railing or in contamination of the
guard-railing. Pedestrian guard-railing shall be protected
from damage and damaged guard-railing shall not be used
in the Permanent Works unless otherwise permitted by the
Engineer. Measures to protect the materials from the
effect of weather shall be submitted to the Engineer for
approval.
Installation of Pedestrian Guard-railing
Installation of 17.38 (1) Pedestrian guard-railing shall be installed to a smooth

Pedestrian alignment to within 10 mm of the specified position and
Guard-railing height.
(2) Pedestrian guard-railing which is to be installed to a

radius of less than 45 m shall be curved in the
workshop and shall not be made up of a series of
straight lengths.
(3) Pedestrian guard-railing shall be fixed to concrete

using rag, indented, expansion or resin bonded bolts
and shall be bolted to metalwork. Bolts for fixing to
concrete shall be fitted into pockets filled with cement
mortar or resin grout.
June 2022
17/11
PART 4 : UNTENSIONED BEAM BARRIERS
Materials
Beams 17.39 (1) Beams for untensioned beam barriers shall be

formed from steel plates complying with BS
1449-1.1, type BHR, and BS EN 10149-3, Grade
S315NC.
(2) The beams shall be capable of withstanding a tensile

force of at least 300 kN and shall not deflect by more
than 40 mm when loaded centrally with a point load of
1 t over a simply supported span of 3 m.
(3) Beams shall comply with the following requirements:
(a) the base metal thickness shall be within 0.2 mm

of the specified thickness;
(b) the strip width shall be within + 2.5 mm

and - 0 mm of the specified width;
(c) the camber of the strip length shall be within

8 mm of the specified camber;
(d) the beam shall be straight to within 1.5 mm in a

1.5 m length;
(e) angles at bends shall be within 2 of the specified

angle.
(4) Bolt slots in beams for connection to posts shall be

prepared in the workshop by cold saw cutting. The
spacing of the slots shall be such that posts will be
spaced at either 4 m or 2 m.
(5) Beams shall be hot-dip galvanized in accordance with

BS EN ISO 1461 to a coating thickness of at least
460 g/sq m.
(6) Welds for end beam sections shall be full penetration

butt welds.
Posts 17.40 (1) Posts for untensioned beam barriers shall be formed
from Grade S275JR steel complying with BS EN
10025.
(2) Posts shall be hot-dip galvanized in accordance with
June 2022
17/12
BS EN ISO 1461 to a coating thickness of at least

610 g/sq m.
(3) Posts fabricated from hollow sections shall be sealed

by welding mild steel sealing plates over the open
ends; the plates shall be at least 3 mm thick.
(4) Posts shall be within the tolerances stated in BS EN

10365.
Cleats and Struts 17.41 (1) Cleats and struts for untensioned beam barriers shall
be fabricated from angle sections complying with
BS EN 10056 and shall be weldable structural steel
complying with BS EN 10025, Grade S275JR.
(2) Cleats and struts shall be hot-dip galvanized in

accordance with BS EN ISO 1461 to a coating
thickness of at least 610 g/sq m.
(3) The dimensional tolerances of steel angles for cleats

and struts shall comply with BS EN 10365.
Bolts and Nuts 17.42 (1) Bolts for untensioned beam barriers shall be M 16 size
and strength grade 4.6 complying with BS 4190.
Bolts for beam splicing, bolts for connecting beams to
posts and bolts for connecting beams to cleats shall be
round or button-headed with oval shoulders; other
bolts shall be ISO metric black hexagon type.
(2) Nuts for untensioned beam barriers shall be strength

grade 4 or 5 complying with BS 4190.
(3) Bolts and nuts shall be hot-dip galvanized in

(4) Nuts shall be tapped 0.4 mm oversize to

accommodate the galvanized coating.
(5) The length of bolts shall be such that the threaded

portion of each bolt projects through the nut by at least
one thread and by not more than 4 threads.
(6) Rag, indented bolts, expansion bolts and resin bonded

bolts shall be a proprietary type approved by the
Engineer and shall be capable of withstanding the
design working load.
June 2022
17/13
Washers 17.43 (1) Washers for untensioned beam barriers shall be

black mild steel and shall comply with BS 4320,
Form E, F or G; washers shall be manufactured from
steel complying with BS 1449-1.1and BS EN
10149-3, Grade S315NC.
(2) Plain washers shall be 2 mm thick and shall be of

dimensions suitable for use with M 16 bolts and nuts.
(3) Plain washers shall be hot-dip galvanized in

(4) Shaped washers shall have a thickness of at least

5 mm and shall be cast iron complying with BS EN
13835; the washers shall be shaped to fit the curvature
of circular hollow sections used as posts.
Submissions
Particulars of 17.44 (1) The following particulars of the proposed materials and
Untensioned methods of construction for untensioned beam barriers
Beam Barriers shall be submitted to the Engineer:
(a) a certificate from the manufacturer for beams in

the format stated in BS EN 10025 showing the
manufacture and showing that the beams comply
with the requirements stated in the Contract and
including carbon equivalent values;
(b) details of method of installation.

submitted to the Engineer for Approval of the source
and type of materials at least 14 days before
installation of the beams starts. Certificates shall be
submitted for each batch of beams delivered to the
Site.

Materials submitted to the Engineer for Approval of the source and
type of each material at the same time as particulars of the
material are submitted:
(1) beams;
June 2022
17/14
(2) posts, cleats and struts;
(3) bolts, nuts and washers.
Storage of 17.46 Beams and posts for untensioned beam barriers shall be
Beams and stored on a levelled, well drained and maintained
Posts hard-standing ground on level supports and in a manner
which will not result in damage or deformation to the beams
and posts or in contamination of the beams and posts.
Beams and posts shall be protected from damage and
damaged beams and posts shall not be used in the
Permanent Work unless permitted by the Engineer.
Measures to protect the materials from the effect of weather
shall be submitted to the Engineer for approval.
Construction of Untensioned Beam Barriers
Installation of 17.47 (1) Untensioned beam barriers shall be ready for

Untensioned assembly when delivered to Site. Beams and posts
Beam Barriers shall be free from blisters, flux, uncoated spots and
other defects.
(2) Untensioned beam barriers shall be installed to a

smooth alignment to within 10 mm of the specified
position and height. Transition sections shall provide
a smooth and uniform transition.
(3) Beams which are to be installed to a radius of less

than 45 m shall be curved in the workshop.
(4) Untensioned beam barriers shall be fixed to concrete

using rag, indented, expansion or resin bonded bolts
and shall be bolted to metalwork. Bolts for fixing to
concrete shall be fitted into pockets filled with cement
mortar or resin grout.
Compacted Earth 17.48 (1) Sub-base material shall be deposited and compacted
Footings in the bottom 250 mm of pits for foundations of
untensioned beam barriers with compacted earth
footings. Fine fill material shall be deposited and
compacted to the remainder of the pit. Sub-base
material and fill material shall be compacted to obtain
a relative compaction of at least 95% throughout.
(2) Posts for untensioned beam barriers shall be securely

fixed in position during deposition and compaction of
June 2022
17/15
fill material.
Concrete 17.49 (1) Concrete for concrete footings shall be Grade 20/20.
Footings
(2) The top surface of concrete footings shall be finished
level with the adjoining ground unless otherwise
shown on the Drawings; the finish to the concrete
surface shall be Class U5.
(3) Posts shall be surrounded with polythene sheeting

before concrete is placed and shall be securely fixed in
position during concreting.
Anchor Blocks 17.50 (1) Concrete for anchor blocks shall be Grade 20/20.
(2) The finish to concrete surfaces of anchor blocks shall

be Class F5 for formed finishes and Class U5 for
unformed finishes.
June 2022
17/16
PART 5 : KERBS, EDGINGS AND QUADRANTS
Materials
Concrete Kerbs, 17.51 (1) Concrete for kerbs, edgings and quadrants shall be
Edgings and Grade 30/20. Concrete for foundations and backings
Quadrants to kerbs, edgings and quadrants shall be Grade 20/20.
(2) Precast concrete kerbs, edgings and quadrants shall

comply with BS EN 1339 except that the requirement
for testing of weathering resistance, abrasion
resistance, slip/skid resistanceshall not be applied.
The nominal length of kerbs shall be 1 m and the
nominal length of edgings shall be 750 mm.
Granite Kerbs 17.52 (1) Granite kerbs, edgings and quadrants shall be worked
Edgings and straight or circular. Corners shall be square with the
Quadrants top front and back edges shall be parallel. The length
of granite kerbs and edgings shall be at least 600 mm.
(2) The ends of the kerbs, edgings and quadrants shall be

chisel-dressed square to form a close butt-joint with
adjacent kerbs. Kerbs shall be chisel-dressed to a
depth of at least 140 mm on the front face, at least
75 mm on the back face and for the full width of the
top face.
Construction of Kerbs, Edgings and Quadrants
Construction of 17.53 (1) Precast concrete and granite kerbs, edgings and
Precast Concrete quadrants shall be laid and bedded on a regulating
and Granite Kerbs, layer of cement mortar; the thickness of the layer shall
Edgings and be at least 10 mm and shall not exceed 40 mm.
Quadrants
(2) Except as stated in this clause, joints between each
kerb, edging and quadrant shall not exceed 10 mm in
width; the joints shall be filled and flush pointed with
cement mortar. Joints in kerbs, edgings and
quadrants at expansion joints on bridge decks shall be
as stated in the Contract. Transverse expansion and
contraction joints in kerbs, edgings and quadrants laid
on or adjacent to concrete carriageways shall be in
(3) Radius kerbs shall be used for curves less than 10 m

external radius.
Construction of 17.54 (1) In-situ concrete kerbs, edgings and quadrants shall be
June 2022
17/17
In-situ Kerbs, constructed in accordance with BS 5931 and shall be

Edgings and laid by an automatic extrusion machine of a type
Quadrants approved by the Engineer.
(2) In-situ concrete kerbs, quadrants and edgings shall

have regular sides, edges, arises and chamfers; the
finish to the concrete surface shall be Class U5.
Kerbs, edges and quadrants shall not be finished or
dressed with cement mortar.
(3) Contraction joints shall be formed at intervals not

greater than 4 m. Transverse expansion and
contraction joints in kerbs, edgings and quadrants
which are laid on or adjacent to concrete carriageways
shall be in accordance with Section 16. Joints shall
be flush pointed with cement mortar.
Tolerances
Tolerances: 17.55 (1) The line of kerbs, edgings and quadrants shall be
Kerbs, Edgings within 3 mm of the specified line.
and Quadrants
(2) The level of the top of kerbs, edgings and quadrants
shall be within 3 mm of the specified level.
June 2022
17/18
PART 6 : FOOTWAYS, CYCLETRACKS AND PAVED

AREAS
Materials
Concrete for 17.56 Concrete for footways, cycletracks and paved areas shall
Footways, be Class 30/20.
Cycletracks and
Paved Areas
Construction of Footways, Cycletracks and Paved

Areas
In-situ Concrete 17.57 In-situ concrete for footways, cycle tracks and paved areas
Footways, shall be laid in areas not exceeding 20 sq m and in a
Cycletracks and pattern to the Approval of the Engineer. The finish to the
Paved Areas concrete surface shall be Class U4.
Flexible Surfacing 17.58 (1) Bituminous materials for footways, cycletracks and
to Footways, paved areas shall be laid and compacted with steel
Cycletracks and wheeled and pneumatic tyred rollers. Compaction
Paved Areas shall be started before the temperature of the newly
laid material falls below 100C and shall continue
until the material has cooled and all roller marks have
been removed. For locations where rollers cannot
operate effectively, the bituminous material can be
compacted by hand-operated mechanical compaction
plant approved by the Engineer.
(2) Cores shall be taken in accordance with Section 15

of this Specification for the checking of air void
content and compacted layer thickness of the
bituminous material for works with area of not less
than 200m2. For works with area smaller than
200m2 but greater than 50m2, at least 2 cores shall
be taken from each layer of bituminous material laid.
For works with area less than 50 m2, no coring is
required unless otherwise instructed by the Engineer.
(3) The cores taken in accordance with Clause 17.58(2)

shall be tested to determine the air void content.
The average air void content of the cores shall be not
less than 3% nor greater than 9%. If the test result
does not comply with the specified requirement, 2
additional cores shall be taken at locations agreed by
the Engineer and the average air void content
determined from these 2 cores shall replace the
original value for compliance checking.
June 2022
17/19
Notwithstanding this, no cores shall have an air void

content of less than 2.5% nor greater than 10%.
(4) Each core taken from the final surfacing layer shall
also be measured to determine the compacted layer
thickness that shall not deviate by more than 5mm
from the specified thickness. If the measured
thickness does not comply with the requirement, 2
additional cores shall be taken at locations agreed by
the Engineer and the average thickness determined
from these 2 cores shall replace the original
measured value for compliance checking.
(5) If no bulk sample is taken for determination of the

Rice’s specific gravity, the corresponding value
obtained from the mix design shall be used in
determining the air void content of the core unless
other value is suggested by the Contractor and
agreed by the Engineer.
(6) If either the air void content or the compacted

thickness of the core is outside the specified limits,
the sub-area from which the cores were taken shall
be considered as not complying with the
requirements specified in this clause.
Protection of Footways, Cycletracks and Paved Areas
Protection of 17.59 Footways, cycletracks and paved areas shall not be used
Footways, by Constructional Plant or vehicles other than those which
Cycletracks and in the opinion of the Engineer are essential to construct the
Paved Areas subsequent work.
June 2022
17/20
PART 7 : PRECAST CONCRETE UNITS FOR PAVING
General
Glossary of 17.60 (1) Unit is a term used to describe a precast concrete

Terms paving slab, block or sett unless otherwise specified by
the Engineer.
(2) Depending on their quality, units are classified as

either Grade A or Grade B as follows:
- Grade A units shall comply with all the clauses of

this Section.
- Grade B units shall comply with all the clauses of

this Section except those stipulated for Grade A
units only.
Materials
Units 17.61 (1) The dimensions of units shall be within 3 mm of the

specified dimensions unless otherwise stated.
Chamfers shall not exceed 5 mm in width and depth
or shall be round unless otherwise approved by the
Engineer.
(2) Units may incorporate integral spacer nibs to aid the

laying but these spacer nibs shall not be included in
the size of the units.
(3) Units shall come in wide ranges of colours to facilitate

pavement design by the Engineer. The colours of
units shall be consistent over the area to be paved,
stable and fade resistant under any outdoor climate
situations.
(4) Units shall not exhibit defects such as cracking or

flaking.
(5) Units shall be free of any surface sealant unless

otherwise directed by the Engineer
Precast Concrete 17.62 (1) Paving slabs shall be square or rectangular of metric
Paving Slabs size 200 mm x 300 mm or 300 mm x 300 mm unless
otherwise specified by the Engineer.
(2) Paving slabs shall be 60 mm thick for footpaths.

Paving slabs of other thickness may be used if
June 2022
17/21
Precast Concrete 17.63 (1) Paving blocks shall be as shown in relevant

Paving Blocks Highways Department Standard Drawings, unless
otherwise specified by the Engineer. 200 x 200 x 60
mm paving units shall be considered as paving
blocks.
(2) Paving blocks shall be 60 mm thick for footpaths and

80 mm thick for carriageways and vehicular
accesses. Paving blocks of other thickness may be
used if approved by the Engineer.
Precast Concrete 17.64 (1) Paving setts shall be square of metric size 100 mm x
Paving Setts 100 mm unless otherwise specified by the Engineer.
(2) Paving setts shall be 60 mm thick for footpaths and

80 mm thick for carriageways and vehicular
accesses. Paving setts of other thickness may be
used if approved by the Engineer.
Concrete 17.65 (1) Concrete for units in footways and cycle tracks shall
be Grade 30. Concrete for units in carriageways or
areas to which vehicles will have access shall be
Grade 45.
(2) The nominal maximum aggregate size for concrete in

precast units shall be 10 mm.
Additional 17.66 (1) Grade A units shall have an abrasion resistance of

Requirements for not more than 23 mm to BSEN 1338.
Grade A Units
(2) Colour Pigments for Grade A units shall comply with
BS EN 12878. They shall be UV-stable and shall be
iron oxides, chrome oxide, titanium oxide or cobalt
aluminum oxide unless otherwise approved by the
Engineer.
Sand 17.67 (1) Sand for bedding units shall have the particle size
distribution stated in Table 17.1. The sand shall have
a moisture content exceeding 4% and not exceeding
8% at the time of laying.
(2) Sand for filling joints between units shall have the
particle size distribution stated in Table 17.2. The
sand shall have a moisture content of less than 0.5%
at the time of filling joints.
June 2022
17/22
Table 17.1 : Particle Size Distribution of Sand for Bedding Precast

Units
BS test sieve size Percentage by mass passing

10 mm 100
5 mm 85 - 100
2.36 mm 65 - 100
1.18 mm 40 - 98
600 μm 25 - 72
300 μm 10 - 35
150 μm 0 - 15
75 μm 0 - 10
Table 17.2 : Particle Size Distribution of Sand for Filling Joints

Between Units
BS test sieve size Percentage by mass passing

2.36 mm 100
1.18 mm 90 - 100
600 μm 60 - 90
300 μm 30 -60
150 μm 15 - 30
75 μm 5 - 10
Submissions
Particulars 17.68 (1) The following particulars of the proposed materials and
of Paving Units methods of construction for paving units shall be
submitted to the Engineer:
(a) name and address of manufacturer;
(b) a certificate from the manufacturer showing the

source and the particle size distribution of the
aggregates;
June 2022
17/23
(c) a certificate from the manufacturer showing the

manufacturer's name and the date and place of
manufacture and including results of tests for:
– compressive strength of concrete cubes at

28 days;
– bending strength of paving slabs to BS EN

1339; and
– compressive strength of paving blocks and

setts to Appendix 17.1;
(d) drawings showing the layout of the units within

the paved area.

Approval of the source and type of the units and for
Approval of the layout of the units at least 14 days
before laying of the units starts.
Particulars 17.69 (1) The following particulars of the proposed materials

of Units – for Grade A units shall be submitted to the Engineer:
Additional
Requirements for (a) A certificate fro the manufacturer showing the
Grade A Units results of tests for:
- Dimensional deviations of paving slabs to

BS EN 1339;
- Dimensional deviations of paving blocks

and setts to BS EN 1338;
- Slip/skid resistance value of paving slabs

to BS EN 1344;
- Slip/skid resistance value of paving blocks

to BS EN 1344, or unpolished slip/skid
resistance value of paving blocks to BS
EN 1338;
- Slip/skid resistance value of paving setts

to BS EN 1342;
- 24-hour cold water absorption value of

paving slabs, blocks and setts to AS/NZS
4456.14; and
June 2022
17/24
- Abrasion resistance of paving slabs,

blocks and setts to BS EN 1338.
Samples of 17.70 Samples of each type of unit shall be submitted to the

Materials Engineer for Approval of the source and type of each unit at
the same time as particulars of the unit are submitted.
Samples of 17.71 (1) Samples of each type of Grade A units showing the
Materials – actual size, colour, variation in colour, finish/texture
Additional as specified, and general characteristics of the
Requirements for appearance shall be submitted to the Engineer for
Grade A Units approval at the time as particulars of the units are
submitted.
(2) Samples submitted to the Engineer shall be subject

to a visual inspection by the Engineer and shall
comply with the following requirements:
(a) When examined in accordance with BS 6717,

there shall not be significant visible differences in
colour and texture between any samples;
(b) When examined in accordance with BS 6717, the

samples shall not exhibit defects such as
cracking, flaking or dislodging of aggregates;
(c) Fine materials shall not be easily dislodged from

the surfaces of any samples during gentle
manual handling; and
(d) The edges of all samples shall be sharp and

straight without any defect.
Handling and 17.72 Units shall be handled and stored on pallets to avoid
Storage of Units damage to corners and chamfer edges. Pallets shall be
stored on a level base and in a manner which will not result
in damage to the units or in contamination of the units.
The units shall be protected from damage and damaged
units shall not be used unless permitted by the Engineer.
Storage of Sand 17.73 Sand for filling joints between units shall be stored on
ground in waterproof bags and shall be kept under cover on
a levelled, well drained and hard-standing ground on level
supports until used.
June 2022
17/25
Laying Units
Laying Units 17.74 (1) Units shall not be laid until the layout of the units within
the paved area has been approved by the Engineer.
(2) Kerbs and edgings shall be completed before the units

are laid; the compressive strength of in-situ concrete
kerbs and edgings shall be at least 20 MPa before
units are laid.
(3) Measures shall be taken to prevent water draining

across or through the area during laying, bedding and
compaction of the units.
(4) Laying of units shall start as soon as practicable after

the formation has been completed. The formation
shall be protected as stated in Section 6 until laying
starts.
(5) Paving blocks for carriageways and paved areas to

which vehicles will have access shall be laid in a
herring-bone pattern unless otherwise stated in the
Contract.
(6) Units shall be cut to size where required using

mechanical cutting devices. The cut edge shall be
similar to that of an uncut unit and shall be true to line
and free from chips and cracks.
(7) The units shall be laid to any design or pattern

specified by the Engineer. The design or pattern may
involve a single colour or a combination of different
colour.
Laying Sand 17.75 (1) A layer of sand shall be laid and shall be screeded
and tamped to a uniform depth over the complete
width of the area to be paved. The quantity and
thickness of sand shall be appropriate to the
methods of preparation of the sand layer, and shall
be sufficient to give the required nominal thickness of
the sand layer after compaction of the sand and
units.
(2) The sand layer shall not be disturbed by additional

compaction, foot-marks or other damage after the
layer has been screeded and tamped to the required
level and before the units are laid.
June 2022
17/26
(3) Sand shall not be screeded and tamped more than

1 m in advance of the units which have been laid.
Bedding Paving 17.76 (1) Paving slabs shall be laid on the prepared sand layer
Slabs immediately after screeding and tamping in such a
manner that the sand is not disturbed.
(2) Paving slabs shall be adjusted to form uniform joints

between 2 mm and 3 mm wide and shall be bedded
into the final position using a wooden mallet or a plate
vibrator fitted with a rubber base-pad.
(3) Paving slabs shall not be bedded closer than 1 m

behind the laying edge other than on completion of the
paved area against a kerb or edging.
(4) Final levelling of the slabs shall be carried out as soon

as practicable after bedding and before changes in the
moisture content of the prepared sand layer occur.
(5) Damaged paving slabs shall be immediately removed

and replaced.
Bedding Paving 17.77 (1) Paving blocks and setts shall be laid on the prepared
Blocks and Setts sand layer immediately after screeding and tamping in
such a manner that the sand is not disturbed. Paving
blocks and setts shall be individually laid on the
prepared sand layer by manual methods or in clusters
by mechanical methods.
(2) Paving blocks and setts shall be laid in such a manner

that the blocks are not in direct contact with each other
and that uniform joints of between 2 mm and 3 mm
wide are formed. Paving blocks and setts shall be
bedded flush by at least 2 passes of a heavy-duty
plate compactor fitted with a rubber base-pad.
(3) Paving blocks and setts shall not be bedded closer

than 1 m behind the laying edge other than on
completion of the paved area against a kerb or edging.
(4) Final levelling of the paving blocks and setts shall be

carried out as soon as practicable after bedding and
before changes in the moisture content of the
prepared sand layer occur.
(5) Damaged paving blocks and setts shall be

immediately removed and replaced.
June 2022
17/27
Filling Joints and 17.78 (1) After the units have been bedded, sand for filling the
Compaction of joints shall be spread over the surface of the units and
Units brushed into the joints in such a manner that all joints
are completely filled.
.
(2) Joints shall be filled as soon as practicable after
bedding and on the day the units are laid and bedded
(3) After all joints are completely filled with sand, units
shall be fully compacted by using a plate compactor
fitted with a rubber base-pad. Additional sand shall
be added to refill the joints as required and
compacted into the joints by using the plate
compactor with two or more passes.
(4) Carriageways and paved areas with regular heavy

traffic shall be compacted by at least ten
evenly-spaced passes of a pneumatic tyred roller
having a gross weight of between 10 t and 12 t, or by
a plate compactor which shall have the following
capacity:
- Minimum plate area of 0.25 m2;

- Minimum effective force per unit area of plate of
75 kN/ m2;
- Frequency of 65 –100 Hz; and
- Minimum mass of 200 kg.
Other suitable compacting equipment to the approval of

the Engineer can be used. Sand shall be added as
required and brushed and compacted into the joints.
(5) Units shall not be compacted closer than 1 m behind

the laying edge of the units other than on completion
of the paved area against a kerb or edging.
(6) Excess sand shall be removed after completion of

compaction.
(7) Damaged units shall be immediately removed and

replaced.
Mortar and 17.79 Pigmented mortar or concrete shall be placed to the full
Concrete Seal depth of the unit to form a seal between units and
adjacent kerbs, edgings, quadrants, covers, frames and
other hardware. The work shall only be carried out upon
the approval by the Engineer. Unless otherwise
June 2022
17/28
instructed by the Engineer, colour of pigmented mortar or

concrete shall match the colour of the adjacent units.
Reinstatement of Units
Reinstatement of 17.80 (1) If excavation is to be carried out in paved areas

Units constructed using paving slabs or paving blocks, the
units shall be extracted by manual methods for a
distance of at least 300 mm beyond the limit of the
excavation.
(2) Unbroken units shall be thoroughly cleaned to remove

all sand and deleterious material. The units shall be
stacked on pallets for re-use.
(3) Units to be re-used shall be re-laid in accordance with

Clauses 17.74 to 17.79.
Tolerances
Tolerances: 17.81 The level of paved areas constructed using units shall be
Levels within 3 mm of the specified level. The difference in level
of adjacent units shall not exceed 2 mm.
Testing
Batch: 17.82 (1) A batch of units shall be any quantity of paving slabs,
Units blocks, or setts of the same type, size, and finish, of
the same concrete grade, manufactured in the same
place, covered by the same certificates and delivered
to the Site at any one time. Paving slabs, blocks, or
setts of different colours can be grouped together to
form their respective batches provided that they are
manufactured with the same type of materials and
production methods.
(2) Sampling shall be carried out at random. The

sample shall comprise units that are distributed
throughout the batch.
Testing 17.83 (1) Paving slabs shall be tested for bending strength as
Requirements for stated in Clause 17.84.
Units
(2) Paving blocks shall be tested for compressive
strength as stated in Clause 17.85.
(3) Paving setts need not be tested for bending strength,

compressive strength or slip/skid resistance unless
June 2022
17/29
otherwise required by the Engineer.
Bending Strength 17.84 (1) One sample of units in a batch shall be provided from
Test of Paving every 1000 m2 of units or part thereof. A batch with
Slabs units for area(s) less than 1000 m2 may be added to
the untested previous or following batch(es) as the
case may be for testing purposes. The number of
specimens in each sample shall be 8.
(2) Each sample of paving slabs shall be tested to

determine the bending strength to BSEN 1339.
(3) The mean bending strength of a sample of paving

slabs shall not be less than 4.0 MPa with bending
strength of individual paving slabs not less than 3.2
MPa.
Compressive 17.85 (1) One sample of units in a batch shall be provided from
Strength Test of every 1000 m2 of units or part thereof. A batch with
Paving Blocks units for area(s) less than 1000 m2 may be added to
the untested previous or following batch(es) as the
case may be for testing purposes. The number of
specimens in each sample shall be 8. For paving
blocks of size 200x200x60mm, specimens of size
200x100x60mm shall be cut from these blocks in
accordance with Clause 17.74 (6) to form samples
(2) Each sample of paving blocks shall be tested to

determine the characteristic compressive strength at
28 days.
(3) The method of testing shall be as stated in Appendix

17.1.
(4) The characteristic compressive strength of a sample

of paving blocks shall be:
(a) 30 MPa for paving blocks in footways and cycle

tracks, and
(b) 45 MPa for paving blocks in carriageways and

paved areas to which vehicles will have access.
Additional Testing 17.86 (1) One sample of units in a batch shall be provided from
for Grade A Units: every 1000 m2 of units or part thereof. A batch with
June 2022
17/30
Dimensional units for area(s) less than 1000 m2 may be added to

Deviation of Paving the untested previous or following batch(es) as the
Slabs, Blocks and case may be for testing purposes. The number of
Setts specimens in each sample shall be 8. The sample
can be used for other tests.
(2) The overall dimensions and thickness of each sample

of paving slabs shall be measured in accordance with
BS EN 1339.
(3) The overall dimensions and thickness of each sample

of paving blocks and setts shall be measured in
accordance with BS EN 1338.
(4) The tolerances for the dimensions of each individual

unit shall be within ±2 mm for length and width, and
±3 mm for thickness.
Slip/Skid units for area(s) less than 1000 m2 may be added to
Resistance of the untested previous or following batch(es) as the
Paving Slabs, case may be for testing purposes. The number of
Blocks and Setts specimens in each sample shall be 5. The sample
(2) Each sample of paving slabs shall be tested to

determine the slip/ skid resistance to BS EN 1344.
(3) Each sample of paving blocks shall be tested to

determine the slip/skid resistance to BS EN 1344.
(4) The mean slip/skid resistance of a sample shall not

be less than 45 Skid Resistance Value for units in
footways and cycle tracks.
(5) Notwithstanding sub-clause (4) above, if considered

appropriate by the Engineer for application on steep
roads, pavements with steep pedestrian crossings or
exceptional high cross fall, or other difficult site
conditions, the required slip/skid resistance of the
units in footways and cycle tracks may be increased
up to 60 Skid Resistance Value.
June 2022
17/31
Water Absorption units for area(s) less than 1000 m2 may be added to
Value of Paving the untested previous or following batch (es) as the
Slabs, Blocks and case may be for testing purposes. The number of
Setts specimens in each sample shall be 10. The sample
(2) Each sample of paving slabs and blocks shall be

tested to determine the 24-hour cold water absorption
value to AS/NZS 4456.14.
(3) The sample shall have a characteristic water

absorption value not more than 6% by 24-hour cold
immersion method to AS/NZS 4456.14.
(4) The characteristic water absorption value (Wc) shall

be calculated from the following equation:
Wc = Wm + 1.65 Xs %
where:
- Wm is the average water absorption rate of the
sample
- Xs is the unbiased standard deviation as stated in
AS/NZS 4456.2.
June 2022
17/32
APPENDIX 17.1
Determination of Characteristic Compressive Strength of

Paving Blocks
Scope 17.1.1 This method covers the determination of the characteristic

compressive strength at 28 days of paving blocks by means
of a load test.
(1) A compression test machine complying with CS 1.

Bearing faces of the platens on the test machine shall
be at least as large as the paving blocks and shall
have a flatness tolerance of 0.05 mm.
(2) If test machines with smaller platens are used, steel

plates of adequate size shall be placed centrally
between the platens and the paving block to be
tested. The flatness tolerance of the bearing faces
of the plates measured in accordance with CS 1 shall
not be more than 0.05 mm and the thickness of the
plates shall be at least 25 mm.
(3) Two pieces of packing, each with a thickness of

between 5 mm and 6 mm and with dimensions
exceeding those of the paving block by between
15 mm and 25 mm. The packing shall be plywood,
chipboard or medium density hardboard.
(1) The paving block shall be capped on the running

surface and underside with a suitable capping
material in accordance with Clause 15.5.2 of CS1
and immersed in water for at least 24 hours before
compression.
(2) The paving block shall be placed symmetrically on

the lower platen of the test machine, between the
two pieces of packing with the running surface
facing upwards.
(3) Load shall be applied without shock and shall be

steadily increased at a constant rate within a stress
range of between 150 KPa/sec and 700 KPa/sec.
June 2022
17/33
(4) The load at which the paving block fractures shall be

recorded as the breaking load.
(5) The test shall be repeated for the other 7 blocks.
Calculation 17.1.4 (1) The compressive strength (C) of each paving block
shall be calculated from the equation:
W 2.5
C= x MPa
A 1.5 + L/H
where:
– W is the breaking load (N),
– A is the nominal gross plan area based on the

manufacturing dimensions of the paving
blocks or the area of the tested portion if the
paving block size is reduced for testing
(sq mm),
– L is the lesser of the two plan dimensions (mm).
– H is the nominal height of paving block (mm).
(2) The unbiased standard deviation (s) shall be

calculated from the following equation:
 C2 - n(Cm)²
s= [ ] MPa
n-1
where:
– n is the number of paving blocks,
–  C2 is the sum of the square of the compressive

strengths of the n number of paving blocks (MPa),
– Cm is the average of the compressive strengths of

the n number paving blocks.
(3) The characteristic strength (Cc) of the batch shall be

calculated from the following equation:
Cc = Cm - 1.65s MPa
June 2022
17/34
where:
– Cm is the average of the compressive strengths of

the n number paving blocks as stated in Clause
17.1.4(2),
– s is the unbiased standard deviation as stated in

Clause 17.1.4(2).

Results
(1) source, name of manufacturer and type of blocks;
(2) identification marks of blocks;
(3) date of manufacture of blocks;
(4) nominal gross plan area of each block to the nearest

100 mm² ;
(5) nominal height of each block to the nearest mm;
(6) breaking load of each block to the nearest kN;
(7) compressive strength of each block to the nearest

MPa;
(8) average of the n number compressive strengths to the

nearest MPa;
(9) unbiased standard deviation to the nearest MPa;
(10) characteristic compressive strength to the nearest

MPa;
(11) that the test method used was in accordance with this
Specification.
June 2022
17/35
SECTION 19
DEEP FOUNDATION WORKS
Part 1, General. Clauses 19.1 to 19.13
Part 2, Materials. Clauses 19.14 to 19.35
Part 3, Submissions. Clauses 19.36 to 19.40
Part 4, Construction of Deep Foundation Works.

Clauses 19.41 to 19.86
Part 5, Inspection and Testing. Clauses 19.87

to 19.119
PART 1 : GENERAL
Deep Foundation 19.1 All reference to Deep Foundation Works shall be deemed to
Works include all Piles, Barrettes, Caissons and Diaphragm Wall
Works. Deep Foundation Works shall comply with the
Buildings Department’s Code of Practice for Foundation, BS
EN1997-1, except as stated in this Section.

Reinforcement 19.3 Steel reinforcement shall comply with Section 10 of this

Concrete 19.4 Concrete shall comply with Section 11 of this Specification

Materials for 19.5 Grout for Deep Foundation Works shall comply with
Grout Section 11 of this Specification except as stated in this
Section.
Grouting 19.6 Grouting for Deep Foundation Works shall comply with
Section.
Prestressing 19.7 Prestressing shall comply with Section 12 of this

Specification.
June 2022
19/1
Steelwork 19.8 Steelwork shall comply with Section 7 of this Specification

Marine Works 19.9 Marine works shall comply with the requirements as stated
in the Contract.
Glossary of 19.10 (1) "Hand dug caisson" is any foundation or earth

Terms retaining structure, or part thereof, the construction of
which includes the excavation of a shaft in the ground
by means of digging carried out by any person inside
the shaft with or without the aid of machine tools.
The shaft may be any of the following:
(a) unlined;
(b) lined with a ring wall following each incremental

advance of the excavation; or
(c) partly unlined and partly lined.
(2) "Barrette" is a pile which is excavated using grabs and

chisels through a thixotropic suspension of bentonite
or other agent which supports the sides of the shaft as
excavation proceeds and which is concreted in one
continuous operation.
(3) "Diaphragm wall" is a continuous wall consisting of a

series of abutting reinforced concrete panels
constructed in a trench temporarily supported by a
thixotropic suspension of bentonite or other agent. It
may be used as a temporary wall for supporting deep
excavation, or used as the permanent wall for a
basement structure, and may be used as a
foundation system for supporting vertical loads.
(4) "Minipile" is a pile with a diameter of less than 450 mm

in which the load bearing element consists of a steel
tube or one or more steel reinforcement bars. The
grouted core of the minipiles shall be socketted into
bedrock.
(5) "Secant pile wall" is a wall consisting of interlocking

concrete piles.
(6) "Contiguous pile wall" is a wall consisting of a row of

bored cast-in place piles that are immediately adjacent
to each other.
June 2022
19/2
(7) “Large diameter bored piles” should be greater than

750 mm in diameter and is usually installed by
machine boring to the required level with concrete
filling the bored hole subsequently. Bell-out with a
gradient not exceeding 30 degree from vertical, and
the size not exceeding 1.5 times the shaft diameter
may be permitted at the pile base to increase the end
bearing capacity.
(8) “Socketted steel H-pile” is a pile formed by inserting

steel H-pile in a pre-bored hole sunk into Grade III or
better rock, and subsequently filling the hole with
non-shrink cement grout.
(9) "Trial piles" are piles constructed using identical

materials and method of construction proposed for the
permanent piles for the purpose of testing and
assessment of workmanship.
(10) Rock is naturally occurring material of Grades I to III as

classified in Table 4 of Geoguide 3 “Guide to Rock and
Soil Descriptions”.
(11) An "obstruction" to excavation shall be defined as an

object or material encountered in an excavation which
requires additional effort to remove.
Safety of Deep Foundation Works
General 19.11 Reference shall be made to the following documents

regarding matters relating to safety of Deep Foundation
Works:
(1) Eurocode 7, Geotechnical Design – Part 1: General

Rules : BS EN 1997-1
(2) Guide to safety precautions and

procedures for the construction
and descent of machine bored
shafts for piling and other purposes : BS 8008
(3) Code of Safe Working Practices for Hand-dug

Caissons, published by the Occupational Safety and
Health Council.
(4) Section 7 of the Guidance Notes on Hand Dug

Caissons published by the Hong Kong Institution of
Engineers, 1981.
June 2022
19/3
(5) Code of Practice for Foundations, published by the

Buildings Department 2017.
(6) Drilling and Foundation Equipment – Safety : BS EN

16228
Safety: Hand-dug 19.12 (1) The dangers inherent in the construction of hand dug
Caissons caissons shall be recognised by the Contractor.
Appropriate safety guidelines shall be implemented to
minimise risks involved and ensure safe construction.
(2) BS 8008 “Guide to Safety Precautions and Procedures

for the Construction and Descent of Machine Bored
Shafts for Piling and Other Purposes” shall be
complied with, in particular requirements for the safety
of persons required to enter boreholes.
(3) The Engineer will only approve the use of hand dug
caissons in the following circumstances:
(a) when the depth of the hand dug caisson does not
exceed 3 metres and the diameter of the
inscribed circle of the hand dug caisson is not
less than 1.5 metres; or
(b) for the site concerned, when the use of a hand

dug caisson is the only practical construction
method; or
(c) for the site concerned when there is no other safe

engineering alternative.
Safety and 19.13 (1) The Contractor shall take all necessary precautions to
Emergency ensure stability of the excavations and guide walls and
Procedures for shall take all necessary precautions and be
Diaphragm Wall responsible for safety of all personnel in the area of
Works operation. The Contractor shall also take into
account the effect of lateral movements associated
with the swelling of the CDG stratum at low effective
stresses. The Contractor shall maintain, available for
immediate use, a sufficient quantity of slurry to allow
for any sudden loss of slurry in the excavation.
(2) Should the loss of slurry continue despite the

additional of the slurry and the stability of the trench be
placed at risk, the Contractor shall immediately advise
the Engineer and take such immediate remedial action
as is necessary to preserve the stability of the trench
June 2022
19/4
and ensure the safety of neighbouring buildings,

structures, services, railway works, pavement and
utilities.
PART 2: MATERIALS
Steel Piles 19.14 (1) Steel bearing piles shall comply with the Code of
Practice for Structural Use of Steel by Buildings
Department.
(2) Steel sheet piles shall be of a proprietary section

Pile Shoes 19.15 (1) Cast iron pile shoes for precast concrete piles shall be
manufactured from chill hardened iron as used for
making grey iron castings complying with BS EN 1561,
Grade EN-GJL-150. The chilled iron point of the
shoe shall be free from major blow holes and other
surface defects.
(2) Steel pile shoes for precast concrete piles shall be

manufactured from steel complying with BS EN 10025,
Grade S275 JR.
(3) Cast steel pile shoes for precast concrete piles shall
be manufactured from steel complying with BS EN
10293, Grade GE.
(4) Straps and fastenings for cast pile shoes for precast
concrete piles shall be manufactured from steel
complying with BS EN 10025, Grade S275 JR and
shall be cast into the point of the shoe to form an
integral part of the shoe.
(5) Pile shoes for driven cast-in-place piles shall be

manufactured from durable materials approved by the
Engineer and capable of withstanding driving stresses
without damage. The shoes shall be designed to
provide a watertight joint with permanent casings.
(6) Cast steel pile shoes for steel bearing piles shall be
manufactured from steel complying with BS EN 10293,
Grade GE.
(7) Welded fabricated pile shoes for steel bearing piles

shall be manufactured from steel complying with BS
EN 10025, Grade S275 JR.
June 2022
19/5
Epoxy Paint 19.16 Epoxy based paint for epoxy coatings to steel piles shall be
a proprietary type approved by the Engineer.
Bituminous 19.17 Bituminous coating material for steel piles shall be

Coating Material hot-applied filled or unfilled bituminous material complying
with BSI EN 10300.
Grout for Deep 19.18 (1) Grout for Deep Foundation Works shall comply in all
Foundation respect with Section 11, Part 3 of this Specification,
Works except as stated below. Grout for piling works shall
consist of Portland cement (PC) and water. Sand, PFA
and admixtures may be used with the approval of the
Engineer.
(2) The minimum cementitious content of grout shall be

600 kg/m3.
(3) Grout used to fill core holes shall have a minimum

crushing strength of not less than the specified grade
strength of the concrete surrounding the core hole.
(4) Grout used in minipiles shall have a minimum crushing

strength of 30MPa at 28 days.
(5) Free expansion of grout shall not exceed 10% at the

ambient temperature.
(6) The chloride ion content of admixtures for concrete

containing embedded metal or for concrete made with
SRPC shall not exceed 2% by mass of the admixture
or 0.03% by mass of the cementitious content,
whichever is less.
(7) The maximum total chloride content of grout,

expressed as a percentage relationship between the
chloride ion and the cementitious content by mass in
the grout, shall not exceed 0.1%.
Reinforcement 19.19 Reinforcement connectors for minipiles shall be capable of

Connectors transmitting the total pile load in tension or compression as
appropriate.
Surface 19.20 (1) Surface preparation and application of protective

Treatment coatings other than bituminous coatings to steel piles
of Steel Piles shall be carried out in a fully enclosed well-ventilated
workshop.
(2) The method of application of protective coatings to
June 2022
19/6
steel piles, the ambient temperature and humidity at

the time of application and the time interval between
the application of successive coats shall be in
The complete coating shall be applied in and around
clutches.
Surface 19.21 The surfaces of steel piles to which protective coatings will
Preparation of be applied shall be prepared by blast cleaning to Sa 2½ of
Steel Piles BS EN ISO 8501:Part 1 or medium profile grade in
accordance with BS EN ISO 8503:Part 1.
Epoxy 19.22 (1) Epoxy coatings to steel piles shall consist of 3 coats of
Coatings epoxy based paint, each coat having a minimum dry
to Steel Piles film thickness of 75μm. The first coat shall be applied
within 2 hours of blast cleaning.
(2) The finished surface of epoxy coatings shall be

smooth with a dense and uniform texture and shall be
free from sharp protuberances and pinholes. The
thickness and continuity of completed epoxy coatings
shall be measured using a magnetic thickness gauge
or by other methods approved by the Engineer.
(3) Damaged areas of epoxy coatings shall be repaired by

cleaning the damaged areas to bare metal, feathering
back the adjacent areas with coarse grade sandpaper
and re-applying the coating.
Bituminous 19.23 (1) Bituminous coating material or primer if the bituminous

Coatings to coating consists of a built-up system, to steel piles
Steel Piles shall be applied within 2 hours of blast cleaning. The
thickness of bituminous coatings shall be at least 300
μm.
(2) Damaged areas of bituminous coatings shall be over

coated with the same bituminous coating material to
restore the specified thickness.
Surface 19.24 The splice areas of steel piles which are extended in-situ
Treatment of shall be prepared by blast cleaning and the protective
Extended Steel coating shall be applied to the area. Steel piles for marine
Piles works shall be spliced and the surface treatment applied to
the splice areas before the piles are driven.
Removal of 19.25 Protective coatings shall be removed by blast cleaning,

Protective flame cleaning or by other methods approved by the
Coatings to Steel Engineer from the heads of steel piles which will be
June 2022
19/7
Piles encased in concrete. The coatings shall be removed to a

level of 75mm above the underside of the concrete into
which the pile will be encased.
Concrete 19.26 (1) Structural concrete for Deep Foundation Works shall
have a minimum cementitious content of 400 kg/m3
where placed by tremie pipe, but shall otherwise
comply in all respects with Section 11 of this
Specification.
(2) When infill piles are used within secant pile wall
construction the infill pile concrete shall be Class 7/20
and the compressive strength of the concrete shall be
such that no individual test cube shall be less than
5MPa or greater than 10MPa. The compliance
compressive strength criteria shall be demonstrated by
trials to the approval of the Engineer.
Cast-in Pipes 19.27 Closed end steel pipes with minimum thickness of 2.5mm
for Ultrasonic shall be installed in all bored pipes in excess of 500 mm
Testing diameter as tabulated below. For circular piles the tubes
shall be placed symmetrically round the perimeter. For
barrettes the large tube shall be placed centrally.
Size 150mm tube 75mm tube

Piles
≤ 500φ
> 500φ but ≤ 900φ 1 1
> 900φbut < 1200φ 1 2
1200 and above 2 2
Barrettes
≤ 800 wide 1 2
> 800 wide 1 4
Bentonite Slurry
Bentonite Mix 19.28 The Contractor shall submit for the Engineer's Approval the
proposed bentonite mix in accordance with Clauses 19.116
and 19.117.
Bentonite 19.29 (1) Bentonite for use in excavation support slurry shall
Powder comply with section 6 of API Specification 13A (OCMA
grade bentonite) or similar Specification of EEMUA
publication No. 163. Samples of the bentonite to be
used by the Contractor, together with the
manufacturer's details including names and quantities
June 2022
19/8
of any additives incorporated, shall be submitted to the

(2) A certificate shall be submitted to the Engineer with

each consignment stating the properties of samples
tested. At least one test shall have been carried out
for every ten tonnes of bentonite powder supplied.
Tests shall be carried out to provide the following
information:
(a) apparent viscosity and gel strength of a

suspension of bentonite in water at the
concentration to be used on Site. Tests for gel
strength shall be carried out using a Fann
Rheometer;
(b) moisture content of the bentonite powder and wet

screen residue on US 200 mesh sieve / 75
micron mesh sieve;
(c) a statement of the conditions of tests, such as

water analysis, mixer type, mixer speed during
testing, time of stirring and time of testing after
initial addition of bentonite to the water.
Bentonite 19.30 The properties of each consignment of bentonite powder

Powder: shall not deviate from the approved properties of fresh
Properties bentonite slurry by more than the following limits:
(1) Moisture content ±2%;
(2) Apparent viscosity ±3 seconds;
(3) Gel strength (at 10 minutes) ±1 N/m2.
Bentonite 19.31 The Contractor shall take one sample of bentonite powder
Powder: Site for each fresh mix on the date work is commenced and he
Testing shall conduct the same tests as carried out by the supplier
or manufacturer at the concentration to be used on Site.
Bentonite 19.32 Water used for the mixing of the bentonite slurry shall be
Slurry mains water of potable quality. Bentonite powder shall be
mixed thoroughly into the water by a suitable high shearing
action mixer until all the lumps have been broken up and
dispersed within the mix. The proportion of bentonite to be
included in the slurry shall take into account the rheological
properties of the bentonite and the slurry shall be capable of
maintaining the stability of the excavation in the ground
June 2022
19/9
conditions encountered. The density and head of slurry

above groundwater shall together be sufficient to ensure the
stability of the trench excavations throughout its entire
depth.
Alternative 19.33 The Contractor may submit proposals for additional or

Materials alternative ingredients and additives to the support slurry
specified above. Samples and full details including the
supplier and manufacturer of such ingredients shall be
submitted to the Engineer for Approval. Any such
materials shall not detrimentally affect the stability of the
excavation or have any detrimental effect upon the
concreting or formed concrete. Ingredients to counter the
loss of slurry to the surrounding strata shall be deemed to
be covered by this clause.
Handling and 19.34 (1) The identification number, grade of steel and length of
Storage of Piles pile shall be marked on steel piles. The identification
number, date of casting and length of pile shall be
marked on precast concrete piles.
(2) Piles shall be stored horizontally off the ground on

level supports and in a manner which will not result in
damage or deformation to the piles or in contamination
of the piles. Coated piles shall be handled and stored
in a manner which will not result in damage to the
coatings. Bituminous coated piles shall not be
stacked.
(3) Different types and sizes of piles shall be stored

separately.
Handling and 19.35 Bentonite shall be handled and stored in a manner which
Storage of will not result in spillage on the Site. It shall be stored in
Bentonite cool dry conditions and particular care shall be taken with
bulk storage to prevent balling of the bentonite powder due
to damp, or deterioration of properties due to damp and
heat. A suitable design of hopper cone and bentonite
feeding device shall be submitted to the Engineer for
Approval.
June 2022
19/10
PART 3 : SUBMISSIONS
Particulars of 19.36 (1) The following particulars of the proposed materials,

Driven Piles plants and methods of construction for driven pile
works shall be submitted to the Engineer for Approval :
(a) details of constructional plant;
(b) methods and sequence of installation of piles,

including methods of avoiding damage to
adjacent piles, buildings, structures and utilities
and measures to be taken to deal with hard
material and obstructions;
(c) calculations of driving stresses;
(d) methods of jointing and lengthening piles;
(e) methods of controlling groundwater or

groundwater treatment;
(f) anticipated ground vibration, ground movement

and groundwater drawdown and methods of
instrumentation and monitoring;
(g) methods and sequence of excavation, including

methods of supporting excavations and of
cleaning the excavation;
(h) methods of concreting;
(i) details of protective coatings to steel piles,

including manufacturer's literature;
(j) details of trial piles;
(k) methods of testing, including details of the

specialist firm for non-destructive testing of welds
and the programme for integrity testing.
(2) The particulars shall be submitted at least 21 days

before the relevant trial piles are constructed. If trial
piles are not required, the particulars shall be
submitted at least 21 days before the relevant piling
work starts.
June 2022
19/11
Bored Piles, plant and methods of construction shall be submitted

Secant Piles, to the Engineer for Approval:
Socketted H Piles
and Barrettes (a) details of constructional plant;
(b) methods and sequence of installation of piles,

adjacent piles, buildings, structures, railway
works, pavement and utilities and measures to be
taken to deal with hard material and obstructions;
(c) proposals for installing piles to the tolerances

required including details of guide walls;
(d) methods of jointing and lengthening of steelwork

members and controlling position;
(e) details of splicing of steel piles;
(f) details of temporary casting;
(g) methods of controlling groundwater or

groundwater treatment;
(h) anticipated ground vibration, ground movement

and groundwater drawdown and methods of
instrumentation and monitoring;
(i) methods and sequence of excavation, including

methods of supporting excavations and of
cleaning the excavation;
(j) methods of concreting & grouting;
(k) methods of testing, including details of the

specialist firm for non-destructive testing of welds
and the programme for integrity testing;
(l) contingency proposals for the remedy of pile

misalignment, verticality and alike.
(2) The particulars shall be submitted at least 21 days

before the relevant trial piles are constructed. If trial
piles are not required, the particulars shall be
submitted at least 21 days before the relevant piling
work starts.
June 2022
19/12
Diaphragm plant and method of construction for diaphragm walls

Wall shall be submitted to the Engineer for Approval:
(a) the Contractor shall submit detailed design

proposals which shall include, but not be limited
to, drawings, calculations and schedules. The
proposals shall be submitted at least 4 weeks
prior to the commencement date for construction
of the diaphragm wall;
(b) trench stability calculations together with design

calculations and construction details for
continuously reinforced guide walls;
(c) the layout and horizontal length of the panels to

be concreted;
(d) the method of formation of the joints between

panels;
(e) the sequence of excavation and concreting of

panels;
(f) the methods of monitoring and checking the

stability of neighbouring buildings, structures,
railway works, highways and services;
(g) the methods of monitoring and checking the

stability of the diaphragm wall trench;
(h) the mixing, transporting and placing equipment

for the bentonite slurry;
(i) the method of disposal of contaminated bentonite

slurry;
(j) the type, source, chemical and physical

properties of the bentonite to be used and details
of its cleaning and use.
(2) The Contractor shall note and make allowances for the
restricted headroom on portions of the Works and shall
satisfy the Engineer that his method of excavation,
spoil handling, placement of reinforcement cages, stop
ends and concreting can be accommodated within
these restrictions.
June 2022
19/13
Minipiles plant and methods of construction for minipiles shall

be submitted to the Engineer for Approval:
(a) details of reinforcement or pipe section,

including spacers and couplings;
(b) details of grout mix as stated in Section 12 of

this Specification;
(c) sequence and timing of grouting, including

details of secondary pressure grouting.

least 7 days before trial mixes for the grout are made.
Particulars 19.40 (1) The following particulars of the proposed materials,

of Hand Dug plant and methods of construction for hand dug
Caissons caissons, including details of linings, shall be
submitted to the Engineer for Approval :
(a) details of equipment and plant;
(b) methods and sequence of caisson construction,

adjacent piles, buildings, structures, railway
works, pavement and utilities and measures to
be taken to deal with hard material and
obstructions;
(c) method of supporting excavation and the

controlling of groundwater;
(d) a Safety and Hazard Analysis report;
(e) safety measures to be adopted to minimise risks

involved;
(f) measures to be adopted on Site to ensure full

implementation of safety measures.

least 21 days before the relevant excavation starts.
Refer to Clause 19.12 for restrictions on the use of
hand dug caissons.
June 2022
19/14
PART 4 : CONSTRUCTION OF DEEP FOUNDATION

WORKS
General Requirements
Restricted 19.41 Where there is restricted headroom on portions of the

Headroom Works the Contractor shall satisfy the Engineer that his
method of working can be accommodated within these
restrictions.
Commencement 19.42 (1) Founding level of Deep Foundation Works shall be

of Deep checked by preboring and approved by the Engineer
Foundation prior to commencement of the pile construction.
Works Preboring shall be carried out in accordance with
(2) Deep Foundation Works, groundwater control and

ground treatment shall not commence until the
relevant proposed materials, plant and methods of
construction, including construction and testing of trial
piles, have been approved by the Engineer.
Prevention of 19.43 (1) The position of existing utilities shall be determined

Damage Due to and underground utilities adjacent to the Deep
Deep Foundation Foundation Works shall be exposed or otherwise
Works accurately located before any Deep Foundation Works
start.
(2) All necessary measures shall be taken to minimise the

settlement of the ground and adjacent structures and
utilities and to prevent the formation of cavities in the
ground resulting from the Deep Foundation Works.
(3) The vibrations due to the Deep Foundation Works at

adjacent buildings, structures, railway works,
pavement, utilities and previously installed piles,
measured in terms of peak particle velocity, shall not
exceed 25 mm/s or other values as specified
elsewhere in the Contract or by the Engineer.
(4) The vibrations due to piling works at structures, utilities

and previously installed piles measured in terms of
vibration amplitude shall not exceed 0.2 mm.
June 2022
19/15
Monitoring of 19.44 Measurements of noise level, vibration, ground movement

Noise, Vibrations, and groundwater level shall be carried out in accordance
Ground with Section 2 of this Specification.
Movements and
Groundwater
Levels
Ground 19.45 (1) The founding level of all Deep Foundation Works shall
Investigation for be proven by continuous rotary core drilling in rock or
Deep Foundation by rotary core drilling and/or in-place testing in soil.
Works The depth of drilling or in-place testing shall be five
metres or three times the design foundation
width/diameter below the founding level whichever is
greater. Representative, continuous core samples of
the rock and/or in-place test results of the soil shall be
obtained.
(2) For large diameter bored piles founding on rock or

rock socket, the Contractor shall carry out pre-drilling
for each pile. For mini-piles, socketed steel H-piles,
steel H-piles driven to bedrock and similar small
diameter bored piles founding on rock or rock socket,
pre-drilling should be carried out such that the tip of
every pile should be within 5 m distance from a
pre-drilling hole.
(3) For friction barrette, pre-drilling should be carried out

such as the tip of every barrette should be within 5m
distance from a pre-drilling hole. For end-bearing
barrette founding on rock, at least one pre-drilling hole
per barrette should be carried out.
(4) For each diaphragm wall panel with length less than
4 m, at least one pre-drill hole shall be carried out.
For each diaphragm wall panel with length equal to
or greater than 4 m, pre-drill holes shall be carried
out to a spacing equal to or less than 4 m centre to
centre.
(5) All drillholes shall have a diameter of not less than

"NX" size and shall be fully cored in rock to produce a
core recovery. Each Segment is 1m and shall be not
less than 85% in Grade III rock; or 95% in Grade II
rock; or 100% in Grade I rock or better in accordance
with Geoguide 3.
(6) The methods of sampling and testing in these

drillholes shall be in accordance with Section 24 of this
June 2022
19/16
Specification.
(7) The drillhole shall be extended at least 5m below the

founding level. Point load tests or unconfined
compressive tests shall be carried out on rock cores
recovered on Site from selected drillholes to confirm
rock strength.
(8) Drillholes records shall be submitted within 3 days of

completion of the proving drillholes and not less than
10 days prior to the commencement of Deep
Foundation Works construction. Drillhole records
shall be provided in accordance with Section 23 of this
Specification.
(9) All ground investigation for piles founded on rock,

including pre-drilling and proof-drilling as well as any
core-drilling on the constructed piles, shall be carried
out by an independent Specialist Contractor for Public
Works registered under the Work Category of "Ground
Investigation Field Works", who is required to make a
declaration that it is not a holding / subsidiary / an
associated company or a related party of the
Contractor or any of his sub-contractors responsible
for the piles for which the ground investigation is
carried out, and that it has no financial interest in the
piling works to be tested.
Founding Levels 19.46 The Contractor shall allow the Engineer to inspect the
material at the proposed founding level and shall inform the
Engineer immediately the founding level is reached.
Trial Piles
Trial Piles 19.47 (1) Before Deep Foundation Works start, a minimum of
one trial pile for each type (i.e. tension, compression,
mini-piles, H-piles, etc.) and size of pile or as
otherwise stated in the Contract shall be constructed
and tested.
(2) Trial piles shall be constructed using the materials and

methods of construction proposed for the working piles
and which have been submitted to the Engineer. The
location and details of trial piles shall be as instructed
by the Engineer.
(3) The relevant piling works shall not commence until the
construction, testing and records of the trial have been
June 2022
19/17
approved.
(4) Trial piles shall be left in position, cut off, incorporated

in the Permanent Works or withdrawn and disposed of
as stated in the Contract. Trial piles intended to be
incorporated in the Permanent Works and which do
not comply with the specified requirements shall be
removed from the Works.
Driven Piles
Supports for 19.48 (1) Driven piles shall be supported and restrained by
Driven Piles means of leaders, trestles, temporary supports or
other guide arrangements in such a manner that:
(a) the piles are maintained in position and

alignment;
(b) the piles are not loosened in the ground; and
(c) damage resulting from oscillation, vibration or

movement of free-standing piles does not occur.
The supports and restraints shall be maintained at all

times during driving and until the piles are incorporated
into the structure.
(2) Driven piles for marine works shall be driven from fixed
staging. The staging shall be rigid and strong enough
to ensure that the piling works can be carried out
efficiently and accurately. The Contractor shall
provide and install a corrosion protective system for
all structural steelworks in marine environments in
accordance with BS EN ISO 12944.
Followers 19.49 Followers or long dollies shall not be used unless permitted
by the Engineer; if permitted, the set shall be revised by the
Contractor and approved by the Engineer, to allow for the
reduction in effectiveness of the hammer blows.
Marking of Piles 19.50 Piles, including temporary and permanent casings, shall be
marked at 1 m intervals before pitching.
Driving Piles 19.51 (1) Each pile shall be driven without interruption until the
required depth or set has been achieved. If a
minimum depth of penetration is stated in the Contract,
the Contractor shall submit to the Engineer his
proposals for achieving this requirement and it shall be
June 2022
19/18
his responsibility to ensure that the minimum

penetration and set are achieved without causing
damage to the pile.
(2) The sequence and method of driving piles shall be

such as to minimise detrimental effects of heave and
lateral displacement of the ground and to cause the
least possible displacement to previously installed
piles. Piles, including casings, shall not be driven
within a centre to centre distance of 3 m or 5 times the
diameter of the pile or casing, whichever is less, from
an unfilled excavation or from an uncased concrete
pile which has been cast for less than 48 hours.
(3) The Contractor shall immediately inform the Engineer

of any sudden change in driving characteristics.
Driving 19.52 (1) Concrete piles shall not be driven until the concrete
Concrete has attained the specified grade strength.
Piles
(2) The driving stresses in precast reinforced concrete
piles and prestressed concrete piles shall not exceed
one half of the specified grade strength of the
concrete; calculations of the driving stresses shall be
submitted to the Engineer for Approval.
Displaced 19.53 Piles which have been displaced as a result of driving

Piles adjacent piles shall be corrected. Particulars of the
method of correction and measures to be taken to avoid
displacement in subsequent driving shall be submitted to
the Engineer for Approval.
Redrive Checks 19.54 No redrive checks shall be carried out within 24 hours of
completion of first driving.
Lengthening 19.55 The strength of piles at joints shall be not less than the
Driven Piles strength at any normal section of the pile. Lengthened
piles shall not be driven until the joint has developed the
designed strength. Pile joints shall be tested as stated in
the Contract.
Measurement of 19.56 (1) Set shall be measured for each driven pile at times
Set of Driven Piles approved by the Engineer and in the presence of the
Engineer. The final set shall be measured as either:
(a) penetration per 10 blows; or
(b) number of blows required to produce 25mm
June 2022
19/19
penetration.
(2) If driving is interrupted for more than 30 minutes, the

set shall not be measured after driving restarts until at
least 20 blows of the same driving energy used prior to
interruption have been struck.
(3) When final set is measured:
(a) the exposed part of the pile shall be in good

condition without damage or distortion;
(b) the dolly and packing shall be in sound condition;
(c) the hammer blow shall be in line with the axis of

the pile and the impact surfaces shall be flat and
at right angles to the axes of the pile and
hammer; and
(d) the hammer shall be in good condition and

operating correctly.
(4) The temporary compression of each driven pile shall

be measured.
(5) The Contractor shall inform the Engineer at least

1 hour before final set and temporary compression are
to be measured.
Excavation for Deep Foundation Works
General 19.57 (1) With the exception of diaphragm wall panels and
barrettes which shall be in accordance with Clause
19.67(4), other Deep Foundation Works shall not be
excavated within a distance equivalent to 3 times the
smallest dimension of the Deep Foundation Works
section, from other Deep Foundation Works which
have been cast within 3 days and/or which contain
workable or partially set concrete where a flow of
concrete or instability could be induced or damage
caused to any installed Deep Foundation Works. The
proposed sequence of construction shall be submitted
to the Engineer for approval prior to commencing any
Deep Foundation Works.
(2) Temporary support shall be provided to maintain the

stability of the excavation. The support shall extend
to the full depth of the excavation. Care shall be
June 2022
19/20
taken not to destabilise ground by excavating too far

ahead of the temporary support.
Cleaning 19.58 (1) Prior to placing steel or concrete, any support fluid
Excavations for including water shall be cleaned by appropriate means
Deep Foundation or replaced with clean support fluid so that settling of
Works suspended sediments during concreting does not
occur which may lead to inclusions or other defects in
the concreted shaft or the accumulation of settled
sediment at the base of the excavation.
(2) The bases of excavations for Deep Foundation Works

shall be cleaned by airlifting or by another method
approved by the Engineer before concrete is placed.
If excavation is carried out under water, cleaning shall
continue until the water is clear and free from particles
of soil. Measures shall be taken to prevent the
accumulation of silt and other material at the base of
the excavation.
(3) If the rate of ingress of water does not exceed 0.3

l/sec., the base of excavations for piles shall be dried
immediately before concrete is placed. Otherwise
Section 11 of this Specification shall be used for
placement of concrete under water.
Depth of 19.59 The depth of Deep Foundation Works shall be as shown in

Deep Foundation the Contract. Where the Contractor wishes to increase the
Works depth of the Deep Foundation Works as part of his
Temporary Works requirements, this shall be subject to the
Engineer's Approval.
Guide Walls 19.60 The design and construction of guide walls shall be the
responsibility of the Contractor and shall take into account
the actual site and ground conditions and the equipment to
be used on site to ensure stability and avoid undercutting as
appropriate. The inner face of the guide wall shall be
constructed to the profile of the finished wall.
Deep Foundation 19.61 Where the concrete is cast against previously completed
Works Joints Deep Foundation Works, the previously formed concrete
shall be cleaned so that all deleterious material is removed
before the joint is formed.
Excavation 19.62 (1) Excavations for piles constructed using bentonite

using Bentonite slurry shall be filled with the slurry from the time that
Slurry excavation commences until concreting is complete.
The slurry shall be maintained at a level of at least 1 m
June 2022
19/21
above the level of the external groundwater and such

that the slurry pressure exceeds the pressure exerted
by the soil and ground water.
(2) If there is a loss of bentonite slurry from the excavation

which is sufficient to result in a lack of stability, the
excavation shall be immediately filled with an
approved material. The cause of the loss of slurry
shall be investigated and excavation shall not
recommence until remedial measures have been
(3) Subject to the Engineer’s approval and the availability

of the necessary equipment, the Contractor may use
polymer slurry as an alternative to bentonite slurry. The
handling and disposal of polymer slurry shall follow the
supplier’s recommendation and be subject to the
Engineer’s agreement.
Disposal of 19.63 Spoil removed from the excavation shall be separated from
Spoil the slurry employed in the excavation process. It shall be
disposed of as quickly as possible to an approved dump
site and in a manner approved by the Engineer.
Disposal of 19.64 Used bentonite or contaminated slurry, not suitable for

Bentonite Slurry re-use shall be disposed of in a manner approved by the
Engineer. Bentonite may be disposal of directly or mixed
with sufficient decomposed rock or similar material before
disposal to approved Public Fills, in accordance with the
requirements under the Construction Waste Disposal
Charging Scheme and other relevant documents issued by
CEDD or EPD.
Site Cleanliness 19.65 The Contractor shall ensure that the Site be kept clear of
slurry to the satisfaction of the Engineer and that operations
be conducted in such a manner so as to prevent any
spillage of slurry over the Site or areas accessible by the
public.
Cast-in Place Piles
Excavations for 19.66 (1) Except as stated in Clause 19.70(1), excavation for
Cast-in Place Piles cast-in place concrete piles shall be carried out by
mechanical methods. Blasting and compressed air
shall not be used.
(2) The stability of excavations for cast-in-situ concrete

piles shall be maintained by one of the following
June 2022
19/22
methods:
(a) temporary casings;
(b) permanent casings;
(c) thixotropic support consisting of a slurry

containing bentonite or other agent.
(3) The bottom of casings shall be kept sufficiently deep to

prevent the flow of soil into the casing.
(4) The used piling method must be such that the works
can be carried out as planned and not causing and
adversely affect to the surrounding ground / structures.
(5) Where casings are used, the drilling method shall be

selected to suit the site conditions and soil properties.
Disturbance and increase of pore water pressure shall
be minimised by selecting a drilling method that suit
the soil properties, limiting the used flushing or
grouting pressure and intermittent drilling or slowing
down piling speed.

the Engineer from trial pile installation prior to the
installation of the Works piles, that his adopted
equipment, method and procedure of construction
including flushing medium used, control of flushing,
support for maintaining stability of excavations, and
toe cleaning, are suitable for the type of ground
conditions and prevent the collapse of the excavations
or causing significant ground loss.
Barrettes and Diaphragm Walls
Excavation for 19.67 (1) Excavation for barrettes and diaphragm walls shall be
Barrettes and carried out by mechanical methods.
Diaphragm Walls
(2) The stability of excavations shall be maintained by
thixotropic support consisting of a slurry containing
bentonite or other agent.
(3) The height of guide walls shall be such that the head
of slurry is sufficient to ensure the stability of
excavations and that excessive movements of the
adjacent ground will not occur. The position,
alignment and level of guide walls shall be checked at
June 2022
19/23
regular intervals approved by the Engineer.
(4) Diaphragm wall panels and barrettes shall not be

excavated within a distance of 6m or equivalent to 3
times (maximum 8.4m) the smallest dimension of the
such panels or piles section, from other deep
foundation works which have been cast within 12
hours and/or which contain workable or partially set
concrete, unless they are separated by other deep
concrete foundations completed for over 14 days or
when their concrete has achieved 70% of the design
strength, whichever is earlier.
(5) Stepping at the base of any single diaphragm wall

panel or barrette is not allowed.

the Engineer from trial diaphragm wall panel or trial
barrette construction prior to the construction of the
Works diaphragm wall or barrette, that his adopted
including support for maintaining stability of
excavations, and toe cleaning, are suitable for the type
of ground conditions.
Minipiles
Excavation for 19.68 (1) The stability of excavations for minipiles shall be
Minipiles maintained where necessary by temporary casings or
by other methods consented to by the Engineer.
(2) Temporary casings shall be used if excavation is car-

ried out by wash boring methods or when coring water
or air is used as a flushing medium. Where
temporary casings are used, excavation of mini piles
shall be carried out using the ring bit system or the
closed loop system or a system that recovers the
excavated material through a passage inside the drill
bit or the steel casings. The advancement of the
casings shall be carried out ahead or at least
simultaneously with the advancement of the
excavations. The advancement of the excavations
shall not be carried out ahead of the casings unless
excavations are in self supporting ground such as
rock.

the Engineer from trial pile installation prior to the
June 2022
19/24
installation of the Works piles, that his adopted

including flushing medium used, support for
maintaining stability of excavations, and toe cleaning,
are suitable for the type of ground conditions and
prevent the collapse of the excavations.
Grouting 19.69 Grouting trials shall be carried out to demonstrate accurate

Trials for control of water/cement ratio, consistency of mixing,
Minipiles satisfactory workability and achievement of strength
requirements. The trial shall be carried out on one minipile
which is representative of those which will be use in the
Permanent Work and at location approved by the Engineer.
Hand Dug Caissons
Excavations for 19.70 (1) Excavation for hand dug caissons shall be carried out
Hand Dug using manual methods or power tools. Blasting shall
Caissons not be used.
(2) The stability of excavations for hand dug caissons

shall be maintained where necessary by linings.
Liners 19.71 (1) In-situ concrete tapered rings used as permanent

liners shall be at least 100mm thick and shall not
exceed 1 m deep. The rings shall be constructed
with well-compacted concrete of Class 30/20 or
stronger. The internal surface of the liner formwork
shall be smooth and coated with debonding agent.
The formwork and stripping time shall be in
(2) Where the concrete liners are to be removed during

any future excavation, the internal surface of the liner
shall be coated with debonding agent prior to the
placement of the permanent concrete.
(3) Shaft linings shall be placed as soon as practicable

and not more than 24 hours after each increment of
excavation is complete.
(4) Voids between linings and excavated faces shall be

filled with concrete of the same grade as the lining.
Sealing and 19.72 (1) Leakages of groundwater through liners of hand dug
Scaling of Hand caissons shall be stopped by a method approved by
Dug Caissons the Engineer. Where leakage cannot be stopped to
the satisfaction of the Engineer the Contractor shall
June 2022
19/25
place the pile concrete by tremie methods in

accordance with Clause 19.79.
(2) Loose rock on the faces of the shafts shall be scaled

off and removed.
General 19.73 (1) All underground services in the area shall be located
Precautions and rendered safe. A check shall also be carried out
to ensure that there are no obstructions such as;
cellars; underground water-courses; underground
railway structures; or ground conditions which may
create hazards during the operation. Results of the
check shall be recorded and submitted to the Engineer
for Approval.
(2) The Contractor shall allow for the risk of the cores of
pendant/bridle ropes fracturing due to shock loading.
These ropes shall be opened up and the cores
carefully examined at 3 monthly intervals. The results
of the examination shall be recorded and submitted to
the Engineer for Approval.
(3) Any crane used for raising or lowering personnel into

the caisson shall be fitted with power lowering and/or
dead man's handle. Cages used for lifting personnel
shall be tested and a record kept of weekly
inspections.
(4) All lifting appliances and gear shall carry current

certificates of test and thorough examination in
accordance with the Factories and Industrial
Undertakings Regulations. Particular attention shall
be paid to the risk of damage to gear by sharp edges.
Facilities for 19.74 The Contractor shall provide facilities for inspection to be
Descent into undertaken at any stage during excavation. The facilities
Caissons provided and the manner in which the works are conducted
shall comply with BS 8008 “Safety precautions and
procedures for the construction and descent of
machine-bored shafts for piling and other purposes” except
where amended as follows:
(1) descent shall be by means of a steel cage of approved

design of a minimum height of 1.8m. The side of the
cage shall be open to allow inspection of the sides of
the excavation;
(2) the cage shall be fitted with three points of suspension
June 2022
19/26
each capable of sustaining a minimum upward force of

10kN. A certificate shall be provided showing that the
system has been tested to this load;
(3) safety harnesses of a recognised standard shall be

provided, worn and be attached to rescue lines for
each person descending;
(4) caisson hoists shall have a motor that powers the

winding gear in both directions to allow a slow,
controlled descent. A "fail-safe" mechanism shall be
fitted to the winding gear and the minimum capacity of
the hoist shall be 10kN. The frame supporting the
hoist shall be designed such that it is stable under the
full winding capacity of the hoist. The headworks
assembly shall be load tested in excess of its Safe
Working Load (SWL) in accordance with the Factories
and Industrial Undertakings (Lifting Appliances and
Lifting Gear) Regulations prior to being put into use
and a written certificate produced which will be
retained by the Site Safety Officer. The maximum
SWL shall be clearly marked on the carrier beam.
Working in 19.75 The Contractor shall provide the following items and adopt
Hand Dug the following procedures:
Caissons
(1) a continuous fresh air supply to the bottom of each
caisson, the intake of which shall be at least 2m above
ground level. Before entry the atmosphere in the
caisson must be purged with fresh air for at least 10
minutes;
(2) a powerful battery operated light or 110v C.T.E. supply

lamp;
(3) a calibrated atmosphere monitor suitable for any

gases which may be encountered and able to indicate
low/high oxygen. The monitor shall be kept in good
working condition either in, or at the head of, the
caisson at all times when work is in progress. Before
any person enters a caisson for the first time after a
break or overnight stop the atmosphere shall be
monitored and a record kept of the date and time of
the check and the person recording it;
(4) a knotted rope of 25mm diameter securely fixed at

ground level and reaching to the bottom of the
caisson, or steel climbing irons built into the caisson
June 2022
19/27
lining;
(5) a toeboard or other means around the head of the

caisson to prevent material falling in;
(6) a means to prevent the inflow of ground/flood water

into the caisson;
(7) 110 volt C.T.E. power supply for hand tools. Special
care shall be taken regarding electrical cables, sockets
and switches at the head of the caisson;
(8) winch control panel/pendant to be kept out of reach

when not in use;
(9) when not in use and after every shift stout timber
boards shall be firmly fixed in place to cover the
caisson excavation;
(10) head of caisson to be kept clear of spoil;
(11) lining of caissons to be checked every shift and

repaired if signs of weakness or water seepage
observed;
(12) safety helmet, hearing protection and eye protection

shall be worn at all times. Respiratory protection or
breathing apparatus shall be worn as dictated by
prevailing conditions;
(13) submersible water pump with sufficient power cable

and delivery hose;
(14) a means of eliminating airborne dust within the

caisson;
(15) all persons descending into, or working in, hand dug

caissons shall wear a suitable rescue harness
attached to a safety rope at all times.
(16) The minimum clear working space inside a caisson

(i.e. excluding the lining) shall not be less than 1.8m
diameter. Caissons with an enlarged base shall not be
used unless otherwise specified.
Obstruction 19.76 Upon encountering an obstruction to excavation the

Engineer shall be informed immediately. The Contractor
shall submit for the approval of the Engineer his proposed
June 2022
19/28
method for overcoming the obstruction. The method for

overcoming the obstruction shall not cause excessive
overbreak, undermining, settlement or vibration of adjacent
buildings, structures, pavements, utilities or services.
Diaphragm Wall, Secant Pile Wall and Contiguous Pile

Wall
Performance 19.77 (1) The Contractor is responsible for constructing a

watertight wall, such that leakage is restricted to damp
patches with no visible flow of water in any area of the
wall. Single leaks indicated by jetting or spraying
shall not be present.
(2) Upon initial excavation of panels/piles, the total inflow

over a given area shall not exceed 0.12 litre/m2 per
day overall, and 0.24 litre/day on any separate square
metre. No leakage occurring in the form of a water jet
or spraying of water shall be allowed.
Reinforcement for Deep Foundation Works
Reinforcement 19.78 (1) Reinforcement for Deep Foundation Works shall

comply with Section 10 of this Specification.
(2) Reinforcement cages for Deep Foundation Works

shall be marked on Site to identify their required
orientation during placement in the excavation.
(3) Lifting points and design of lifting lugs of reinforcement

cages shall be submitted to the Engineer for Approval.
Cover spacers shall be circular and comply with
Section 10 of this Specification. They shall be
capable of resisting deformation during cage
placement within the excavation and shall not entrap
slurry during concreting.
(4) The reinforcement shall be adequately fixed to avoid

displacement and to maintain the nominal specified
cover during concreting.
Placing Concrete in Deep Foundation Works
Placing 19.79 (1) All Deep Foundation Works shall be concreted to a

Concrete level such that sound concrete is present at the final
trimmed levels specified. All concrete for Deep
Foundation Works shall be placed by tremie method in
accordance with Section 11 of this Specification. Care
June 2022
19/29
shall be taken to ensure that all bentonite slurry is

expelled from the pipe during the initial charging
operation.
(2) Concrete shall be placed as soon as practicable after

the Approval of the Engineer has been obtained.
Concrete shall be placed without interruption until the
complete pile/panel is concreted. If the continuity of
placing the concrete is interrupted the Contractor shall
submit remedial proposals for the approval of the
Engineer.
(3) Each batch of concrete shall be placed before the

previous batch has lost its workability. Removal of
temporary supports, when used, shall be completed
before the concrete within the excavation loses its
workability.
(4) The level of the top of the sound concrete shall be at

least 750mm above the specified cut-off level.
(5) If the top of the guide wall is at the specified cut-off

level, concrete shall continue to be placed until the top
of the concrete is free from contamination.
(6) After the concrete has hardened, excess concrete

shall be removed to the specified cut-off level.
(7) Operations likely to disturb or affect the concrete or

placing of the concrete shall not be carried out until
approved by the Engineer. Particular care shall be
taken to ensure that the requirements as stated in
Section 11, Part 1 of this Specification are complied
with.
Stop Ends 19.80 (1) Stop ends, inserted before placement of concrete in
for Diaphragm the diaphragm wall panel, shall be clean and have a
Wall smooth regular surface. Any shutter release agent
shall be to the approval of the Engineer. Where stop
ends are inserted in sections, adequate joint
connections must be provided to ensure stop end
verticality over the whole length.
(2) The extraction of stop ends shall be carried out at such

a time and in such a manner that no damage is
caused to the concrete placed against them, or to the
adjacent soil and structures, including guide walls.
June 2022
19/30
(3) Stop ends shall not be permanently encased in the

diaphragm wall.
(4) Stop ends shall be adequately restrained to prevent

movement during concreting.
Box Outs 19.81 Methods for forming Box Outs shall be submitted to the
Removal of 19.82 (1) A sufficient quantity of concrete shall be maintained

Temporary within temporary casings which are being withdrawn to
Casings ensure that the pressure from external water or soil is
exceeded and that the excavation is not reduced in
section or contaminated.
(2) Temporary supports which are in contact with concrete

and which are not withdrawn before the initial set of
the concrete has taken place shall be left in place.
Construction 19.83 Construction joints shall be formed in accordance with

Joints Section 8 of this Specification.
Test Cubes 19.84 Test cubes shall be made and tested in accordance with
Backfilling 19.85 Where concrete is not brought to the top of the empty
Above Cut-off excavation, the excavation shall be backfilled as soon as
Level possible with an approved granular material. Prior to
backfilling, the excavation shall be adequately protected to
avoid causing a safety hazard.
Cleaning and 19.86 (1) All deleterious material adhering to the face of Deep
Remedial Works Foundation Works exposed during excavation shall be
removed and the concrete surface thoroughly cleaned
by pressure (minimum 10 bar) water jetting. Any
defects, voids, inclusions, leakage or other
imperfections in the Deep Foundation Works shall be
rectified immediately in accordance with Section 11 of
this Specification.
(2) The face of Deep Foundation Works shall be cleaned

and repaired to the satisfaction of the Engineer before
any concrete is cast against the Deep Foundation
Works.
(3) Concrete protrusions shall be trimmed back, where

required by the Engineer, in accordance with Section
11 of this Specification.
June 2022
19/31
PART 5 : INSPECTION AND TESTING
Inspection of Deep Foundation Works
Inspection of 19.87 The Contractor shall allow the Engineer to inspect

Excavations excavations for Deep Foundation Works before placing
concrete and at other times as required by the Engineer.
The Engineer shall decide on the most suitable method to
be used for inspecting excavations and the Contractor shall
provide all the necessary facilities and equipment to enable
the Engineer to carry out the inspection in a safe manner.
The Contractor shall inform the Engineer 24 hours, or such
shorter period approved by the Engineer, before placing
concrete in Deep Foundations Works.
Inspection of 19.88 (1) If instructed by the Engineer, installed Deep

Installed Deep Foundations Works shall be exposed for inspection or
Foundations testing. The face of excavations shall be at least
Works 750mm from the face of the Deep Foundations Works
and shall be to a depth approved by the Engineer.
The excavation shall be maintained in a stable
condition and kept free from water.
(2) The surface of the Deep Foundations Works shall be

washed clean of all silt, mud or other adhering
materials to permit inspection.
(3) After inspection, excavations for exposing Deep

Foundations Works shall be filled using an approved
fill material compacted in accordance with Section 6,
to obtain a relative compaction of at least 95% above
the groundwater table.
Interface Coring 19.89 Large Diameter Bored Piles, Barrettes, Diaphragm Wall
and the Like
To ascertain the soundness of the interface, the

Contractor shall carry out core-drilling at the concrete/rock
interface for each of the large diameter bored piles,
barrettes, diaphragm wall panels and the like. The
core-drilling shall cover at least 1 m above and 1 m, or
half a diameter of the pile base, whichever is larger, below
the interface.
Socketed H-piles, H-piles driven to bedrock, Mini-piles

and similar small diameter bored piles
June 2022
19/32
To verify the quality of rock for founding or forming of rock

socket, additional proof drill holes should be sunk at least
5 m below the as-built top level of the rock socket, or the
as-built rock socket length of the nearest pile, whichever is
the deeper. The recommended number of such drill
holes should be at least 2 for sites with 100 or less piles;
or 1% of the number of piles for sites with more than 100
piles (any fraction of a drill hole so calculated should be
construed as one additional drill hole).
For interface core drilling, triple tube core barrel of

minimum size equal to HMLC or 3C-MLC or other size
approved by the Engineer shall be used.
The water supply rate, hydraulic pressure and rotary

speed shall be reduced when the drilling depth is 500mm
above to 500mm below the anticipated interface level to
ensure a better core recovery.
The contractor shall record the penetration rate, such that

time period taken for every 200mm penetration throughout
the drilling process.
The contractor shall make sure that the interface between
concrete and rock is kept intact throughout the drilling
process.
Proof Test by 19.90 Proof core-drilling test is commonly used in large diameter
Core-drilling bored piles, barrettes and the like which can reveal the
soundness of the founding rock, concrete and the
interface between the pile and the rock. When carrying
out core-drilling tests :
(1) the core-drilling should be taken through the full

depth of the pile and carried down to a distance of at
least half a diameter of the pile base, or 1 m,
whichever is larger, into the ground upon which the
pile is founded
For proof core drilling, the water supply rate,

hydraulic pressure and rotary speed shall be reduced
when the drilling depth is 500mm above to 500mm
below the anticipated interface level to ensure a
better core recovery.
The contractor shall record the penetration rate, such

that time period taken for every 200mm penetration
throughout the drilling process.
June 2022
19/33
The contractor shall make sure that the interface

between concrete and rock is kept intact throughout
the drilling process. The contractor shall carry out
the interface coring by three or more core runs. The
first core run shall be terminated at approximately
750mm above the interface. The second core run
shall cover approximately 1.5m core and enable the
interface to be located around the middle of this core
run;
(2) the completed core so taken should be properly

marked and arranged in proper order for inspection;
(3) the concrete cores should not show evidence of

honeycombing or segregation of individual
constituent materials;
(4) any rock core obtained should be visually examined

to conform with the required rock material specified
in the design;
(5) the cores should also be examined to confirm the

adequacy of the interface between the concrete and
rock; and
(6) where piles are founded on soil, standard penetration

tests should be carried out at a maximum interval of
1.5 m from the pile founding level down to a distance
of at least 3 times the diameter of the pile base, or 5
m, whichever is larger, to verify the required soil
strength.
Welding Test 19.91 Weld tests shall be for surface flaw and volumetric
imperfection in accordance with Section 7 of this
Specification. A sampling rate of not less than 10% of
the total number of welded joints should be tested by
means of non-destructive tests prior to driving in the
spliced sections of the piles. Such test reports, with the
joint locations specified, should be included in the piling
records.
Tolerances
Tolerances: 19.92 Dimensional tolerances of steel bearing pile sections shall

Steel Bearing comply with the relevant standards stated in Table 2 of BS
Piles EN 1090:Part 2. Fabrication tolerances for steel bearing
piles and related steelwork shall comply with BS EN 1090:
Part 2.
June 2022
19/34
Tolerances: 19.93 The manufacturing tolerances for precast concrete piles

Precast shall comply with the following requirements:
Concrete Piles
(1) The external cross-sectional dimensions shall be
within +6 mm and 0 mm of the specified dimensions;
(2) The wall thickness of hollow spun concrete piles shall

be within +25 mm and 0 mm of the specified
thickness;
(3) There shall be no irregularity exceeding 6 mm in a 3 m

length along the face of the pile measured using a 3 m
straight edge;
(4) There shall be no irregularity exceeding 25 mm in a

3 m length along the internal face of hollow spun
concrete piles measured using a 3 m straight edge;
(5) The centroid of any cross-section of the pile shall not

be more than 12 mm from the straight line connecting
the centroid of the end faces of the pile; for the
purpose of determining the centroid, the centroid of
any cross-section of a hollow pile shall be determined
by assuming that the pile has a solid section.
Tolerances: 19.94 (1) Piles, including hand dug caissons, barrettes and
Pile Installations mini-piles, shall be installed to within the tolerances
stated in Table 19.1.
June 2022
19/35
Table 19.1 : Tolerances of Installed Piles
Description Tolerance
Land piles Marine piles
Deviation from specified 75 mm 150 mm
position in plan,
15mm for
measured at cut-off level
minipiles
Deviation from vertical 1 in 75 1 in 25
1 in 100 for
minipiles
Deviation of raking piles 1 in 25
from specified batter
Deviation from specified 25 mm
cut-off level
The diameter of cast in-situ piles shall be at least 97% of the
specified diameter
(2) the plan dimension of any cast-in place pile shall not
be less than the specified dimension of the pile.
(3) Piles which do not comply with the specified

tolerances shall not be forcibly corrected.
(4) The Contractor shall submit his proposed method for

checking pile tolerances to the Engineer for Approval.
Tolerances: 19.95 Deep foundation wall construction shall be carried out in

Deep Foundation accordance with the following tolerances.
Wall
Construction (1) The minimum clear distance between the faces of the
guide walls shall be the specified wall thickness plus
25mm. The maximum clear distance shall be the
specified wall thickness plus 50mm. The guide walls
shall be propped, as necessary, to maintain these
tolerances.
(2) The finished face of the guide wall towards the

excavation and on the side of the excavation nearest
to any subsequent main excavation shall be vertical to
within 1:200. The top edge of the wall shall not vary
from straight line or specified profile by more than
15mm in 3m.
June 2022
19/36
(3) The plane of the wall face to be exposed shall be

vertical to within a tolerance of 1:100 along and
perpendicular to theoretical wall profile. In addition to
this tolerance, a tolerance of 100mm shall be allowed
for protrusions resulting from irregularities in the
ground excavated, beyond the general face of the wall.
Horizontal offset to be ±75mm when cutoff level
within 5m below ground and ±50mm plus 1 in 100
when cutoff level is lower than 5m below ground.
Vertical offset at cutoff level to be 0mm to 25mm.
(4) Where recesses are to be formed by inserts in the

wall, they shall be positioned within a vertical tolerance
of ±75mm located within 25m below ground and
±100mm for deeper recesses, and horizontal tolerance
measured along the face of the wall of ±75mm plus
1:100 along and perpendicular to wall direction.
(5) The tolerances in positioning reinforcement and

couplers shall be as follows:
(a) longitudinal tolerance of cage head at the top of

the guide wall and measured along the trench :
±75mm plus 1:100;
(b) vertical tolerance at cage head in relation to the

top of the guide wall : ±75mm within 25m below
ground and ±100mm at deeper levels;
(c) lateral tolerance of cage head at the top of the

guide wall and measured across width of wall :
±25mm.
(6) Notwithstanding the requirements of this Clause the

tolerances may be aggregated only to the extent that
they do not exceed 150mm for depths < 15m; 300mm
for depths between 15m to 25m; 400mm for depths
between 25m to 35m; to be specified by Engineer in
Particular Specification for depths exceeding 35m.
Tolerances: 19.96 If at any stage during the Deep Foundation Works it is

Non Compliance detected that the specified tolerances have been exceeded,
the Contractor shall submit for the approval of the Engineer
his proposals for rectifying the defects. In addition the
Contractor shall submit for the Engineer's approval an
amended method statement for all subsequent Deep
Foundation Works.
June 2022
19/37
Records of Deep Foundation Works
General 19.97 Records of Deep Foundation Works construction shall be

kept by the Contractor on the Site and submitted to the
Engineer within 24 hours after each Deep Foundation has
been completed. The records shall be kept on standard
forms as shown in Appendices 19.3 to 19.6 and shall be
Records of 19.98 Records of prefabricated piles shall be kept by the

Prefabricated Contractor on the Site and submitted to the Engineer at the
Piles Delivered time the piles are delivered to the Site. The records shall
include test certificates, analyses and mill sheets for steel
piles and proprietary piles.
Records of 19.99 Records of tests on bentonite slurry shall be kept by the

Bentonite Slurry Contractor on the Site and a report shall be submitted to the
Engineer on a weekly basis. The records shall be kept on
standard forms as shown in Appendix 19.7 and shall be
Records of Load 19.100 Records of load tests on piles shall be kept by the
Tests on Piles Contractor on the Site and a report shall be submitted to the
Engineer within 48 hours after the test has been completed.
The records shall be kept on standard forms as shown in
Appendix 19.2 and shall be available to the Engineer for
inspection at all times. The records shall include graphs
showing load and movement versus time, plotted in the
format agreed by the Engineer.
Records of 19.101 Records of integrity tests on Deep Foundation Works shall

Integrity Tests be kept by the Contractor on the Site and a report shall be
submitted to the Engineer within 3 days after the test has
been completed. The records shall be available to the
Engineer for inspection at all times. The report shall
contain full details including the following items:
(1) details stated in Clause 1.4;
(2) Deep Foundation Works reference numbers;
(3) measured length of Deep Foundation Works;
(4) defects such as cracks, fractures or discontinuities;
(5) interpreted stiffness of deep Foundation Works from

integrity test.
June 2022
19/38
Record 19.102 (1) Record drawings of installed Deep Foundation Works

Drawings & Piling shall be prepared by the Contractor and two copies
Works shall be submitted to the Engineer within 14 days of
completing the Deep Foundation Works, including
cutting and trimming. The drawings shall include the
as-constructed co-ordinates of the centre of each
pile/panel at cut-off level, the final depth and cut-off
level of each pile/panel and any other information
required by the Engineer.
(2) Within 14 days of completing the piles in each pile

group or building block for minipiles, socketted steel
H-piles and small-diameter bored piles, the Contractor
shall submit to the Engineer a piling record plan
showing the following:
(a) The top levels of the rock sockets;
(b) The bottom levels of the rock sockets;
(c) The lengths of the rock sockets; and
(d) The contours of the rock-head inferred from drill

hole logs.
Testing : Load Tests on Piles
General 19.103 (1) The number of piles to be tested by load testing shall
be at least one for each batch of completed piles or in
accordance with the Contract.
(2) Piles shall be tested to determine the movement of the

piles under load. Testing shall be carried out in
accordance with a procedure approved by the
Engineer. The method of testing shall be as stated in
Appendix 19.1.
(3) Piles shall not be tested until the concrete or grout has
attained sufficient strength to withstand the tests. The
tests shall be carried out within 28 days of the
Engineer's instruction to carry out the test.
Compliance 19.104 (1) On completion of testing in accordance with Clause

Criteria 19.103 the results of load tests on piles shall comply
with the following requirements:
(a) the movement of the pile head at any load shall
June 2022
19/39
be less than twice the movement at 90% of that

load (Brinch Hansen's criteria);
(b) under working load the gross pile head

movement shall not exceed 20mm for building
piles and 10mm for piles for other structures;
(c) The maximum movement of the pile head shall

not exceed :
2WL + D + 4mm
AE 120
W =
Design working load (kN)
L =
Pile length (mm)
A Pile cross - sectional area (mm2)
=
E =
Youngs modulus of pile concrete
(kN/mm2)
D = Least lateral pile dimension (mm)
(d) If the rate of recovery after removal of the

maximum test load is less than 0.1mm/hour in a
period of not less than 15 minutes, the residual
movement at the head of the pile shall not
exceed D/120 + 4mm.
(2) Where piles are to comply with the requirements of the

Buildings Department (BD), the results of load tests on
piles shall, in addition to compliance with Clause
19.103(1), satisfy any criteria required under the
Buildings Ordinance.
Non-compliance: 19.105 (1) If the result of any load test on piles does not comply
Load Tests on with the specified requirements for movement in
Piles Clause 19.104 additional piles shall be installed and
tested in accordance with Clauses 19.103(2) and (3).
The number of additional piles and additional tests
shall be as instructed by the Engineer.
(2) The position of additional piles shall be determined by

ground investigation as stated in Clause 19.45.
(3) Where additional piles are to be incorporated into the

Permanent Works, extended pile caps shall be
designed and constructed by the Contractor to the
June 2022
19/40
Concrete Cores From Deep Foundation Works
Sampling and 19.106 (1) All piles/panels acting in tension and a minimum of
Testing 10% of other piles/panels (with minimum of 2 nos.)
shall be cored for testing in accordance with Section
11 of this Specification. The positions from which
the cores are taken shall be as instructed by the
Engineer. Core size to be 100mm unless a smaller
size is approved by the Engineer.
(2) Holes formed by taking concrete cores from Deep

Foundation Works shall be reinstated using an
approved concrete mix or an approved grout mix in
(3) Prestressed precast concrete piles from which

concrete cores have been taken shall be abandoned.
Compliance 19.107 The compliance criteria for concrete cores from Deep
Criteria Foundation Works shall be as stated in Section 11 of this
Specification.
Non-compliance 19.108 (1) If the result of any concrete core test does not comply
with the specified requirements for compressive
strength in Section 11 of this Specification, additional
Deep Foundation Works shall be installed and tested
in accordance with Clause 19.105(2) and (3). The
number of additional piles/panels and additional tests
shall be as instructed by the Engineer.
(2) The position of additional piles/panels shall be

determined by ground investigation as stated in
Clause 19.45.
(3) Where additional piles/panels are to be incorporated

into the Permanent Works, extended pile caps or
panels shall be designed and constructed by the
Contractor to the approval of the Engineer.
Testing : Non-destructive Tests on Welds in Piles
Testing: 19.109 The number and type of non-destructive tests on welds in

Non-destructive piles shall be as stated in the Contract and shall be carried
Tests on Welds in out in accordance with Section 7 of this Specification.
Piles
June 2022
19/41
Non-compliance: 19.110 If the result of any test on welds in piles does not comply
Non-destructive with the specified requirements for the test, the complete
Tests on Welds in weld shall be cut out, the joint shall be rewelded and the
Piles weld shall be tested all in accordance with Section 7 of this
Specification.
Testing : Integrity Tests on Deep Foundation Works
Integrity Tests 19.111 (1) The Contractor shall employ a specialist subcontractor
to carry out non-destructive integrity testing of the
Deep Foundation Works. Such integrity testing shall
comprise sonic logging and transient vibration testing
of the completed Deep Foundation Works which shall
be carried out in accordance with Approved methods.
(2) The number of Deep Foundation Works tested by

sonic logging shall depend upon the Contractor's
method of construction but shall not be less than 25%
of the total number of cast-in place piles/panels.
(3) For driven concrete and if deemed necessary by the

Engineer, cast-in-place piles, vibration testing of the
piles shall be carried out in addition to the sonic
logging defined above.
(4) The number of piles tested by vibration shall depend

upon the Contractor's method of construction of these
piles, but shall be not less than 10% of the total
number of piles.
(5) On completion of the sonic logging testing all pipes

shall be filled using a grout mix in accordance with
(6) Integrity testing shall be completed allowing sufficient

time before other related works start, to permit
remedial works to be carried out in the case of
non-compliance.
(7) The results of integrity tests shall be used to enable the

Engineer to select piles for further testing.
(8) Steel tube for sonic logging test to be 2.5mm thick min.
and internal diameter 42mm diameter min.; sonic pipes
installed to full depth to 300 above top of concrete cast
and 300mm above pile toe; larger sonic pipes used
also for purpose interface coring (100 to 150mm) for
June 2022
19/42
interface coring to be placed at 1 m above the pile toe.
(9) For diaphragm wall and barrettes and the like,

minimum 3 sonic pipes per panel or barrette of
dimension less than 3m long and minimum 6 sonic
pipes per panel or barrette of dimension of more than
or around 5.6m.
(10) Sonic logging test to be carried out for all barrettes and
loading panels of diaphragm wall. Frequency of
testing shall be 10% for non-loading panels.
Non-compliance 19.112 If the result of any integrity test on Deep Foundation Works
indicates a defect or discontinuity, additional tests shall be
carried out. The number of additional tests shall be as
instructed by the Engineer. If further tests confirm the
presence of a defect or discontinuity, additional piles/panels
shall be installed and tested as stated in Clause 19.105.
Testing : Bentonite Slurry
Samples: 19.113 (1) For Deep Foundation Works samples of bentonite

Bentonite slurry shall be provided for testing at a frequency of
Slurry one for each shift during excavation and one before
concreting or approved by the Engineer.
(2) Samples for testing to determine the density of the

slurry shall be provided each day. A sample of
bentonite slurry taken from the base of the
excavation shall be tested to determine the density of
the slurry before placing of concrete.
Bentonite 19.114 The test equipment employed shall be as specified in

Slurry: American Petroleum Institute Standards (Ref. API-RP-13B).
Testing Additional or alternative equipment may be employed with
Equipment the approval of the Engineer.
Fresh 19.115 The Contractor shall propose bentonite slurry property

Bentonite values, to ensure the requirements stated in Clause 19.113,
Slurry: Testing 19.114 and 19.115 are met, for the approval of the
Engineer. All freshly mixed bentonite slurry shall be tested
for the following properties:
(1) density using a mud balance : > 1.015 g/ml;
(2) fluid loss and residue using Bariod filter press :  25ml;
June 2022
19/43
(3) viscosity using a Marsh funnel :  35s;
(4) pH using an Electrical Meter : 8.5 – 10.5.
(5) Filter cake thickness by Baroid filter press:  1mm;
Test Compliance: 19.116 The values of slurry properties in the excavation during
Bentonite Slurry excavation process shall be as follows:
for the Excavation
(1) density : 1.08 – 1.15 g/ml ;
(2) pH : 8 - 11;
(3) fluid loss and residue : < 45ml; and
(4) filter cake :  5mm.
(5) Samples to be tested for viscosity using the Fann

viscometer shall be screened before testing using a
300 µm BS test sieve.
Slurry samples shall be taken at the location as directed

by the Engineer. Notwithstanding these limits, the
Contractor shall also comply with the requirements of
Clause 19.32.
Testing Bentonite 19.117 Density, viscosity, gel strength, sand content, pH and fluid
Slurry prior to loss shall be measured on a sample taken from near the
Concreting bottom of the excavation approximately 0.2m above the
base of the excavation. Immediately before concreting the
values of the slurry properties in the excavation shall be as
follows:
(1) density : ≤ 1.15 g/ml;
(2) sand content : < 3 %;
(3) pH : 8 - 11;
(4) viscosity using March funnel :  40s;
(5) fluid Loss and residue: ≤ 40 ml ;
(6) filter cake :  5mm.
Notwithstanding these limits the Contractor shall also

comply with the requirements of Clause 19.32.
June 2022
19/44
Testing Bentonite 19.118 Used bentonite slurry shall be tested after setting and prior
Slurry Prior to to re-use and shall comply with the following properties:
Re-use
(1) density :  1.3 g/ml;
(2) fluid loss :  50 ml;
(3) viscosity using Marsh funnel :  50s;
(4) pH : 7.5 – 11.5;
(5) filter cake : ≤ 5mm.
Bentonite Slurry: 19.119 Density measurements shall take into account the moisture
Density content of the bentonite powder in determining the
bentonite concentration.
June 2022
19/45
APPENDIX 19.1
Determination of the Movement of Piles by Load Test
Scope 19.1.1 This method covers the determination of the movement of

piles by means of a load test.
(1) kentledge, anchor piles or other anchorages

supported or installed at suitable locations to provide
adequate reactions against jacking;
(2) hydraulic jacks and associated equipment;
(3) 4 deflectometers, readable and accurate to

0.025mm, and precision levelling equipment and
load measuring equipment of a type approved by the
Engineer;
(4) a reference beam;
(5) working platforms;
(6) screens and protection from exposure to conditions

which may affect the test;
(7) test loads.
Procedure: 19.1.3 The procedure before testing shall be as follows:

Before Testing
(1) The kentledge, anchor piles or other anchorages shall
be installed. The centre of each anchor pile shall be
at least 2 m or 3 times the pile diameter, whichever is
greater, from the centre of the pile to be tested and
from the centre of any adjacent pile.
(2) If required, the pile to be tested shall be extended

from cut-off level to ground level. The strength of
piles at joints shall not be less than any normal
section of the pile.
(3) A temporary pile cap designed by the Contractor shall

be constructed.
(4) Working platforms, screens and protection shall be

installed.
June 2022
19/46
(5) The reference beam shall be set up on supports

which are at least 2 m or 3 times the pile diameter,
whichever is greater, from the test pile and anchor
pile.
Procedure: 19.1.4 The procedure for the load test shall be as follows:
Load Test
(1) Trial piles shall be tested to not less than twice the
working load of the pile or other loads stated in the
Contract. Working piles shall be tested to not less
than 1.8 times working load. Reductions for group or
boundary effects shall not be made in determining the
test loads.
(2) Test loads shall be applied and removed in 3 stages

as stated in Table 19.1.1.
(3) The test loads shall be applied in increments, and

removed in decrements, of 25% of the working load.
Increments of load shall not be applied until the rate
of settlement of the pile is less than 0.1mm in
20 minutes.
(4) The full loads for Stage I shall be applied in

increments and shall then be maintained for at least
24 hours after the rate of settlement has reduced to
less than 0.1mm per hour. The test loads shall be
removed in decrements and the recovery of the pile
recorded before loading is resumed.
(5) The procedure stated in Clause 19.1.4(4) shall be

repeated for Stage II loading.
(6) The full loads for Stage III shall be applied in

increments and shall be maintained for the greater
of :
(a) 24 hours after the rate of movement has been

reduced to less than 0.1mm/hour; or
(b) 72 hours;
After Stage III, the test load shall be removed and the
recovery of the pile shall be determined.
(7) The settlement of the pile shall be measured at hourly

intervals or other intervals permitted by the Engineer.
June 2022
19/47
The settlement of the pile under each increment and

decrement of loading shall be measured. The exact
times at which increments are applied and
decrements are removed shall be recorded in the
presence of the Engineer.
(8) The level of the reference beam shall be checked at

regular intervals as permitted by the Engineer during
the test.
Table 19.1.1 : Test Loading Stages
Stage Test Load
I 25% of Maximum Test Load
II 50% of Maximum Test Load
III 100% of Maximum Test Load
Procedure: 19.1.5 After testing, equipment shall be removed, temporary pile

After Testing caps shall be demolished and pile extensions shall be
removed to cut-off level. Anchor piles shall be withdrawn.

Results
(1) the loads applied to the nearest 0.05 t;
(2) the settlement of the pile to the nearest 0.05mm at

hourly intervals and under each increment and
decrement of loading;
(3) the exact times at which increments are applied and

decrements are removed;
(4) the levels of the reference beam, to the nearest

0.05mm;
(5) that the test method used was in accordance with

this Specification;
(6) the recovery of piles at the end of each stage.
June 2022
19/48
APPENDIX 19.2
PILE LOAD TEST RECORD

(Test Result)
Contract No. Title

Contractor
Pile data
Reference No. Location
Type Size
Pile dia/diagonal width(D) Cross pile length(Lp)
Sectional area(A) Young's modulus(E)
Testing data
Design working load(P)
Test load(Q) = 2(P)
Pressure gauge No. Calibration Certificate ref. Date
Dial gauge number 1 2 3 4

Serial number
Calibration certificate ref.
Date of calibration
Level of fixed point on load reaction system : before testing

after testing
ground settlement =
Date Load Pressure Cumulative Remarks

& (kN) Gauge Dial Gauge Readings Settlement
Time Reading (mm)
Dial 1 Dial 2 Dial 3 Dial 4 Ave
June 2022
19/49
PILE LOAD TEST RECORD

(Test Result)
Load in kN
1000 2000 3000 4000 5000 6000
10
15
20
Settlement
in
(mm)
25
30
35
40
Maximum settlement at working load: (Allowable = 20mm for buildings and 10mm for all other
structures)
Actual =
Settlement at maximum test load (S1): (Allowable = S1 less than twice settlement at 90% of
maximum test load (2S2).)
Actual S1 = 2S2 =
Reported by Verified by
Contractor's Representative *IOW/Engineer/Architect
Date Date
(*delete as appropriate)
June 2022
19/50
APPENDIX 19.3
PILE DRIVING RECORD

(Precast concrete, prefabricated steel and driven cast-in-place piles)
Contract No. Title
Contractor
Pile data
Type Size Rake
For precast concrete and steel piles; Preformed length
For precast concrete piles; Date of casting
Drive system data
Hammer: Type mass kg drop (at set) mm rated energy kj
Helmet, dolly & anvil: type mass kg
Packing: type Condition thickness mm
Levels
Commencing ground/sea bed*level (PD/CD)*
Depth of overburden/height of working platform above sea bed level
Reference working level/platform level*
Date Drop Depth No. of Cumulative Length of individual Remarks (State details of
& (m) Pene-tr blows + No. of segments, location of obstruction, delays,
Time ated blows splices and tests interruptions and location
(m) carried out of concrete samples)++
+ per 0.25m for top 3.0m of pile ++ for cast in place piles
(* delete as appropriate)
June 2022
19/51
PILE DRIVING RECORD

(Precast concrete, prefabricated steel and driven and cast-in-place piles)
Temporary compression record (on graph paper graduated in millimetres to be

pasted in space below)
Final penetration depth mm Top of pile level
Temporary compression mm Cut off level
Final set mm/last 10 blows Pile head level
or blows/25mm Final toe level
Deviation from plumb or rake 1 in Deviation at cut-off level x-x mm
y-y mm
For driven cast-in-place piles:
Length of temporary Length of permanent Length of cage

casing m casing m reinf. m
Concrete grade Date of concreting
Theoretical volume of concrete required m3
Actual volume of concrete placed m3
Date Date
June 2022
19/52
APPENDIX 19.4
PILE DRIVING RECORD

(Bored cast-in-place piles)
Contract No. Title
Contractor
Pile data
Type Diameter mm Design Length mm Rake 1 in

Bore hole record
Commencing ground/sea bed* level (P.D./C.D.)*
Depth of overburden/height of working platform above sea bed level m
Casing/drilling fluid* type
Reference working level/platform level*
Date Depth Details of strata Details of soil testing, Remarks (State details
& pene- penetrated/ground water proving of bedrock and of obstruction, delays,
Time trated level under-ream interruptions and
location of concrete
samples
Deviation from plumb or rake 1 in Deviation at cut-off level x-x mm

y-y mm
Length of temporary casing m Length of permanent casing m
June 2022
19/53
PILE DRIVING RECORD

(Bored cast-in-place piles)
Bore hole condition prior to concreting
Bottom visible/invisible* Measured depth of bore m
Depth of water/drilling fluid* m
Damage and debris observations
Concrete record
Concreting in dry/by tremie* Water inflow rate litres/second
Concrete grade Slump
Actual concreted level Cut-off level
Overall Lt = %
La
Length of cage reinforcement m

Date Delivery note Quantity Theore-tic Actual Lt % Cumulative Remarks
& No./ Truck (m3) al length length La length (Inter-ruptions in
Time load No. filled placed placed (m) placing, cause of
Lt (m) La (m) excessive ±Lt% ,
La
location of concrete
samples, ref. No. of
cubes taken, etc.)
Date Date
Note : The Engineer shall be informed of any deviation greater than ± 10% from the expected
(theoretical) level of concrete placed.
June 2022
19/54
APPENDIX 19.5
PILE RECORD
(Piles cast in hand-dug caissons)
Contract No. Title
Contractor
Pile data
Caisson type Diameter mm Design length m
Excavation data
Commencing ground level (PD) Depth of overburden m

Date Depth Details of strata penetrated/ Details of soil testing, Remarks (State details of
reached surrounding ground water level proving of bedrock, and obstructions, interruptions
(m) under-ream and delays)
Deviation from plumb 1 in Deviation at cut-off level x-x mm
y-y mm
Bedrock level* Water level*
Base level of shaft Diameter of bell-out* mm
Length of toe-in* mm Depth of bell-out mm

*If none write 'N/A'
June 2022
19/55
PILE DRIVING RECORD

(Piles cast in hand-dug caissons)
Concrete record
Concreting in dry/by tremie* Water inflow rate litres/second
Overall Lt = %
La
Date Delivery note Quantity Theore-tic Actual Lt % Cumulative Remarks (Inter-

& No./ Truck (m3) al length length La length placed ruptions in placing,
Time load No. filled placed (m) cause of excessive
Lt(m) La(m) ±Lt %, location of
La
concrete samples, ref.
No. of cubes taken,
etc)
Date Date
Note : The Engineer shall be informed of any deviation greater than ±10%
from the expected (theoretical) level of concrete placed.
June 2022
19/56
APPENDIX 19.6
PILE RECORDS
(Barrettes)
Contract No. Title
Contractor
Pile data
Size of barrette Shape
Design length m
Excavation data
Commencing ground level (PD) Depth of overburden m
Guide wall levels : top bottom
Date Depth Details of strata penetrated/ Details of soil testing, Remarks (State details of
reached surrounding ground water level proving of bedrock, and obstructions, interruptions
(m) under-ream and delays)
Deviation from plumb 1 in Deviation at cut-off level x-x mm

Base level of excavation
Depth of base from top of guide wall m
June 2022
19/57
PILE RECORD
(Barrettes)
Concreting record
Overall Lt = %
La
Date Delivery note Quantity Theore-tic Actual Lt % Cumulative Remarks (Inter-

& No./ Truck (m3) al length length La length placed ruptions in placing,
Time load No. filled placed (m) cause of excessive
Lt(m) La(m) ±Lt %, location of
La
concrete samples, ref.
No. of cubes taken,
etc)
Date Date
Note : The Engineer shall be informed of any deviation greater than ±10% from the expected
(theoretical) level of concrete placed.
June 2022
19/58
APPENDIX 19.7
BENTONITE SLURRY RECORD

Contract No. Title
Contractor
Sample data
Ref No. of pile Location
Source of test sample: (a) freshly mixed slurry*

(b) as supplied to excavation*
(c) from bottom of excavation prior to placing concrete
Date and time of sampling
Test Method and Test Result

Apparatus Used
Density (g/mL)
Viscosity (seconds)
pH
Sand Content (%)
Fluid Loss (mL)
Temperature (oC)
Filter Cake (mm)
Remarks :-
Date Date
June 2022
19/59
SECTION 20
BRIDGEWORKS
Part 1, Bridge Bearings. Clause 20.1 to 20.27
Part 2, Vehicular Parapets. Clause 20.28 to 20.41
Part 3, Movement Joints. Clause 20.42 to 20.63
Part 4, Waterproofing. Clause 20.64 to 20.74
PART 1 : BRIDGE BEARINGS
Glossary of Terms
Schedule of 20.1 "Schedule of bearings" is the schedule of bearings stated in

Bearings the Contract.
Type of Bridge 20.2 "Type of bridge bearing" is a term used to identify bridge
Bearing bearings of exactly the same design and same capacity for
all bearing loads, movements and rotations.
Materials
Holding Down 20.3 Holding down bolts for bridge bearings shall be of a
Bolts for Bridge proprietary type of stainless steel and approved by the
Bearings Engineer.
Cement Mortar, 20.4 (1) Cement mortar for bedding and construction of
Grout and unreinforced plinths for bridge bearings shall be a
Adhesive for proprietary non-shrink type approved by the Engineer
Bridge Bearings having a grade strength of at least 50MPa or as stated
in the Contract.
(2) Chemical-resin mortar for the construction of plinths

for bridge bearings shall be a proprietary non-shrink
type approved by the Engineer having a grade
strength of at least 50MPa.
(3) Grout for grouting base plates and holding down bolts
shall be a proprietary non-shrink cementitious type
approved by the Engineer having a grade strength of
at least 50MPa. The grout shall be flowable and shall
not bleed or segregate. The suitability of the grout
June 2022
20/1
shall be demonstrated by site trials to the approval of

the Engineer. Chemical-resin based grout shall not
be used.
(4) Adhesives and chemical resin mortars for locating and

bedding elastomeric bridge bearings shall be a
proprietary type approved by the Engineer. They
shall be compatible with the elastomer.
Dowel Bars for 20.5 Dowel bars for bridge bearings shall be stainless steel
Bridge Bearings of Grade 1.4401, BS EN ISO 683-3, BS EN ISO 683-4,
BS EN ISO 683-5, BS EN 10095, BS EN 10250-4 and PD
970.
Protective 20.6 Metal components of bridge bearings shall be protected

Coatings to against corrosion by a protective coating system
Bridge Bearings complying with a system consistent with corrosivity
category CX, durability class very high (VH) of BS EN ISO
14713 or BS EN ISO 12944.
Marking of 20.7 (1) Bridge bearings shall be marked by the manufacturer

Bridge Bearings either with the type numbers stated in the schedule of
bearings or with the manufacturer's own type or other
numbers. The bearing type numbers or
manufacturer’s own type or other numbers marked on
the bridge bearings shall be visible before and after
installation of the bridge bearings. A schedule shall
be provided which relates the manufacturer's own type
or other numbers to the type numbers stated in the
schedule of bearings.
(2) The design movement directions and magnitudes and

the axes of bearing shall be marked on the upper
faces of bridge bearings to facilitate checking of the
installation. Movement indicators shall be provided
for sliding and roller bearings to permit checking of
movements of the bearings before and after
installation.
Design of Bridge Bearings
General 20.8 (1) Unless otherwise stated in the Contract, bridge

bearings shall be designed in accordance with the
bearing schedules as stated in the Contract.
(2) The design and manufacture of bridge bearings and

the materials used shall comply with BS EN 1337,
except as stated in Clauses 20.9, 20.10 and 20.15(4).
June 2022
20/2
Inspection and maintenance of bridge bearings shall

be easy to carry out and the bearings shall be easily
replaceable.
(3) The maximum bearing stress in concrete underlying

or overlying a bridge bearing under the design load at
the ultimate limit state shall comply with Clause
10.9.5.2(2) of BS EN 1992:Part 1-1.. Higher bearing
stresses may be adopted provided that in the opinion
of the Engineer sufficient steel reinforcement is
provided to resist the resulting bursting forces
complying with BS EN 1992:Part 2.
(4) The deflection of bridge bearings which have a

specified zero horizontal movement in a particular
direction shall not exceed 1 mm in that direction
under the maximum horizontal loadings.
Design of Sliding 20.9 (1) Clause 4.3.4.2 of BS 5400: Part 9: Section 9.2 shall
Bearings not apply to sliding bearings.
(2) Stainless steel sliding surfaces of sliding bearings

which are attached to backing plates by mechanical
fasteners instead of continuous welding along the
edges shall be bonded to the backing over the full
area and supplemented with peripheral sealing if
necessary. Mechanical fixing only stated in Clause
7.2.1 of BS EN 1337:Part 2 shall not be used.
Design of 20.10 The performance requirements for the shear modulus of

Elastomeric elastomeric bearings at low temperatures and very low
Bearings temperature stated in Clause 4.3.1.2 and 4.3.1.3
respectively of BS EN 1337:Part 3 shall not apply.
Design of Guides 20.11 The clearance between guides and complementary sliding
for Bridge Bearings surfaces of a guided bearing shall not exceed 1 mm.
Design of Fixings 20.12 (1) Except for elastomeric bearings, bridge bearings,
for Bridge Bearings including bearings that are not required to provide
horizontal restraint, shall be fixed to the
superstructure and substructure with mechanical
fixings or by other methods approved by the
Engineer. The friction between the bearing and the
superstructure or substructure may be used to resist
the horizontal forces provided that a factor of safety
of at least 2 is applied to the proven coefficient of
friction and that the worst combination of vertical load
and horizontal load is considered.
June 2022
20/3
(2) The ultimate capacity of the mechanical fixings for

bridge bearings shall not be less than the worst
combination of loading at ultimate limit state stated in
the schedule of bearings.
Submissions
Particulars of 20.13 (1) The following particulars of the proposed bridge

Bridge bearings shall be submitted to the Engineer for
Bearings Approval:
(a) details of type of bridge bearings, including

materials, and the name and address of the
manufacturer;
(b) design calculations, including (i) calculations of

bearing stresses above and below the bearings,
(ii) calculations for bursting or other necessary
additional or revised reinforcement, and (iii)
calculations to show that the bearings comply
with the requirements of BS EN 1337;
(c) shop drawings and drawings of any additional or

revised reinforcement details;
(d) a certificate for each type of bridge bearing

showing the manufacturer's name, the date and
place of manufacture and showing that the
bridge bearings comply with the requirements
stated in the Contract and BS EN 1337 and
including results but not limited to the following
tests:
– friction tests;
– load tests;
– tests on elastomers;
– quick production tests;
– stiffness tests;
(e) values of stiffness in compression and in shear

of elastomeric bearings;
(f) details of fixings to superstructures and

substructures;
(g) details of protective coatings;
June 2022
20/4
(h) methods of installation, and
(i) programme of manufacture, testing and delivery,

including name and address of testing
laboratory.

least 28 days before the Engineer's Approval of the
bridge bearings is required. Certificates shall be
submitted for each batch of bridge bearings delivered
to the Site
Storage of 20.14 Bridge bearings shall be stored on a levelled, well drained

Bridge and maintained hard-standing ground on level supports
Bearings and in a manner which will not result in damage or
deformation to the bearings or in contamination of the
bearings.
Installation of Bridge Bearings
Installation 20.15 (1) Bridge bearings shall be installed as recommended in

of Bridge BS EN 1337:Part 11 and as stated in Clauses 20.15
Bearings (2) to (7). All bearings shall be supplied and installed
by specialist contractors on the approved list of
suppliers of material and specialist contractor in the
“Supply and Installation of Bearings for Highway
Structures Category” of Public Works to the approval
of the Engineer.
(2) Bridge bearings which have been pre-assembled

shall not be dismantled unless approved by the
Engineer.
(3) The levels of substructures stated in the Contract on

which bridge bearings will be installed shall be
adjusted to suit the thickness of the bearing so that
the superstructure will be at the specified level after
completion.
(4) Bridge bearings, other than elastomeric bridge

bearings, shall be set level on substructures using
only a thin layer of cementitious mortar, unless the
Engineer permits the bearings to be set on plinths. If
setting on plinths is permitted, the plinths shall be
June 2022
20/5
constructed of cementitious mortar or grout, unless

otherwise approved by the Engineer, and the
thickness of such plinths shall be at least 25mm and
shall not exceed 40mm. If approved by the
Engineer, the plinths may be constructed of chemical
resin mortar, having a thickness of at least 5mm and
not exceeding 10mm. The thickness of mortar joint
stated in Clause 6.6 of BS EN 1337:Part 11 shall not
apply.
(5) Elastomeric bearings shall be set directly on the

substructure. A thin layer of cementitious mortar
may be used to level the surface if the substructure is
concrete. Elastomeric bearings shall not be set in
position by grouting between the substructure and the
underside of the bearing.
(6) The top surface of bridge bearings which will support

precast concrete or other prefabricated beams shall
be covered with a thin layer of cementitious mortar
immediately before the beam is placed. The beam
shall be temporarily supported on folding wedges or
by other methods approved by the Engineer until the
mortar has achieved sufficient strength to transmit the
weight of the beam to the bearings; the temporary
supports shall then be removed.
(7) Temporary locking devices for bridge bearings shall

be removed before post-tensioned superstructures
are stressed. Temporary locking devices for other
types of superstructures shall be removed at times
Tolerances
Tolerances: 20.16 (1) The centreline of bridge bearings shall be within 3mm
Bridge of the specified position.
Bearings
(2) The level of bridge bearings shall be within 0.0001
times the adjacent span or the lesser of the adjacent
spans or within 5mm of the specified level, whichever
is less.
(3) The inclination of bridge bearings shall be within 1 in

200 of the specified inclination.
(4) The horizontal axis of bridge bearings shall be within

0.005 radian of the specified alignment.
June 2022
20/6
(5) Departure from the common plane between twin or

multiple bridge bearings shall be within the tolerances
Testing: Bridge Bearings - General Requirements
Batch: 20.17 A batch of bridge bearings is any quantity of bridge

Bridge bearings of the same type and any sub-type fabricated by
Bearings the same manufacturer and which for the purpose of
testing elastomeric bearings contains the same type of
elastomer.
Testing: 20.18 (1) Bridge bearings shall be tested by the Contractor at a

Bridge laboratory approved by the Engineer.
Bearings
(2) The Contractor shall inform the Engineer of the date
and place of testing at least 28 days before testing
starts.
(3) The specified procedures for testing bridge bearings

shall not be changed unless permitted by the
Engineer.
(4) The reports of tests on bridge bearings shall include

load/deflection graphs and shall be submitted to the
Engineer for Approval at least 28 days before
installation of the bridge bearings starts.
Testing: Friction Test for Bridge Bearings
Samples: 20.19 One sample of bridge bearing shall be provided from each
Friction Test for batch of sliding bearings and from each batch of other
Bridge Bearings types of bridge bearings which contain sliding parts.
Testing: Friction 20.20 (1) The friction test shall be carried out on each sample
Test for Bridge of bridge bearing provided as stated in Clause 20.19
Bearings to determine the coefficient of friction, flatness,
bonding properties and resistance to mechanical
damage. The method of testing shall be in
accordance with Appendix 20.1.
(2) The friction test shall be carried out at room

temperature.
Compliance 20.21 The results of friction tests for bridge bearings shall comply
Criteria: Friction with the following requirements:
Test for Bridge
June 2022
20/7
Bearings (1) The coefficient of friction in any test position shall not
exceed 0.04.
(2) The flatness of the stainless steel shall be within the

specified limits after testing.
(3) The bond to the backing plate shall be unaffected by

the friction test.
(4) The PTFE shall be free from mechanical damage

after testing.
Testing: Bridge Bearings other than Elastomeric

Bearings
Samples: Bridge 20.22 One sample of bridge bearing shall be provided from each
Bearings other batch of bridge bearings other than elastomeric bearings.
than Elastomeric
Bearings
Testing: Bridge 20.23 Vertical load tests and horizontal load tests shall be carried
Bearings other out on each sample of bridge bearing provided as stated in
than Elastomeric Clause 20.22. The test loads shall be the serviceability limit
Bearings state loads. If stated in the Contract, additional tests with
test loads up to the ultimate limit state loads shall be
carried out. The method of testing shall be in accordance
with Appendix 20.2.
Compliance 20.24 The results of tests on bridge bearings other than

Criteria: Bridge elastomeric bearings shall comply with the requirements
Bearings other stated in Appendix 20.2.
than Elastomeric
Bearings
Testing: Elastomeric Bearings
Samples: 20.25 (1) Except as stated in Clause 20.25(2), one sample of

Elastomeric elastomeric bearing shall be provided from each
Bearings batch of elastomeric bearings for testing by the "Quick
Compressive Test".
(2) Samples shall not be provided for the "Quick

Compressive Test" if in the opinion of the Engineer
there is sufficient evidence that tests have been
carried out within the previous 18 months on identical
materials and that the results of the tests comply with
the specified requirements for the test.
June 2022
20/8
(3) Two samples of elastomeric bearings shall be

provided from each batch of ten or part thereof of
elastomeric bearings to determine the stiffness in
compression and stiffness in shear.
Testing: 20.26 (1) Each sample of elastomeric bearing provided as

Elastomeric stated in Clause 20.25(1) shall be tested to determine
Bearings the physical and weathering properties of the
elastomer and the bond of the elastomer to metal.
The method of testing shall be the "Quick
Compressive Test" in accordance with Clause 4.3.3.2
of BS EN 1337:Part 3.
(2) One sample of elastomeric bearing provided as

stated in Clause 20.25(3) shall be tested to determine
the stiffness in compression and the other sample
shall be tested to determine the stiffness in shear.
The method of testing to determine the stiffness in
compression shall be in accordance with Annex H of
BS EN 1337:Part 3. The method of testing to
determine the stiffness in compression shall be in
accordance with Annex F of BS EN 1337:Part 3.
Compliance 20.27 The results of tests on elastomeric bearings shall comply

Criteria: with the following requirements:
Elastomeric
Bearings (1) There shall be no evidence of surface flaws in the
bearings during or after the test.
(2) There shall be no irregularities in the deflected shape

of laminated bearings during or after the test.
(3) The stiffness in compression shall be within 20% of

the value quoted by the manufacturer and approved
by the Engineer.
(4) The stiffness in shear shall be within 20% of the value

quoted by the manufacturer and approved by the
Engineer.
June 2022
20/9
PART 2: VEHICULAR PARAPETS
Materials
Vehicular 20.28 (1) Vehicular parapets shall be of the types stated in

Parapets the Contract.
(2) Steel for vehicular parapets, including welding, shall

comply with Section 7 of this Specification except
that the requirements for testing shall not apply.
The requirements for testing of materials and
welded components shall follow Clauses 7.69 to
7.81, 20.35 to 20.41 except:
(a) Clause 7.71(1)(a), (b), (c), (h) and 7.74; and
(b) Clause 7.6 and 12.4.2.3 of BS EN 1090:Part 2.
(3) Protective treatment to steel for vehicular parapets

shall comply with Section 7 of this Specification and
shall be applied after welding, drilling and cutting
are complete.
(4) Aluminium for vehicular parapets shall comply with

the following or equivalent approved by the
Engineer:
Wrought aluminium and

aluminium alloys for general
engineering purposes
– plate, sheet and strip : BS EN 485

– rivet, bolt and screw
stock : BS1473
– bars, extruded round
tubes and sections : BS EN 755
(5) Aluminium shall be anodised to Class AA 25 in

accordance with BS EN ISO 7599 or equivalent
(6) Welding of aluminium for vehicular parapets shall

comply with BS EN 1011 Part 4 or equivalent
approved by the Engineer
(7) All bolts, nuts and washers for vehicular parapets
June 2022
20/10
shall be made of stainless steel. Stainless steel

bolts and nuts shall be grade A4-80 and shall
comply with BS EN ISO 3506 Part 1 and Part 2 or
equivalent approved by the Engineer. Stainless
steel washer shall be grade A4 and comply with BS
EN ISO 7089, BS EN ISO 7090, BS EN ISO 7092
or BS EN ISO 7093:Part 1.
Holding Down 20.29 (1) Holding down bolts, nuts and washers for vehicular
Bolts for Vehicular parapets shall be made of stainless steel and
Parapets comply with Clause 20.28(7).
(2) For post-drilled applications, the holding down bolts

shall be a proprietary type approved by the
Engineer and made of stainless steel and comply
with Clause 20.28(7).
Grout for 20.30 Grout for holding down bolts for vehicular parapets shall
Vehicular be based on polyester resins and shall be a proprietary
Parapets type approved by the Engineer. Epoxy resin based
grout shall not be used.
Submissions
Samples of 20.31 Samples of the proposed posts and rails for vehicular
Materials for parapets shall be submitted to the Engineer at least 14
Vehicular days before installation of the parapets starts.
Parapets
Storage of 20.32 Vehicular parapets shall be stored on a levelled, well

Vehicular drained and maintained hard-standing ground on level
Parapets supports and in a manner will not result in damage or
deformation to the parapets or in contamination of the
parapets.
Installation of Vehicular Parapets
Installation of 20.33 (1) Vehicular parapets shall be installed to a smooth

Vehicular alignment and with the posts vertical.
Parapets
(2) Grouting shall be carried out by setting the vehicular
parapets in position and grouting the gap between
the vehicular parapets and the structure. Vehicular
parapets shall be held in position until connections
June 2022
20/11
and fixings are complete and until the fixings have

gained sufficient strength.
Tolerances
Tolerances: 20.34 Vehicular parapets shall be within 10mm of the specified

Vehicular position and height.
Parapets
Testing of Vehicular Parapets
Batch: 20.35 (1) A batch of vehicular parapets is the amount of

Vehicular parapet materials stated in the Contract and which
Parapets is completed or delivered to the fabrication yard or
Site at any one time.
(2) The Contractor shall submit to the Engineer a list

of the parts of vehicular parapets included in each
batch at least 14 days before testing starts.
Samples: 20.36 (1) Samples shall be selected from positions, which in

Vehicular the opinion of the Engineer or the approved
Parapets for inspection authority or testing consultant are
Testing representative of the batch as a whole.
(2) The Engineer shall inform the Contractor of the

samples selected for testing at least 7 days before
testing starts.
Testing: 20.37 (1) The relevant tests stated in Clauses 20.38 to

Vehicular 20.41 shall be carried out on each batch of
Parapets vehicular parapets.
(2) The Contractor shall inform the Engineer at least 7

days before tests are carried out.
Testing: 20.38 (1) The tensile test and Charpy impact test of
Parapets Materials materials for vehicular parapets shall be carried
out in accordance with BS EN ISO 6892:Part 1
and BS EN ISO 148:Part1 respectively in
conjunction with the relevant standard of the
material supplied for use in the works.. The
frequency of tests and results of material tests
shall conform to the relevant standard stated in
Tables 2 and 3 of BS EN 1090:Part 2for steel
parapets and Table 4 of BS EN 1090:Part 3 for
aluminum parapets.
June 2022
20/12
(2) Vehicular parapet material which has not been

tested for quality grade by the manufacturer shall
not be accepted.
Testing: 20.39 (1) The tensile test of stainless steel fasteners for
Fasteners vehicular parapets shall be carried out in
accordance with BS EN ISO 3506 Part 1 and Part
2 or equivalent approved by the Engineer.
Testing: 20.40 (1) Inspection and testing of welds for components of

Welded vehicular parapets on each batch shall be carried
Components of out after cleaning and before application of hot-dip
Vehicular galvanizing and other protective treatment.
Parapets De-burring, dressing, grinding, machining and
peening shall be carried out after the visual
inspection for cracks, surface pores and joint fit-up
and before other inspections and tests are carried
out.
(2) All welds shall be visually inspected for vehicular

parapets in accordance with the techniques in BS
EN ISO 17637 or equivalent approved by the
Engineer. Non-destructive testing shall be carried
out on a proportion of welds after visual inspection.
(3) Non-destructive testing of welds for components of

vehicular parapets shall comply with the following:
(a) For the components of vehicular parapets

which are butt welded or fillet welded with
nominal leg length greater than 12mm, 10% of
welds for each type of components shall be
examined by ultrasonic testing in accordance
with BS EN ISO 17640 or equivalent approved
by the Engineer.
(b) 10% of the welds other than sub-clause

20.40(3)(a) shall be tested as follows:
- Magnetic particle to joints in steel parapet

in accordance with BS EN ISO 17638 or
equivalent approved by the Engineer or
- Liquid penetrant method to welds in

aluminum parapet in accordance with BS
EN ISO 3452 Part 1 or equivalent
June 2022
20/13
(4) The compliance criteria for welds to be inspected,

examined and tested shall be in accordance with
BS 6779 Part 1 Clauses 9.4.3.1.2 to 9.4.3.1.4.
For the butt welds to be tested the individual pores
shall also be less than 2.5mm diameter and the
localized pores shall be less then 3% by the area.
The width of defect of buried slag shall be less
than 1.5mm. Linear groups of inclusions are
acceptable provided that adjacent groups shall be
separated by a distance of at least 4 times and 6
times the length of longest defect for parent metal
thickness less than 20mm and larger than 20mm
respectively.
(5) If non-conformities are found as stated in

sub-clause 20.40(4), the test shall be carried out
on additional samples from the batch. The
number of additional tests shall be twice the
number of original tests.
(6) The batch shall be considered as not complying

with the compliance criteria for the test if the result
of any additional test does not comply with the
compliance criteria for the test.
(7) If the whole batch is not in compliance, the

Contractor may propose to carry out 100% testing
on the batch at his own costs.
(8) If the result of every additional test complies with

the compliance criteria for the test, only those
parts the samples from which have failed in the
original tests shall be considered as not complying
with the compliance criteria for the test.
(9) Welds for vehicular parapets that have been

fabricated and tested by non-destructive testing at
fabrication yard shall be visually inspected for
cracks when the vehicular parapets are delivered
to the Site. If welding quality of the vehicular
parapets is in doubt, 5% of the welds shall be
tested by magnetic particle method in accordance
with BS EN ISO 17638 or equivalent approved by
the Engineer. The surface protection of vehicular
parapets shall be made good to the satisfaction of
the Engineer after the tests.
June 2022
20/14
(10) Inspection and testing of vehicular parapet shall be

carried out by an approved inspection authority or
testing consultant in accordance with Clause 7.80..
Testing: 20.41 (1) Destructive static testing of metal vehicular

Metal Vehicular parapet posts on each batch shall be carried out in
Parapet Posts accordance with the procedures stated in Annex E
of BS 6779 Part 1. The frequency of destructive
testing shall be as follows:
No. of posts per batch No. of posts to be tested per

batch
<150 1
(The Engineer may waive this
testing requirements if
satisfactory tests within 3
months are provided)
150-300 1
>300 1 for each 300 posts or

remaining part thereof
(2) The results of test on post shall comply with the

following criteria:
(a) The post shall sustain a moment of 1.05 times

its theoretical moment of resistance (product
of nominal yield stress and plastic modulus) at
its critical section without failure.
(b) The material thickness, effective weld throat

sizes and external dimensions of the post shall
be within the tolerances.
(3) In the event that any of the acceptance criteria as

stated in sub-clause 20. 41(2) are not met, further
two posts shall be selected from the same batch of
posts and tested. If any further test fails to meet
the acceptance criteria, the whole batch shall be
rejected.
June 2022
20/15
PART 3 : MOVEMENT JOINTS
General
Movement 20.42 Movement joints formed in place shall comply with

Joints Section 8 except as stated in this Section.
Formed in
Place
Glossary of Terms
Fabricated 20.43 "Fabricated movement joint" is a manufactured

Movement assembly, including nosings, designed to carry traffic
Joint smoothly over a movement joint and to seal the joint
against the ingress of water and debris.
Movement 20.44 "Movement joint" is a permanent joint or hinge throat

Joint which allows expansion, contraction or angular rotation
to occur.
Movement 20.45 "Movement joint formed in place" is a movement joint

Joint Formed formed during construction of a structure to permit
in Place adjacent structural elements to move relative to each
other without damage.
Materials
Joint Filler 20.46 Joint filler for movement joints formed in place shall be
non-absorbent.
Joint Sealant 20.47 (1) Joint sealant for movement joints formed in place
shall be a polysulphide-based sealant.
Polyurethane- based sealant shall not be used
unless approved by the Engineer.
(2) Joint sealant shall be resistant to attack by petrol,

diesel oil, dilute acids and alkalis, synthetic and
mineral oils, hydraulic fluids and paraffin. The
sealant shall have a transverse butt joint movement
range for repeated cyclic movement of at least 25%
of the width of the joint.
Compression 20.48 Compression seals shall be a proprietary type approved

Seals by the Engineer and shall be manufactured from natural
rubber, neoprene or other synthetic material.
Compression seals shall have the dimensions specified
June 2022
20/16
by the manufacturer for each joint width.

PVC Capping 20.49 PVC capping strip shall be a proprietary type Approved
Strip by the Engineer.
Holding Down 20.50 Holding-down bolts for movement joints shall be a

Bolts for proprietary type approved by the Engineer.
Movement Joints
Grout for 20.51 Grout for holding-down bolts for movement joints shall be
Movement based on polyester resins and shall be a proprietary type
Joints approved by the Engineer. Epoxy-resin based grout
shall not be used.
Design of Fabricated Movement Joints
Design of 20.52 (1) Fabricated railway movement joints shall be a

Fabricated proprietary type approved by the Engineer.
Railway
Movement (2) Fabricated railway movement joints shall be
Joints capable of withstanding the following loads, either
separately or in combination:
(a) vertically: two 120 kN wheel loads, 1.4m

apart, each spread over a contact area giving
an average pressure of 1 MPa, applied in
such a manner as to produce the worst
possible effect; and
(b) horizontally: a horizontal force of 800 kN per

track applied perpendicular to the alignment of
the joint, together with any forces arising from
strain of the joint.
Allowance for additional loading due to impact is not

necessary.
(3) Fabricated railway movement joints shall be

capable of accommodating the movements and
rotations stated in the Contract without damaging
the joint and without loading the supporting
structure with forces which arise from strain of the
joint exceeding 5kN/m run of the joint.
(4) Fabricated railway movement joints shall either be

watertight or shall be provided with a drainage layer
or channel to collect water passing through the joint
and to divert the water away from the underlying
structure.
June 2022
20/17
(5) Facilities shall be provided in fabricated railway

movement joints for easy clearance of grit or silt
entering slots, grooves or channels forming or
associated with the joint.
(6) All metal components not embedded in the

concrete shall be adequately protected against
corrosion by hot-dip galvanising or hot zinc
spraying. The protective coatings shall comply
with Section 7 of this Specification. The
environment is corrosivity category C5, with
durability category H.
(7) Surfaces of fabricated movement joints, which will

be exposed at finished road level, shall be treated
to provide a resistance to skidding not less than
that of the adjacent road surface.
(8) Fabricated movement joints shall not impair the

riding quality of the rail traffic and the passage of
rail traffic shall not cause undue noise or vibration.
The size of gaps, including gaps sealed with flexible
material, on the riding surface of the joint shall not
exceed 65mm.
(9) The passage of pedestrians shall not be impeded or

endangered by fabricated movement joints.
(10) Facilities shall be provided for access to railway

movement joints for maintenance. All moving
parts or components subject to wear, requiring
lubrication or requiring maintenance or adjustment
are to be readily accessible.
Design of 20.53 (1) Fabricated road movement joints shall be a

Fabricated proprietary type approved by the Engineer.
Road Movement
Joints (2) Fabricated road movement joints shall be capable
of withstanding the following loads, either
separately or in combination :
Load Case A:
– vertically : two 112.5kN wheel loads, 1m apart,

each spread over a contact area to give an
average pressure of 1MPa and applied in such
a manner that the worst possible effect results;
June 2022
20/18
– horizontally : a traction force applied

perpendicular to the alignment of the joint of
75kN per metre run of the joint together with
any forces arising from strain of the joint.
Load Case B:
– vertically : two 75kN wheel loads, 1m apart,

each spread over a contact area to give an
average pressure of 1MPa and applied in such
a manner that the worst possible effect results;
– horizontally : a traction force applied

perpendicular to the alignment of the joint of
50kN per metre run of the joint together with
any forces arising from strain of the joint.
The load case to be applied in any instance shall be

as stated in the Contract.
Allowance for additional loading due to impact is not

necessary.
(3) Fabricated road movement joints shall be capable

of accommodating the movements and rotations
stated in the Contract without damaging the joint
and without loading the supporting structure with
forces which arise from strain of the joint exceeding
5kN/m run of the joint.
(4) Fabricated road movement joints shall be watertight

or shall be provided with a drainage layer or
channel to collect water passing through the joint
and to divert the water away from the underlying
structure.
(5) All metal components not embedded in the

concrete shall be adequately protected against
corrosion by hot-dip galvanising or hot zinc
spraying. The protective coatings shall comply
with a system consistent with corrosivity category
C5, durability High of BS EN ISO 14713.
(6) Facilities shall be provided in road fabricated

movement joints for easy clearance of grit or silt
entering slots, grooves or channels forming or
associated with the joint.
June 2022
20/19
(7) Surfaces of fabricated road movement joints which

will be exposed at finished road level shall be
treated to prevent skidding not less than that of
adjacent road surface.
(8) Fabricated road movement joints shall not impair

the riding quality of the road surface for vehicular
traffic and the passage of vehicular traffic shall not
cause undue noise or vibration. The size of gaps,
including gaps sealed with flexible material, on the
riding surface of the joint shall not exceed 65mm.
(9) The passage of pedestrians and cyclists shall not

be impeded or endangered by fabricated road
movement joints.
(10) Facilities shall be provided for access to road

movement joints for maintenance. All moving
parts or components subject to wear, requiring
lubrication or requiring maintenance or adjustment
shall be readily accessible.
Design of 20.54 (1) The holding down and fixing arrangements for
Fixings for fabricated movement joints shall be capable of
Fabricated withstanding the loads stated in Clauses 20.52(2)
Movement and 20.53(2). The diameter of bolts fixed as
Joints double row bolts on one side shall be at least 12mm
and the diameter of other holding down bolts and
studs shall be at least 16mm.
(2) Fixings for fabricated movement joints shall be

compatible with the reinforcement in the underlying
concrete. Any revisions to the reinforcement
required to suit the fixings shall be designed by the
Contractor and submitted to the Engineer for
Approval.
Submissions
Particulars 20.55 (1) The following particulars of the proposed movement

of Movement joints shall be submitted to the Engineer:
Joints
(a) details of type of movement joint and the
name and address of the manufacture;
(b) design calculations and drawings;
June 2022
20/20
(c) details of fixings, including the size, length

and spacing of holding down bolts and any
necessary revisions to the reinforcement;
(d) details of materials for making good adjoining

road surfaces and nosings, including
reinforcement, jointing and curing details;
(e) programme of manufacture, testing and

delivery; and
(f) for fabricated movement joints, a written

undertaking from the supplier that he will
install the proposed movement joint.
(2) The particulars shall be submitted to the Engineer

at least 28 days before construction of the
movement joint starts.
Storage of 20.56 Fabricated movement joints shall be stored off a levelled,

Fabricated well drained and maintained hard-standing ground on
Movement level supports and in a manner which will not result in
Joints damage, deformation or contamination of the movement
joint.
Installation of Fabricated Movement Joints
Installation of 20.57 (1) Fabricated movement joints shall be installed in

Fabricated accordance with the manufacturer's
Movement recommendations. The installation shall be carried
Joints out by the supplier of the movement joint.
(2) The vertical faces of recesses in bridge decks for

fabricated movement joints shall be formed by
saw-cutting. Holding-down bolts shall be cast into
the concrete for direct mounting of the joints unless
the Engineer permits the bolts to be grouted. If
grouting is permitted, the grouting shall be carried
out by setting the movement joint in position and
grouting the gap between the movement joint and
the structure. Rebates and pockets for
subsequent trimming to line and level or for
holding-down bolts shall not be used unless
permitted by the Engineer.
(3) The bedding to fabricated movement joints shall be
June 2022
20/21
formed such that there shall be no gaps between

the joint and the bedding.
(4) Relative movement between components and

supports of a fabricated movement joint shall be
prevented during installation of the joint and during
placing and hardening of concrete and mortar under
the components. Joint components shall be free
to move longitudinally relative to each other.
(5) When one side of a fabricated movement joint is

being set, the other side shall be free from
longitudinal restraint. Strongbacks or templates
used to locate the sides of a joint shall not be fixed
to both sides at any one time.
Road Surface 20.58 (1) The gap between fabricated movement joints and
Adjoining the adjoining structure shall be made good after
Fabricated installation of the joint with material which has
Movement Joints properties as similar as practicable to those of the
material in the adjoining road surface.
(2) Bituminous road surfaces shall be made good with

a bituminous mixture or elastomeric concrete.
Concrete surfaces shall be made good with a
cementitious matrix reinforced with metal or glass
fibres, elastomeric concrete, polymer concrete or
other material approved by the Engineer. Epoxy
resin mortar shall not be used.
(3) Elastomeric and polymer concrete shall be

prepared, laid and cured in accordance with the
manufacturer's recommendations.
Protection of 20.59 (1) The permission of the Engineer shall be obtained

Fabricated before Constructional Plant or other vehicles cross
Movement a fabricated movement joint or the adjacent surface.
Joints
(2) Constructional Plant or other vehicles shall not
cross fabricated movement joints or adjacent road
surfaces until installation of the joint is complete
unless permitted by the Engineer. If permitted by
the engineer, ramps shall be provided to allow the
vehicles to cross without loads being applied to the
joint.
June 2022
20/22
Construction of Movement Joints Formed in Place
Forming 20.60 Gaps forming part of movement joints formed in place

Movement shall be filled with joint filler fixed in position with
Joints adhesive. The edge of the joint filler shall be covered
with bond breaker tape or a PVC capping strip.
Forming 20.61 Grooves for joint sealant and compression seals for
Grooves movement joints formed in place shall be formed by saw
cutting.
Sealing 20.62 Grooves for movement joints formed in place shall be

rooves sealed with joint sealant or with a compression seal.
Tolerances
Tolerances: 20.63 The surface of fabricated movement joints shall be at

Fabricated least 1mm, and not more than 3mm, below the
Movement surrounding road surface.
Joints
June 2022
20/23
PART 4 : WATERPROOFING
Materials
General 20.64 (1) Waterproofing to Railway Bridges shall be a spray

applied polymer system complying with Section 14 of
this Specification.
(2) Waterproofing to Highway Bridges shall be a system

in compliance with Section 20 of the “General
Specification for Civil Engineering Works (The
Government of the Hong Kong Special Administrative
Region) and subject to the agreement of the Director
of Highways Department of the Government of the
HKSAR.
20.65 Not Used.

Bento
Prefabricated 20.66 (1) Prefabricated sheeting for waterproofing shall be of a
sheeting proprietary type approved by the Engineer.
(2) Prefabricated sheeting shall not rot or support the

growth of mildew and shall be compatible with the
materials with which it is in contact. Prefabricated
sheeting that will be exposed to sunlight after
installation shall be of a type that is unaffected by
ultraviolet light.
(3) Prefabricated sheeting shall have a tensile strength,

pliability and puncture resistance such that the
sheeting will withstand the stresses induced during
handling and laying without damage. The
elongation properties of prefabricated sheeting shall
be such that the sheeting can accommodate the
creep, shrinkage and thermal movements of concrete
without distress.
(4) Prefabricated bituminous sheeting shall be of a

self-adhesive, self-sealing type and shall have a
thickness of at least 1.2 mm.
(5) Prefabricated rubberised base sheeting shall be of a

type which is unaffected by fuels, oils or grease.
(6) Primers and mastic for prefabricated sheeting shall

be of a proprietary type recommended by the
June 2022
20/24
sheeting manufacturer and approved by the

Engineer.
Bentonite panels 20.67 (1) Bentonite panels shall consist of bentonite filler
enclosed in self-degradable boards. The panels
shall have a permeability of less than 1 x 10-7
mm/sec under simulated test conditions similar to
those of the as-built conditions. The performance of
bentonite panels shall not be affected by
contaminants present in the groundwater.
(2) Bentonite panels for slabs less than 200 mm thick or

with soil cover of less than 450 mm shall be special
panels with specific provision for swelling to prevent
lifting of the slab.
(3) Bentonite joint seal and bentonite granules shall be

of a proprietary type recommended by the bentonite
panel manufacturer and approved by the Engineer.
(4) Polyethylene sheeting for use with bentonite panels

shall be of a heavy-duty type.
Bituminous Paint 20.68 Bituminous paint for waterproofing shall be cut-back

bitumen complying with BS EN 15322. The bitumen
shall have a viscosity grade as determined by a standard
tar viscometer within the range 25-50 seconds with a
coverage of 0.5 L/m2. Primers for bituminous paint shall
be of a proprietary type recommended by the bituminous
paint manufacturer and approved by the Engineer.
Submissions
Particulars of 20.69 (1) The following particulars of the proposed

Waterproofing waterproofing systems shall be submitted to the
Systems Engineer:
(a) Manufacturer’s literature and a certificate for

prefabricated sheeting showing the
manufacture and showing that the prefabricated
sheeting complies with the requirements stated
in the Contract and including results of tests for:
-Tensile strength
-Pliability
-Puncture resistance
-Elongation
June 2022
20/25
(b) Manufacturer’s literature and a certificate for

bentonite panels showing the manufacturer’s
showing that the bentonite panels comply with
the requirements stated in the Contract and
including results of tests for permeability.
(c) Manufacturer’s literature and a certificate for

bituminous paint showing the manufacturer’s
showing that the bituminous paint complies with
the requirements stated in the Contract and
including results of tests for viscosity.
(d) Particulars of primers and mastic for

prefabricated sheeting, bentonite joint seal and
bentonite granules and primers for bituminous
paint.
(e) Methods of laying prefabricated sheeting and

bentonite panels.
(f) Manufacturer’s literature and a certificate for

sprayed polymer membrane showing the
manufacture and showing that the sprayed
polymer membrane complies with the
including results of tests as stated in Clause
14.9 of this Specification.

first delivery of the material to the Site. Certificates
shall be submitted for each batch of the material
delivered to the Site.
Samples of 20.70 Samples of the following proposed materials for

Materials for waterproofing systems shall be submitted to the Engineer
Waterproofing at the same time as particulars of the material are
Systems submitted:
(a) Prefabricated sheeting, and
(b) Bentonite panels.
June 2022
20/26
Delivery and Storage of Materials
Delivery of 20.71 Bentonite panels shall be delivered in original unbroken

Bentonite Panels packages bearing the manufacturer’s label.
Storage of 20.72 (1) Prefabricated sheeting and bentonite panels shall be

Materials for stored in accordance with the manufacturers’
Waterproofing recommendations in a dry weatherproof store with a
Systems raised floor.
(2) Bituminous paint shall be stored in sealed containers

marked to identify the contents and protected from
exposure to conditions that may affect the bituminous
paint. The bituminous paint shall be stored in
accordance with the manufacturer’s
recommendations and shall not be used after the
recommended shelf life has been exceeded.
Installation of Waterproofing Systems
Installation of 20.73 (1) Surfaces on which waterproofing systems will be laid

Waterproofing shall be clean, dry and free from voids, loose
Systems aggregate, sharp protrusions, projecting tying wire,
release agents and other substances which are likely
to damage or affect the waterproofing system.
(2) Waterproofing systems shall be laid in accordance

with the manufacturer’s recommendations.
(3) Before waterproofing systems are laid on concrete

surfaces, the concrete surface shall have been cured
for at least 7 days and shall be cleaned with a broom
and sealed with one coat of primer. Primed
surfaces shall not be covered until the solvent
constituent has evaporated. Water shall be allowed
to evaporate from primers containing bituminous
emulsion before the surface is covered. Primed
surfaces shall be protected from contamination.
Installation of 20.74 (1) Prefabricated sheeting shall be laid one sheet at a

Prefabricated time from low points and drains towards high points.
Sheeting The sheeting shall be firmly and tightly brought into
contact with the primer or underlying sheeting.
(2) Laps shall be formed at joints between individual

sheets of prefabricated sheeting. Unless otherwise
approved by the Engineer, end laps shall be at least
150 mm and side laps shall be at least 100 mm.
June 2022
20/27
Joints shall be arranged in such a manner that the

number of layers of sheeting at any joint does not
exceed three.
(3) The perimeter of prefabricated sheeting laid each day

shall be sealed with a trowelled bead of mastic.
(4) A double layer of prefabricated sheeting shall be laid

around pipes, posts or other components, which pass
through the sheeting, and the edges shall be sealed
with a trowelled bead of mastic.
Installation of 20.75 (1) Bentonite panels shall not be laid in water or during
Bentonite Panels wet weather.
(2) Immediately before bentonite panels are laid on a

surface, joints and cracks in the surface shall be
sealed with bentonite joint seal.
(3) Polyethylene sheeting shall be laid below and above

bentonite panels to prevent prehydration. Laps of at
least 100 mm shall be formed at joints in the
sheeting.
(4) Laps shall be formed at the edges of bentonite

panels or the edges shall be closely butted together
and the seam filled with loose bentonite granules.
(5) Bentonite panels shall not be fixed to the underlying

surface unless permitted by the Engineer. If
permitted, the method of fixing shall be by 25 mm
masonry washerhead nails or by other methods
agreed by the Engineer.
(6) Bentonite panels shall be laid continuously around

wall bases and corners. Flat panels shall not be
folded or bent if the panels will be damaged or
bentonite filler will be lost.
(7) Bentonite that is exposed at the edges of bentonite

panels cut to fit around pipes, posts or other
components which pass through the panel shall be
taped or sealed by other methods agreed by the
Engineer to prevent loss of the bentonite filler. The
joint between panels and the pipe, post or component
shall be sealed with a continuous bentonite seal.
(8) Exposed bentonite panels shall be protected from
June 2022
20/28
moisture by polyethylene sheeting unless panels with

a water repellent coating are used. The sheeting
shall be removed before fill material is deposited.
As soon as practicable after each course of panels
has been laid, fill material shall be deposited and
compacted up to a level which is within 50 mm of the
top edge of the panel.
(9) Damaged or expanded bentonite panels shall be

replaced before being covered by the permanent
work.
Bituminous Paint 20.76 Surfaces to which bituminous paint will be applied shall be
Waterproofing treated with a primer before the paint is applied if
Systems recommended by the paint manufacturer. Bituminous
paint shall be applied in two coats. The first coat shall be
allowed to dry before the second coat is applied.
June 2022
20/29
APPENDIX 20.1
Friction Test for Bridge Bearings
Scope 20.1.1 This method covers the determination of the coefficient of

friction, flatness, bonding properties and resistance to
mechanical damage of bridge bearings by means of a
friction test.
(1) compression testing rig;
(2) test loads;
(3) equipment for measuring the loads applied, readable

and accurate to within 2% of the measured load;
(4) equipment for measuring movement, readable and

accurate to 0.01mm;
(5) lubricant of the same type as will be used in service.
(1) The PTFE surface of the bearing shall be lubricated

with the lubricant.
(2) Two sets of sliding surfaces shall be mounted back to

back between the platens of the compression testing
rig with the stainless steel sliding surfaces in the
centre. A vertical load equal to the permanent load
stated in the schedule of bearings shall be applied for
1 hour.
(3) A horizontal load shall then be applied steadily and

without shock to the pair of stainless steel sliding
surfaces and shall be increased at a rate of 0.2% of
the vertical load per minute until movement occurs
between the sliding surfaces. The maximum
horizontal load sufficient to cause movement of at
least 25mm between the stainless steel and PTFE
sliding surfaces at a rate not exceeding 50mm/min
shall be recorded.
(4) The loads shall be removed.
June 2022
20/30
(5) The sliding surfaces shall be removed from the rig

and inspected.
Calculation 20.1.4 The coefficient of friction shall be calculated from the

equation:
Coefficient of friction = maximum horizontal force

2 x vertical load

Results
(1) name of bearing manufacturer.
(2) details of bearing and sliding surfaces.
(3) the vertical load applied.
(4) the maximum horizontal force applied.
(5) the total movement and rate of movement at the

maximum horizontal force applied.
(6) the coefficient of friction to two significant figures.
(7) details of any damage to the sliding surfaces.
(8) that the test method used was in accordance with this
Specification.
June 2022
20/31
APPENDIX 20.2
LOAD TEST FOR BRIDGE BEARING OTHER THAN ELASTOMERIC

BEARINGS
Test loads 20.2.1 The test loads shall be as follows:
(1) Both vertical and horizontal loads, where applicable,

shall be applied to the bearing in the most adverse
combinations. Where load transfer due to tilting of the
bearing can occur, it shall be taken into account.
(2) Load tests to check the performance of a bearing at the

serviceability limit state shall be carried out using the
serviceability design load effects on the bearing
multiplied by the partial factor for the material property,
γM.
(3) Load tests to check the performance of a bearing at the

ultimate limit state shall be carried out using the
ultimate design load effects on the bearing multiplied
by γM.
Loading and 20.2.2 The loading and unloading procedure shall be as follows:
unloading
procedure (1) Before recording measurements, the bearing shall be
bedded in by applying a load equal to the serviceability
limit state load and then releasing it.
(2) The test loads shall then be applied in increments.
(3) The rate of loading shall be slow enough to avoid any

adverse shock effects.
(4) The maximum load shall be maintained until any

obvious short-term creep has ceased.
(5) The load shall then be removed in decrements.
(6) Load deflection measurements shall be made at each

increment and decrement.
Serviceability limit 20.2.3 For serviceability limit state load tests:

state load tests
(1) After complete unloading, the amount of set shall be
June 2022
20/32
checked and, if significant, the loading and unloading

cycle repeated. If the set is shown to be progressive,
the bearing shall be deemed not to comply with the
requirements.
(2) After being tested, the bearing shall be dismantled as

necessary for inspections
(3) A bearing is considered to have passed a serviceability

limit state load test provided that there is no visible
damage or permanent deformation of any part due to
loading cycles subsequent to the initial bedding-in
cycle.
Ultimate and limit 20.2.4 For ultimate limit state load tests:
state load tests
(1) Where a bearing is to be test loaded to both
serviceability and ultimate limit states, it shall be tested
for serviceability first and be dismantled as necessary
for inspection before being tested for the ultimate limit
state. In such cases, it shall have a second bedding-in
cycle before the second load test.
(2) A bearing may be considered to have passed an

ultimate limit state load test if it supports the test load.
(3) Bearings tested for the ultimate limit state shall not be
further used.
June 2022
20/33
SECTION 21
WORK FOR ELECTRICAL AND MECHANICAL INSTALLATIONS
General

Structural 21.2 Structural steelwork for electrical and mechanical

Steelwork installations shall be in accordance with Section 7 of this
Specification.
Glossary of 21.3 "Concealed electrical conduit system" is an electrical

Terms conduit system, including all bends, couplers, bushes,
boxes, covers, plugs, draw wires and other conduit fittings,
which is cast into concrete or fixed in chases in brickwork
with a minimum cover of 20 mm or which is laid directly in
the ground.
Materials
Cable Ducts 21.4 (1) UPVC cable ducts for installation above ground or for
and Fittings casting into concrete shall be Class O UPVC pipes
complying with BS 3506. Cable ducts for installation
below ground shall be Class B UPVC pipes complying
with BS 3506.
(2) Joints and fittings for use with UPVC cable ducts shall
comply with BS 4346:Parts 1, BS EN ISO 1452 Part 1,
2, 3 and 5. Solvent cement for UPVC pipes and
fittings shall comply with BS EN 14814.
(3) Steel cable ducts shall be steel tubes complying with

BS EN 10255, medium series, screwed and socketed
tubes and shall have screwed sockets suitable for
screwing to BS EN 10226, Table 1 pipe threads. The
tubes, sockets, clamps and saddles for ducts shall be
galvanised in accordance with BS EN ISO 1461.
Paint for 21.5 (1) Protective paint systems for steel structures shall
Conduit comply with BS EN ISO 12944. Bituminous paint for
and Duct steel conduits and steel cable ducts shall comply with
Systems BS 3416, type 1.
(2) Zinc chromate primer for cable duct systems shall

comply with BS 4652.
June 2022
21/1
(3) Galvanizing paint for cable duct systems shall be a

proprietary type approved by the Engineer.
Fire Barriers 21.6 Internal fire barriers shall be a type approved by the
Engineer and shall be resistant to fire, smoke, gas and
water.
Cement Grout for 21.7 (1) Materials for grout shall comply with Section 11 of this
Electrical and Specification.
Mechanical
Installations (2) The different types of cement grout for electrical and
mechanical installations shall consist of PC, sand and
PFA in the proportions by mass stated in Table 21.1
together with the minimum amount of water necessary
to achieve a consistency suitable for completely filling
the voids; the mix shall contain a non-shrink
admixture.
Table 21.1: Mix Proportions of Cement Grout
Type Mix proportions by mass

PC Sand PFA
G1 1 - -
G2 1 3 -
G3 1 10 -
G4 1 - 7
Holes and Recesses for Electrical and Mechanical

Installations
Holes and 21.8 (1) The requirements for electrical and mechanical
Recesses for installations shall be as shown on the Drawings and
Electrical and provisions of holes and recesses shall be made in the
Mechanical structure during construction. Holes and recesses
Installations shall not be constructed in hardened concrete
structures.
(2) Holes and recesses in internal floors, stairways and

platforms shall be protected with temporary covers, or
by other methods if permitted by the Engineer. Holes
June 2022
21/2
and recesses in roofs, external walls and external

floors shall be sealed with watertight temporary covers
until the electrical and mechanical installation starts at
each location.
(3) Holes in structures shall be filled and made good after

electrical and mechanical installations are complete;
holes left in structural elements designated as fire
barriers shall be sealed to at least the same degree of
fire resistance as the structural element.
Fire Barriers
Fire Barriers 21.9 Internal fire barriers shall be constructed in service

channels, service shafts and service ducts for electrical and
mechanical installations at the following locations:
(a) at points of intersection with structural elements

designated as fire barriers; and
(b) at termination points and open ends.
Cable Duct Systems for Underground Cables
Installation of 21.10 (1) Changes in direction in cable duct systems shall be

Cable Duct constructed in such a manner that the cables in the
Systems duct will have radii of curvature of at least 800 mm or 6
times the outer diameter of the duct circumference
which ever is greater. Ducts entering draw-in pits
shall be on the same horizontal plane as the draw-in
pit.
(2) UPVC cable ducts shall be jointed and fixed in

(3) Steel cable ducts shall be jointed using screwed

galvanized sockets and spun yarn or by an equivalent
method approved by the Engineer such that the
jointed pipes abut; the threads shall be painted with 2
coats of bituminous paint. Internal rags and burrs
shall be removed to provide a smooth bore through
joints in the cable duct system.
(4) Surface mounted cable ducts shall be secured by

galvanised steel clamps or saddles at spacings not
exceeding 3 m.
June 2022
21/3
Protection 21.11 (1) After jointing, exposed bare metal in cable duct
of Cable Duct systems shall be cleaned and painted with 2 coats of
Systems zinc chromate primer and 2 coats of galvanising paint.
(2) Surface mounted galvanized steel cable ducts shall be

cleaned and painted after fittings and jointing have
been completed.
Cleaning of 21.12 After jointing, cable duct systems shall be cleaned internally
Cable Duct by scrubbing with a brush of a type permitted by the
Systems Engineer. The ends of ducts, including ends of ducts in
draw-in pits and spare ducts, shall be fitted with tapered
hardwood plugs to prevent water, moisture and deleterious
material from entering the system and a 6 mm diameter
nylon draw line shall be installed. The plugs shall be
centrally drilled for the draw line and the draw line shall be
secured by a knot tied on the outer face of the plug to leave
at least 1500 mm of surplus line at each plug.
Grouting for Electrical and Mechanical Installations
Grouting for 21.13 (1) Grouting to structural steelwork, machine bases, crane
Electrical and rails, electrical and mechanical equipment and other
Mechanical electrical and mechanical installations shall comply
Installations with the requirements stated in Clause 21.13 (2) to (8)
inclusive.
(2) Grouting shall be carried out at the times instructed by

the Engineer and shall be completed within 7 days of
the instruction.

before items or equipment are grouted. The
Contractor shall inform the Engineer 3 days, or a
shorter period permitted by the Engineer, before
grouting starts and shall allow the Engineer sufficient
time to inspect the work which is to be grouted.
(4) Concrete surfaces shall be scabbled to remove

laitance and loose material and to expose the
aggregate before the item or equipment is installed in
position.
(5) The voids to be grouted shall be cleaned and

thoroughly wetted immediately before grouting.
Excess water shall be removed by using a
compressed air jet or by other methods if permitted by
the Engineer.
June 2022
21/4
(6) Grout shall be mixed by methods consented to by the

Engineer and shall be used within one hour of mixing.
The grout shall be worked into the voids by rodding at
least 30 times with a flat bottomed 20 mm diameter
steel bar until all entrapped air is removed.
(7) If grouting is to be carried out in two operations,

holding down bolts shall be grouted into preformed
pockets and sufficient time shall be allowed for the
grout to cure and for the bolts to be tensioned before
the remaining voids are grouted.
(8) Exposed grout surfaces shall have a uniform, dense

and smooth surface free from trowel marks and which
is produced by steel trowelling the surface under firm
pressure. The exposed surfaces shall be cured by
either:
(a) using a liquid curing compound applied to the

surface by a low-pressure spray until a
continuous visible covering is achieved; or
(b) covering the surface with hessian or sacking; the

hessian or sacking shall be lapped and securely
held in position and shall be kept damp for at
least 4 days.
Completion and Protection of Work for Electrical and

Mechanical Installation
Completion of 21.14 Work shall be done in accordance with the Conditions of

Work for Electrical Contract and the Particular Specification before structures
and Mechanical are made available to others, including domestic and
Installations nominated sub-contractors, for electrical and mechanical
installations.
Protection of Work 21.15 (1) Structures in which electrical and mechanical

for Electrical and installations are being carried out shall be maintained
Mechanical in a clean, dry secure condition, free from dust, during
Installation the installation.
(2) The dust level in plant rooms shall be kept to a

minimum by using industrial dust extractors of a type
permitted by the Engineer during and after the
installation. Temporary screens shall be installed to
separate dust-affected areas from the installations or
temporary covers shall be installed around the
installation.
June 2022
21/5
Tolerances
Tolerances: Floors 21.16 The tolerance in finished floor level for Power Supply
of Power Supply System Plant Rooms shall be 4 mm in 3000 mm.
System Plant
Rooms
Testing: Load Tests on Beams and Joists for

Electrical and Mechanical Work
Testing: Load 21.17 (1) Load tests shall be carried out on lifting beams, rolled
Tests on Beams steel joists, lifting hooks, eyes and anchorage points
and Joists which are installed by the Contractor for electrical and
mechanical work or the Permanent Works.
(2) Testing shall be carried out by an independent testing

agent approved by the Engineer using methods
(3) A certificate showing the results of the load tests and

signed by the testing agent shall be submitted to the
Engineer within 14 days of the test. The validity of
the certificate shall be at least 3 months after the date
of handover.
Compliance 21.18 The results of tests on lifting beams, rolled steel joists, lifting
Criteria: Load hooks, eyes and anchorage points shall comply with
Tests on Beams statutory requirements.
and Joists for
Electrical and
Mechanical Works
Earthing 21.19 (1) All earth conductors shall be of high conductivity hard
System drawn copper complying with BS EN 13601 and BS
1434. The earthing system, comprising a network of
copper conductors, shall be provided under all stations
and ancillary building structures in accordance with the
Contract and the following:
(a) the part of the earthing system shall consist of

earth mats, test electrodes, principal earth
conductors, test links and a main earth network.
The main earth network shall be routed to pass
through all rooms containing electrical equipment
and shall be in a ring configuration. The
earthing mats, test electrodes, principal earth
conductors and test links shall be provided by the
June 2022
21/6
Contractor unless otherwise specified in the

Contract;
(b) the number of earth mats to be provided by the

Contractor shall be in accordance with the
Contract.
(2) A typical earthing mat shall comprise not less than

eight copper earthing rods or copper tapes driven or
buried into the ground to a suitable depth. The
Contractor shall carry out resistivity tests of the soil
and submit data to the Engineer to confirm earth mat
design before earth mat installation. The actual
number of earthing rods or copper tapes shall be
determined and approved by the Engineer, to provide
an earth resistance of not greater than 0.5ohms for a
single earthing mat and to meet the requirements on
maximum touch, step and rise of earth potential.
Calculations shall be submitted for the approval of the
Engineer. Measurements of the resistance of each
earthing mat shall be taken after completion of earth
mat installation and submit data for Engineer’s
Approval. The earthing mat shall be constructed in
accordance with the requirements in the Contract and
the following :
(a) at 300mm below the base slab, a minimum of 8

holes of 90mm diameter, around 10m deep at
locations selected on Site shall be provided;
(b) earth electrodes shall be formed using a copper

(annealed) tape of 40 x 4mm inserted into the full
depth of each hole and an extra length of 300mm
shall be left at the top to allow for connections to
be made;
(c) a mixture of 60% bentonite and 40% of gypsum

to 125% of water (by volume) mixed to give a
thick slurry shall be grouted into the holes and
then allowed to solidify. The grouting shall not
trap any air in the holes;
(d) the earth electrodes at each locations (i.e. the

copper tapes in bentonite and gypsum) shall be
interconnected by two stranded bare copper
conductors or bare copper bars, with minimum
cross sectional area of 75mm2;
(e) the connections shall be brazed to achieve a

June 2022
21/7
good and reliable joint to withstand anticipated

fault currents. The copper stranded base
conductors shall be flattened and clamped to the
copper tapes while brazing as shown in the
Contract;
(f) two insulated principal earth leads of 50mm x

6mm copper (annealed) tapes shall be provided
and connected to the earth electrodes These
principal earth leads shall be routed separately
and emerge through the finished floor screed in
positions clear from all reinforcement and to be
agreed on Site.
Electrical and Mechanical Cast-in Sockets for Concrete
Non-Metallic 21.20 (1) Non-metallic cast-in sockets for Electrical and

Cast-in Sockets for Mechanical Cable Brackets for concrete shall have
Electrical and material properties as follows or similar Approved:
Mechanical Cable
Brackets (a) Tensile strength > 60N/mm2
(b) Compressive strength > 140N/mm2
(c) Shrinkage/expansion < 0.003mm/mm
(d) Water absorption < 0.25%
(e) Track resistance > 600 mins
(f) Arc resistance > 3 mins
(g) High flame resistance = V-0
(h) Low toxicity when heated
(i) High corrosion and chemical resistance
(2) The material properties shall be tested in accordance

with the following Standards or similar Approved :
(a) Water absorption FED-STD-406/7031
(b) Track resistance ASTM D2303
(c) Arc resistance FED-STD-406/4011
(d) Flame resistance UL-94
June 2022
21/8
(3) Sockets shall have the appropriate pullout and shear

capacity for their purpose and shall be subject to
Approval by the Engineer.
June 2022
21/9

M&W Civil A5 Vol.2 (Sep 2022)

Uploaded by

Copyright:

Available Formats

M&W Civil A5 Vol.2 (Sep 2022)

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

M&W Civil A5 Vol.2 (Sep 2022)

Uploaded by

Copyright:

Available Formats

D/MTRCL/NW/CIV/M&W/002/A5

MATERIALS AND WORKMANSHIP SPECIFICATION

CIVIL ENGINEERING WORKS

REVISION DATE PREPARED REVIEWED CONTROLLED APPROVED

Parker Ko Derek Kwok

© MTR CORPORATION LIMITED 2022

MATERIALS AND WORKMANSHIP SPECIFICATION

SECTION SUBJECT PAGE

11 Concrete and Grout 11/1 - 11/114

12 Prestressing 12/1 - 12/25

14 Waterproofing 14/1 - 14/13

15 Carriageways : Sub-base Materials and

16 Concrete Carriageways 16/1 - 16/23

17 Miscellaneous Roadworks 17/1 - 17/35

19 Deep Foundation Works 19/1 - 19/59

20 Bridgeworks 20/1 - 20/33

21 Work for Electrical and Mechanical Installations 21/1 - 21/9

MATERIAL AND WORKMANSHIP SPECIFICATION

CIVIL ENGINEERING VOLUME 2

• Any reference to material and workmanship compliance criteria mentioned in this

• Reference to Section numbers in Volumes 1, 2 and 3 shall refer to Volumes 1, 2

• Unless noted otherwise in the Contract, all materials shall be applied in

CONCRETE AND GROUT

Part 1, Concrete. Clauses 11.1 to 11.93

Part 2, Sprayed Concrete. Clauses 11.94 to 11.109

Part 3, Grout. Clauses 11.110 to 11.118

Part 4, Pre-cast Concrete. Clauses 11.119 to 11.127

Part 5, Glassfibre Reinforced Concrete. Clauses 11.128 to

Part 6, Silane Treatment of Concrete. Clauses 11.135 to

Part 7, Repair of Concrete and Filling of Tie Holes. Clauses

Glossary of 11.1 (1) "Cementitious Content" is the total weight of Portland

(2) "Water Content" is the total weight of the free water

(3) "W/C ratio" is the ratio of the water content divided by

(4) "Design Cementitious Content" is the total

(5) "TRET" is a Temperature Rise Evaluation Test as

(6) "Acceptance Workability tests" are workability tests

conducted by the Contractor to ascertain if the

(7) "Compliance tests" are all tests which the Contractor is

(8) "Class"; all concrete will be defined by its Class which

(10) "Characteristic Strength" of concrete is a value of cube

(11) “Self-compacting concrete” (SCC) is concrete that is

(12) “High Strength Concrete” is the concrete mix with

General 11.2 (1) The water-tightness of completed concrete structures

(a) in all areas where waterproof membranes are

(b) elsewhere without waterproof membrane,

(c) where diaphragm walls form elements of the

structure, the performance requirements of

(2) The designs are based generally on the grades as

(3) Other grades of concrete called for in the Contract are

(4) Concrete of Grade 20 shall be unreinforced concrete.

(5) High strength concrete (>60MPa) or concrete with

(6) Requirements for all cementitious materials and

(7) All cementitious materials (PC, PFA, GGBS, CSF,

(8) Additional sampling and testing of materials on

(9) Where the cement is supplied as a blend of PC and

(10) Cements supplied as a blend shall comply with Clause

Concrete 11.3 (1) Concrete is classified with regard to temperature,

(2) Category A concrete shall generally include concrete

(3) Category B concrete shall include concrete elements

(4) Category C concrete shall include concrete elements