017-ITC-056 (1) Reinforced Concrete Works For Bridges

Doc: 017-ITC-056
INSPECTION TEST CHECKLIST (ITC) Revision: 1

Sheet: 1 of 11
ITP No. ITC Title Form: 017-F033-2602
017-W056-2602 Reinforced Concrete Works for Bridges
Package Lot From To

Chainage
Sub Lot Number
Description Engineers Name Supervisors Name
Control Line Date Opened
Conforming
Applicable Inspection Test Comments
Item Task RI Acceptance Criteria (Initials)
Standard NCR/RFI or HP/WP No.
Method Frequency Y N N/A
Preliminaries Prior to supply
1.0
of concrete
1.1 CEP/SWMS issued to RMS ENG CEP/SWMS developed and approved for use RMS G22 Review Prior to start
40MPa and 50MPa concrete mix design to be approved by

RMS
At least 5 HP No. :
(a) (i) all details in Clause 3.8.2; or
Drawings working days
(ii) nomination of a mix from the Register of RMS RMS B80, Cl before the
1.2 Submission of Nominated Mixes ENG Approved Concrete Mixes; and Hold Point Released By:
3.8.1 concrete mix
(b) a statement stating that the mix conforms to this B59 Cl 9 is proposed
Specification and is suitable for its intended use, at least 5 to be used. Date:
working days before the concrete mix is proposed to be
used. Concrete mix then reviewed and approved for use
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Sheet: 2 of 11
Conforming
Certified Engineer review and submission of documentation
including formwork documentation and design certification.
(N/A for Category A)
Category A Low Risk includes :
- Abutments, pile caps, footings, piers, columns
N/A for
and walls, with heights less than 3 metres HP No. :
Category A
Headstocks less than 3m from the ground
- Members not included in either Category B or Category B
Category C prior to
RMS B80 Cl
Formwork Design, documentation placing
1.3 ENG Category B Moderate Risk includes : 5.2.4 Hold Point Released By:
and Certification reinforcemen
- Abutments, pile caps, footings, piers, columns AS 3610
t
and walls, with heights greater than 3 metres and
Category C
less than 6 metres
prior to Date:
- Headstocks more than 3m from the ground
erection of
- Decks with max thickness less than 600mm
formwork
Category C High Risk
- Abutments, pile caps, footings, piers, columns
and walls, with heights greater than 6 metres
- Decks with max thickness greater than 600mm.
HP No. :
RMS Bridgeworks Concreting At least 2 weeks prior to the first concrete pour, submit to the
RMS B80 Cl Prior to first
1.4 Grey Card (2 weeks prior to first ENG Principal the names of the personnel who will be involved in Hold Point Released By:
7.1 pour
pour) bridgeworks concreting operations.
Date:
Prior to first
Supplied reinforcement (i.e. Onesteel) conforms to the
1.5 Reinforcement Conformance ENG RMS B80.6 Review Use on
requirements of B80.
bridges
HP No. :
Contractor certification for erected formwork stating which
category the formwork has been erected in accordance with RMS B80 Cl
5.2.4 Each
1.6 Erected Formwork Certification ENG for Category A or B formwork. Hold Point Released By:
AS 3610 Element
Engineering Certification by a member of Engineers
Australia for Category C formwork
Date:
2.0 Pre Pour Works
2.1 Survey Set out ENG Survey set-up to check the formwork as planned and as RMS B80 Cl Check Each Pour
measured characteristics and verification that they are within 5.7.2
the tolerances specified in B80 Table B80.11. Table B80.11
Tolerances as follows:
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Sheet: 3 of 11
Conforming
Item Tolerance
(mm)
Top of pile cap:

RL 25
Plan 50
Variation in Cross Section of

columns, piers, headstocks, slabs,
walls and beams:
<3m -5 to +15
3m -10 to +25
Decks:
Variation in thickness of slab -5 to +15
Deviation of RL top of base slab -10 to +5
Flatness of top surface of bridge
direction in any direction 1 in 1000
Deck Joints width of slot 3
Variation from vertical of specified

batter of columns and piers:
Unexposed concrete 1 in 250
Exposed concrete 1 in 500
Barriers:
Variation from grades 1 in 1000
Variation in plan from straight or -5 to +10
horizontal alignment
Steps in plan and elevation 5
Flatness of front face 1 in 1000
RL for top of headstocks and piers 5
Bearing Pads: 2.5

RL 1 in 200
Variation in grade across pads
Deviation from flat surface 1.0
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Sheet: 4 of 11
Conforming
Departure from plan position:

25
Columns, piers, walls, headstocks,
beams, slabs, kerbs and barriers
Relative displacement of adjoining 10
members
Centreline of bearings 5
Departure from alignment:

Row of columns, faces of piers or 10
walls
Handrails, kerbs and barriers 5
Maximum allowance for irregularities

in exposed surfaces:
Sections less than 1m 2.5
Sections greater than 1m 5
Deviation form design kerb and
barrier dimensions 2.5
Erection of Formwork
Ensure forms are clean and oiled to facilitate easy cleaning
stripping and required surface finish.
For unlined timber, wet timber prior to oiling. RMS B80 Cl
5.7.1
2.2 Formwork Installation SUP Release agent to be compatible with curing components Check Each Pour
Bridge
used. Drawings
Reinforcement, tendons and embedment are clean from
oil/grease used for treating forms.
All gaps, joints, voids to be sealed to prevent slurry loss.
Reinforcement placing and embedment

Location & spacing checked against drawings and
secured. AS4671,
RMS
Provide the appropriate cover as shown on the drawing.
B80.6.4-6.9
Reinforcement placing & Ensure embedments are within tolerances shown below: Table B80.14
2.3 SUP Check Each Pour
embedment Table B80.16
Tolerance Table B80.17
Item
(mm) Bridge
Formed surfaces -5 +10 Drawings
Unformed finished surfaces -5 +10

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Sheet: 5 of 11
Conforming
Slabs cast on gorund -10 +20
Footings cast against ground -20 +40
Ends of reinforcement 50
Spacing (S) of bars in walls/slabs

15 or 0.1S
and beams
Fixings to be secure and capable of withstanding loadings

during concrete pour.
Threads or inserts should be protected with tape or
polystyrene
Lapped splices are to be checked for staggering of splice,
splice length and location. Minimum splice lengths for
deformed bars should be as per below
Bar Diameter Splice length
12 430
16 660
20 910
24 1180
28 1470
32 1770
36 2070
40 2400
Screed rail and height pins to be supported independently

of the underlying reinforcement.
All cast in bolts to be separated from & not touching
adjacent rebar.
Prior to pouring concrete, surfaces must be checked to

ensure that:
- Surfaces are clean Each
Surface inspection prior to RMS B80 Cl
2.4 SUP - Constrution joints are prepared Inspection Concrete
concrete placement 7.1
- All fixtures are embedded and any items are pour
installed.
- Construction joints are saturated
Doc: 017-ITC-056
Sheet: 6 of 11
Conforming
RMS G1 Cl
33
ENG/ Electrical Connectivity of reinforcement to be demonstrated RMS B80 Cl
2.5 Electrical continuity Review Prior to pour
SUP in accordance with RMS G1 Cl 33 and AS2832.5. 6.3.3
Bridge
Drawings
At least two working days prior to placing concrete submit a HP No. :
pour specific method/planning checklist for delivering the
works. Each
Each Placement of concrete into RMS B80 Cl
2.6 ENG Hold Point Concrete Released By:
the works Pre pour check At least 4 working hours prior, submit to RMS a Certificate of 7.3
pour
Conformity for formwork, reinforcement, embedments and
screeding guide rails or height pins Date:
HP No. :
At least four working hours prior to pouring concrete, submit
RMS Bridgeworks Concreting to the Principal a statement stating that at least half of the RMS B80 Cl 4hrs prior to
2.7 ENG Hold Point Released By:
Grey Card (4hrs prior to pour) personnel who will be involved in bridgeworks concreting 7.1 pour
operations hold a RMS Bridgeworks Concreting Grey Card.
Date:
3.0 Concrete Placement
Concrete grade/mix RMS B80 Cl

Check supply against design 4.3.4
3.1 Concrete Grade/Mix ENG Review Each Pour
Check concrete placed and compacted within 1.5 RMS B80 Cl
hours of the addition of the cement to aggregates. 4.3.5
Prior to pouring ensure ambient temperature is between 5o

C and 38o C. Check that the predicted temperature for the
next 24 hours is not expected to drop below 5 o C after
Air Temperature, control of pouring RMS B80 Cl
3.2 ENG Check Each Pour
moisture loss 7.5 - 7.6
Evaporation retarder (Aliphatic Alcohol) may be used where
evaporation rate is more than 1kg/m2/hr, generally for
substructures.
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Sheet: 7 of 11
Conforming
Water may be added to a mixed batch of concrete prior to
the commencement of discharge provided the following
conditions are satisfied:
Less than 45 mins have elapsed since cement was
added to the aggregate
Operate the mixing mechanism at mixing speed for at
RMS B80 Cl
3.3 Addition of Water ENG least 3 mins Review Each batch
4.5
The total quantity of water added is not more than
9kg/m3and the max w/c ratio is not exceeded.
The quantity of water is measured and recorded on the
delivery docket
The slump of the concrete is checked after the water
has been added, in accordance with Clause 4.4
Check and record the slump of the concrete within 45mins of

adding cement to the aggregate or at discharge. Also check
and record the slump immediately prior to discharge when
the actual haul time exceeds 45 minutes and/or when water
is added to a mixed batch.
If test fails, repeat test immediately. If it fails the second
time, the concrete is to be rejected.
Tolerance as per table 5.1 of AS1379. RMS B80 Cl
4.4
3.4 Slump testing ENG Specified slump (mm) Tolerance (mm) Test Each batch
RMS B80
Annexure L
<60 10 AS1379
60 80 15
>80 110 20
>110 150 30
>150 40
RMS B80 Cl
ENG / Concrete temperature: 10C x 32 C at point of
3.5 Concrete temperature 7.5 Inspection Each batch
SUP discharge.
RMS B80/L
28 Day compressive strength tests should be undertaken at
the rate of one pair of tests for:
Mass Concrete one pair per 50 m3 or part thereof RMS B80/L
3.6 Compressive Strength ENG Test Each pour
3
Reinforced Concrete one pair per 25 m or part thereof
Prestressed Concrete one pair per 10 m3 or part thereof
Doc: 017-ITC-056
Sheet: 8 of 11
Conforming
Placing as per concrete placement planning checklist

discussed. Clause 7.4.2 and 7.4.3
Vibration (immersion) is controlled and adequate
vibrators are used and standby vibrators available
Concrete pour record completed.
Vibration of reinforcement to be avoided. RMS
Internal vibrators 50mm nominal diameter. B80.4.3.5,
Ensure full-depth vibration and 100mm into RMS B80.7,
RMS
underlying layer.
ENG / B80.7.4.2 &
3.7 Concrete Placement Internal vibrators to be left in place for min 7 seconds Inspection Each pour
SUP RMS
and until air bubbles cease breaking the surface B80.7.4.3
withdraw slowly. Q6.Cl 7.5.3
Ensure concrete is compacted fully in densely Product
Traceability
reinforced areas prior to encasing the reinforcement
with concrete.
Concrete Traceability Plan completed for deck pours
only
Do not place concrete during rain or when rain
appears imminent unless a waterproof covering is
provided to the exposed surfaces of the concrete.
Unformed surfaces must be compacted, tampered and then
screeded to the specified levels with a wooden float.
If cracks appear before or during concreting, rework
Surface Finishing other than RMS B80 Cl
3.8 SUP concrete using vibrators when initial set has not occurred Check Each Pour
deck and approach slab. 7.11.2
and the surface to be refinished with a wooden float.
Curing to be applied as soon as possible after finishing to as
avoid moisture loss.
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Sheet: 9 of 11
Conforming
For all types of deck and approach slab surfaces, screed the
decks using vibrating screeds set on screeding guide rails.
Set screeding guide rails entirely above the concrete
surface, unless they are removed on completion of
screeding and before commencement of finishing.
Screeding ensure a head of concrete is always present in
Surface Finishing deck and front of leading edge of vibrating screed to avoid low spots. RMS B80 Cl
3.9 SUP Check Each Pour
approach slab. 7.11.2
Finishing occurs when the bleed water (if any) is
disappearing and the concrete is stiff enough to carry a
workmans weight with footprints present.
Tools used wood float, steel towel and broom.
Curing to be applied as soon as possible after finishing too
avoid moisture loss
Ensure the surface of the concrete at construction joints is
roughened to a pronounced profile with a surface RMS B80 Cl
3.10 Preparation of Construction Joints SUP Check Each Pour
roughness not less than 3mm. 7.9
Remove loose aggregate particles and laitance.
Apply curing in accordance with approved regime nominated
in Item (d) of Clause 3.8.2. Concrete surface to be protected
and maintained at not less than 5C throughout the curing
period.
Wet cure all cast-in-place bridge decks and approach slabs
for a minimum of 72 hours after finishing operations are
completed. B80 Cl 7.12
3.11 Curing SUP Review Ongoing
Moisture within concrete to be maintained by covering with AS 3799
canvas, hessian, plastic or other suitable materials and kept
continually wet. It is not to stain formed surface or a surface
that will be visible.
Approved curing compound applied in accordance with
manufacturers directions and spray rate of 0.2 litres/m2 per
coat, or rate as per manufacturer specification.
4.0 Post Pour
Stripping not to commence until a minimum compressive

strength has been reached:
RMS B80 Cl Prior to
4.1 Stripping formwork SUP - For Vertical Surfaces minimum 7MPa Test
5.9 stripping
- For Underside of horizontal surfaces a minimum
of 80% of fc.min
Doc: 017-ITC-056
Sheet: 10 of 11
Conforming
No cracks greater than 0.05mm at the end of curing period.
After 28 days there can be no cracks greater than 0.1mm
4.2 Concrete Cracking SUP If cracking is identified as nonconforming, they must be B80 Cl 7.2 Inspection Each pour
measured and mapped. Crack maps must be submitted to
the Principal
Surface finish & Concrete repairs (where necessary)

Surface finish complies within tolerance limits in Table B80 Cl 5.10
Each
4.3 Finishing and Concrete Repairs SUP B80.11 (refer to Item 2.1) B80 Cl Inspection
Element
Procedure for repair has been approved by the 7.11.2.5
Principal
Average of 28 day pair>f cmin

Concrete Compressive Strength
4.4 ENG Highest 28 day strength values taken if pair of results differs B80 Cl 8 Test Each Pour
Test
by more than 10% of mean.
Non-essential traffic must not access the deck until the

specified 28 day compressive strength of the concrete is
reached.
Control access by essential traffic as follows:
Equipment not exceeding 0.5 tonnes in weight may HP No. :
access the deck after 50% and before 75% of the
specified 28 day compressive strength of the deck
concrete is reached. Each Deck
4.5 Early Trafficking of Bridge Deck ENG Other equipment must not access the deck until 75% B80 Cl 7.15 Hold Point Released By:
Slab Element
of the specified 28 day compressive strength of the
deck is reached.
o Max axle loads: 5.0 tonnes single; 8.0
Date:
tonnes tandem; 9.0 tonnes triaxle.
o Tracked vehicles: Max 15 tonnes/m2
pressure of the track area, providing the
concrete is protected from the surface
damage.
Each
4.6 Survey Asbuilt ENG Survey asbuilt pickup B80 Cl 5.10 Survey
Element
5.0 Completion
Works are complete with exception of minor defects

Q6 Cl
5.1 Lot Closed QMR No outstanding NCR's, test results, Hold Points or other Review Each Lot
8.2.4.3
documentation
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Sheet: 11 of 11
Additional Comments:
I hereby certify that this lot conforms in all respects with the standards and requirements specified for K2K Project.
Work Completed by: Supervisor (SUP)
Date:
Name: Signed
Conformance/Verification Statement:
I hereby certify that this lot conforms in all respects with the standards and requirements specified for the Project. The lot verification records are complete and attached and
any non-conformances and RFIs have been closed.
Lot Complete / Records available: Engineer (ENG)
Date:
Name: Signed
Lot Approved For Closure By: QMR

Date:
Name: Signed

017-ITC-056 (1) Reinforced Concrete Works For Bridges

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Doc: 017-ITC-056

INSPECTION TEST CHECKLIST (ITC) Revision: 1

Package Lot From To

Description Engineers Name Supervisors Name

Control Line Date Opened

40MPa and 50MPa concrete mix design to be approved by

Top of pile cap:

Variation in Cross Section of

Deck Joints width of slot 3

Variation from vertical of specified

RL for top of headstocks and piers 5

Bearing Pads: 2.5

Departure from plan position:

Departure from alignment:

Maximum allowance for irregularities

Reinforcement placing and embedment

Unformed finished surfaces -5 +10

Slabs cast on gorund -10 +20

Footings cast against ground -20 +40

Spacing (S) of bars in walls/slabs

Fixings to be secure and capable of withstanding loadings

Bar Diameter Splice length

Screed rail and height pins to be supported independently

Prior to pouring concrete, surfaces must be checked to

3.0 Concrete Placement

Concrete grade/mix RMS B80 Cl

Prior to pouring ensure ambient temperature is between 5o

Check and record the slump of the concrete within 45mins of

Placing as per concrete placement planning checklist

4.0 Post Pour

Stripping not to commence until a minimum compressive

Surface finish & Concrete repairs (where necessary)

Average of 28 day pair>f cmin

Non-essential traffic must not access the deck until the

Works are complete with exception of minor defects

Lot Approved For Closure By: QMR

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