6.

CONCRETE

6.1 GENERAL

This specification applies to the supply, handling, and placement of concrete.

Produce finished concrete that is sound, dense, impermeable, and durable.
Comply with the material, construction, and testing requirements of AS 3600: Concrete Structures and
substitute it where other Standards refer to AS 1480.
Comply with any additional requirements of the Austroads Bridge Design Code if public traffic will use or
could impact on the works.
Comply with the additional requirements in this section.

6.2 STANDARDS

Conform to the following standards unless specified otherwise:

AS 1012 Methods of testing concrete (Set)
AS 1141 Methods of sampling and testing aggregates (Set)
AS 1319 Safety signs for the occupational environment
AS 1379 Specification and supply of concrete
AS 1478 Chemical admixtures for use in concrete
AS 2350.1 Method of testing portland and blended cements
AS 2758.1 Aggregates and rock for engineering purposes, Part 1: Concrete aggregates
AS 3600 Concrete structures
AS 3610 Formwork for concrete
AS 3972 Portland and blended cements
AS 5100 Bridge Design (Set)
ASTM C294 Standard Descriptive Nomenclature for Constituents of Concrete Aggregates
ASTM C465 Standard Specification for Processing Additions for Use in the Manufacture of Hydraulic
Cements
AUSTROADS AGBT Guide to Bridge Technology Set
Comply with the additional requirements of this Specification.
Comply with the requirements of this Specification if they contradict clauses in the above Standards,

6.3 MATERIALS

6.3.1 General Hold Point

Hold Point - Provide the details of, and obtain approval for:
the manufacturer and type of cement,
mixing water,
type, dosage rates, and method of application of admixtures (provide manufacturer's literature
including authenticated chemical analyses),
all aggregates, and
reinforcement.
Do not use unapproved or non-conforming materials in the works.
Do not change the source or type of any approved material without written approval of the
Superintendent.
Bear all expenses related to additional acceptance testing resulting from changing the source or type of
any material.
Retest for compliance any lot (or portion) of any material that the Superintendent believes has
deteriorated:
during handling and storage, and
since original compliance testing.
Remove from the structure and the site all non-conforming materials and bear all expenses and time
delays related to:
retesting,
replacement of the rejected material,
repair of the structure if necessary, and
consequences of the resultant interruptions and delays.

6.3.2 Cement

Use Class GP cement unless otherwise specified or approved.

Provide a test certificate proving compliance with the appropriate Standard if:
requested,
if the cement is not packaged and marked with the AS Standards Mark, and
is not loaded directly from the manufacturer's storage.
Sample cement in the presence of the Superintendent and test it if a test certificate is not otherwise
available.
Retest cement for compliance which has been stored for more than two months from the date of
manufacture.
All mixes shall contain a minimum mass of Portland cement equal to 55% of the total mass of
cementitious material. GP cement shall have a maximum total alkali content (measured as Na 2O
equivalent) of 0.6%.

6.3.3 Fly Ash

Fly ash may be used in concrete subject to the following conditions:

The Contractor shall nominate an intention to use fly ash (either separately or as blended cement)
and state the proportions when submitting details of the mix design;
Fly ash shall conform to AS3582.1 and shall be obtained from an approved source. Only Fine Grade
fly ash shall be used as defined in Table of AS3582.1;
Fly ash shall be used in accordance with AS3582.1;
Where the concrete supplier wishes to use both fly ash and an air entraining agent in a mix, the
supplier shall provide the Superintendent with proof (from tests on trial mixes or previous production)
that the amount of air entrained can be controlled within specified limits and that the compressive
strength is satisfactory when submitting details of the mix design; and
Fly ash shall have a maximum total alkali content of 2% and a maximum available alkali content of
0.5% (Na2O equivalent).

6.3.4 Slag Ground Granulated Iron Blast Furnace

Slag may be used in concrete subject to the following conditions:

The Contractor shall nominate an intention to use slag (either separately or as blended cement) and
state the proportions when submitting details of the mix design;
Slag shall conform to AS3582.2 and shall be obtained from an approved source;
 Slag shall be used in accordance with AS3582.2; and
Slag shall have a maximum total alkali content of 1% and a maximum available alkali content of 0.5%
(Na2O equivalent).

6.3.5 Fly ash and Slag in Combination

Fly ash and slag in combination may be used in concrete provided that the Contractor nominates an
intention to use both fly ash and slag in combination with Portland cement and state the proportions
when submitting details of the mix design.
6.3.6 Silica fume
Silica fume may be used in concrete subject to the following conditions:
The Contractor shall nominate an intention to use silica fume and state the proportions when
submitting details of the mix design;
Silica fume shall be obtained from an approved source; and
Silica fume shall not be used in decks and slabs.

6.3.7 Water Hold Point

Water shall meet the requirements of AS1379.

Supply a 10 kg sample of the water proposed to be used in the works for analysis, if directed by the
Superintendent. Testing of water quality shall be in accordance with AS3600 and any additional
requirements in AS5100.
Hold Point - Obtain the Superintendent's written approval of the water to be used for works.
Do not use unapproved water.
Do not use recycled wash water in concrete without approval.

6.3.8 Admixtures Hold Point

Hold Point - Do not use any admixtures without obtaining prior Superintendent approval.
Comply strictly with the manufacturer's Specifications.
Admixtures and their use must conform to AS 1478.1.
Approval will not be given for the use of admixtures which may be deleterious to the concrete or
reinforcement.
Ensure that all admixtures are compatible with each other when used in concrete.
Store admixtures in accordance with the manufacturer's recommendations.

6.3.9 Aggregates

6.3.9.1 General Hold Point

Hold Point - No Concrete shall be placed in works until the aggregate samples have been approved by
the Superintendent.
Aggregates to conform to AS2758.1 unless specified otherwise.
In addition to AS2758.1 test aggregates in accordance with AS1141.
Hold Point - If aggregates are found to be alkali reactive, include a minimum of 20% fly ash by mass of
total cementitious material. Obtain Superintendent approval of the type of fly ash to be used.
Use the following nominal size of aggregate unless otherwise shown on the drawings or approved.
Generally 20 mm
Very thin sections and Pedestals 10 mm
 Mass Concrete 20 mm.
Use aggregate appropriate to a "Severe Concrete Exposure Classification".
Provide test certificates showing compliance of the aggregates for:
each uniform lot of material,
at sampling intervals specified in the appropriate Standard within each lot, and
as requested by the Superintendent.

6.3.9.2 Fine Aggregates

Fine aggregates shall consist of natural sand, or a combination of natural and manufactured sands
containing not less than 40% natural sands.
Particles shall be clean, hard, and durable.
Approval may be requested to use a lower percentage of natural sands and will be subjected to
assessment of every manufactured sand source.

6.3.9.3 Coarse Aggregates

Coarse aggregates shall consist of clean durable natural gravel, crushed stone, or combinations thereof.

6.3.9.4 Aggregate Assessment

The aggregates shall be tested in accordance with AS1141.
Aggregates shall not have flakiness index greater than 30%.
The maximum water absorption of the aggregates shall be 2.5%.
The ten percent fines values (wet) and the wet/dry strength shall be carried out on the fraction from AS
13.2mm to AS9.5mm. Any fraction which constitutes less than 10% of the sample shall not be tested.
The results shall confirm to the following table.
Material Group * Minimum 10% fines value (wet) Maximum Wet/Dry Strength
(kN) Variation (%)
Acid Igneous 110 40
Intermediate Igneous 120 35
Basic Igneous 130 30
Metamorphic 120 35
Sedimentary, Duricrust 110 40
*Naturally occurring gravels are to be classified into a material group on the basis of the lithology
of the major granular component.

6.3.10 Handling and Storage of Materials

Stack or store materials so as to facilitate inspection and identification.

6.4 CONCRETE MIX DESIGN AND ACCEPTANCE

6.4.1 General

Use project assessment of concrete unless otherwise agreed.

AS 3600 defines a lot for the purpose of testing as either 30m 3 or a "production interval" - whichever is
the lesser.
Where specified, use shrinkage compensated concrete to entirely counteract long term shrinkage
assuming that ordinary concrete exhibits 500 microstrain shrinkage.
Use concrete which is normal grade except where the durability requirements dictate more stringent
cement contents and water/cement ratios.
6.4.2 Proposed Mix Hold Point

Hold Point - Submit details of the mix design for each specified class of concrete to the Superintendent
for approval not less than 6 weeks prior to the commencement of concreting operations.
The submission shall include the following information:
Grade of concrete specified as the characteristic strength;
The name of the Concrete Supplier, location of the batching plant and the proposed manufacturing
methods and degree of quality control;
Types and proportion by mass of various materials and supplementary cementing materials;
Chemical admixtures, their reasons for inclusion, dosage rates, and supporting product and technical
literature from the manufacturer;
Water supply source
Water/cement ratio;
Target strength; and
Target slump and tolerance.
Where the supplier produces concrete on a regular basis, information is required regarding mean
strength and standard deviation for recent output of each Class of concrete to be supplied.
The minimum cementitious content and maximum water/cementitious ratio shall be as shown in the table
below.

Minimum Cement Proportions for Durability and Strength

Exposure Classification* Minimum Cement Content (kg/m3) Maximum Water/Cement Ratio
B1 320 0.56
B2 390 0.46
C 450 0.40
* As defined in AS 3600.
The approved slump will be used by the Superintendent as one of the on-site criteria for acceptance or
rejection of wet concrete.
Do not deviate from the nominated properties of the concrete mix.
Supply these details sufficiently in advance of placing concrete to enable changes to be made and trial
mixes prepared if approval is not given to the proposed mix.

6.4.3 Target Strength

The minimum target strength shall be calculated from the equation:

ft = fc +1.65s

Where, in the opinion of the Superintendent, adequate plant records are available, the current standard
deviation for the similar Class of concrete may be used but it shall not be less than 0.08f c.
Where adequate plant records are not available an estimated value of standard deviation shall be used
which is not less than 0.12f c, or greater than 0.2fc, depending on the degree of quality control nominated
(refer to Clause 6.5).
The target strength may be reassessed based on the actual standard deviation of a minimum of 15
consecutive tests for the strength grade.
6.4.4 Trial mix

Except as provided hereunder for the supply of ready-mixed concrete and for concrete used in certain
precast units, the Contractor shall make trial mixes for all classes of concrete having a characteristic
strength greater than 20MPa.
Each mix shall use only such aggregates that have been approved for use by the Superintendent.
The mixes shall be made using the plant and degree of quality control proposed for the works. The
minimum volume of the trial mix shall be 25% of the rated capacity of the mixer.
Each trial mix shall be tested for slump, workability and strength. Where the concrete is not batched and
mixed on site, a time delay equal to an average delivery time on site shall be applied between the mixing
of the concrete and the sampling for slump and cylinder tests.
The slump measured shall be within the allowable range.
At least 9 cylinders shall be cast from each trial mix for compressive strength testing. Additional cylinders
(a minimum of three per age) shall be required if strength gain is to be assessed for early age stripping or
loading.
If concrete is supplied by an approved ready-mixed manufacturer in accordance with AS1379 or by an
approved established precast manufacturer, the Superintendent may accept the results of tests on
specimen cylinders cast from identical mixes previously produced by the manufacturer, in lieu of trial
mixes. Notwithstanding such acceptance, the information relating to the mix design as detailed in Clause
6.4 shall be supplied.

6.4.5 Approved Mix

The trial mix, the plant and the degree of quality control for the works shall be approved if the mean of
the 28 day strength cylinder strengths equals or exceeds the target strength, target slump within the
nominated tolerance and the mix conforms to the relevant Australian Standards.
No concrete shall be placed in the works until the approval of the trial mix has been obtained from the
Superintendent. The Superintendent may give provisional approval of a mix based on early testing,
provided the mean compressive strength of at least 3 trial cylinders tested at 7 days is not less than 0.8
of the specified characteristic strength for that class of concrete. Notwithstanding any such provisional
approval, all the concrete shall meet 28 day strength requirements.
Do not alter approved concrete mix without the approval of the Superintendent. The approved mix shall
be used until approval is given for an altered mix.

6.5 QUALITY CONTROL

6.5.1 General

Comply with the quality control requirements of AS 3600 (unless modified by this Specification).
If, during the course of the job, the degree of quality control is not maintained (as evidenced by a decline
in the strength of test cylinders taken on the work and/or by a deterioration in the methods employed in
batching and mixing), the Superintendent may withdraw approval of the mix pending establishment of
improved quality control, or, if necessary, a redesign of the mix.
Where the mix is redesigned, costs associated with proving the new mix shall be at the Contractors
expense.

6.5.2 Consistency

The consistency and workability of concrete shall be such that it can be handled and transported without
segregation and can be placed, worked and compacted into all corners, angles and narrow sections of
forms, and around all reinforcement.
The consistency of each batch of concrete shall be checked by means of slump test. Sampling and
testing shall be carried out in accordance with AS1012, Parts 1 and 3 respectively.
Where 10 batches of a concrete grade have been tested and are conforming, the Contractor may move
to a reduced level of testing. The reduced level of testing shall consist of visually checking every batch
and slump testing one third of batches.
The slump determined on the site in accordance with AS1012, Part 3 shall lie within the range
established using the approved slump and tolerances specified in Table 6 of AS1379.

6.5.3 Sampling Frequency When Concrete Delivered Direct from Mixer

A single batch from the mixer is the equivalent of "One Truck" load.

6.5.4 Additional Samples Where Early Strength Development is Required

Make and test an additional complete series of samples for each discrete construction phase, such as
release of prestress or removal of props, that has a specified requirement for early-age concrete
strength.

6.5.5 Monitoring of Target Strength

If the average strength of three consecutive samples is less than 0.5(f c + ft), the Contractor shall submit
to the Superintendent as a matter of urgency proposals to upgrade the mix and/or procedures to achieve
the approved target strength.

Where a significant amount of concrete is to be placed in a four-week period, monitoring shall include
early age testing (typically 7 days) and a comparison of cylinder strengths with previously measured
strength gain results.

6.5.6 Acceptance or Rejection of Hardened Concrete on the Basis of Strength

Subject to the concrete meeting all requirements set out in this specification it will be accepted or
rejected on a statistical basis using the results of 28 days tests as set out below.
Concrete in a lot shall be rejected if either of the following apply:
Any sample strength (average of 2 or more matched cylinders) is less than 0.9 times the specified
characteristic strength, fc; or
The average strength of 3 consecutive samples from the lot is less than the specified characteristic
strength.
In addition, where 10 or more samples of a particular Class of concrete are tested in four consecutive
weeks or less, all the concrete represented by these samples shall be rejected if the average strength of
all tests for that class of concrete over that period is less than 0.5(f c + ft).
The standard deviation shall be calculated from the tests from that period and compared with the value
used to calculate the target strength. If the standard deviation from test results is significantly greater
than that used in calculating the target strength, the Superintendent may withdraw approval for the mix.
Where hardened concrete is accepted but the characteristic strength of the supplied concrete is below
the specified value, the reinforced or prestressed concrete element shall have its value reduced in
proportion to the reduction in specified characteristic strength achieved.
Where hardened concrete has been rejected, the Contractor may offer any of the following alternatives at
the Contractors expense:
The rejected concrete, and any portion of the structure built on the rejected concrete, shall be removed
and replaced to the approval of the Superintendent;
The rejected concrete may remain in place and additional works, approved by the Superintendent, shall
be undertaken to achieve adequate strength and/or durability; or
The rejected concrete may remain in place and the Contractor shall agree to a reduction in the scheduled
rate for the quantity of concrete rejected equal to the supply cost of the concrete on the site per cubic
metre as determined by the Superintendent.
6.6 PLACING AND COMPACTION OF CONCRETE

6.6.1 Notice and Approval to Place Concrete Hold Point

Hold Point - Give at least 24 hours notice to the Superintendent prior to placing concrete in any part of
the works.
Do not place any concrete unless:
all constituent materials have been approved,
the design of all temporary works has been approved,
the temporary structures, formwork, and reinforcement have been inspected and approved,
qualified testing personnel responsible for sampling the concrete are present,
the method and equipment proposed for placing concrete has been approved,
arrangements for providing curing are on site and ready,
the Superintendent is present, and
the temperature of concrete is guaranteed to remain above 5 degrees Celsius for the duration of the
curing period.

6.6.2 Addition of Mixing Water and Admixtures

Do not add water to the mix from the truck mixer unless:
there is not more than the prescribed amount of water in the truck's tank, or
the tank is equipped with a device of the specified accuracy by which the quantity of water added can
be measured.
Make allowance for the reversion time of superplasticisers: ensure that a consistent amount of time is
allowed for supply, delivery, placement and compaction of the concrete.
Agitate concrete for at least two minutes and 30 revolutions of the mixer prior to dispensing concrete
containing superplasticisers.
Do not add admixtures at the construction site unless the exact amount is premeasured using a device of
the required accuracy and stored and dispensed separately from remaining stocks of material.
Delay the addition of superplasticisers to the concrete mix as long as practicable before the concrete is
discharged from the mixer.
Add dosages of admixtures within 60 minutes of adding water to the mix.

6.6.3 Hot Weather Requirements

Do not place concrete if the shade air temperature at the site is (or is expected to) exceed 40 degrees
Celsius during the setting period of the concrete. Approval may otherwise be given by the
Superintendent if positive action is taken to prevent the concrete from heating up at a faster rate and
reaching a higher temperature than would occur if the same concrete was placed under conforming
atmospheric conditions.
The aim of this provision is to ensure that the concrete remains workable until all placement and finishing
operations are completed satisfactorily and without:
the problems associated with premature initial concrete set and consequent workability difficulties and
weakness planes caused by "cold joints",
the build up of high internal concrete tensions associated with differential thermal effects exceeding
those occurring in concrete placed at normal temperatures, and
the build up of large forces in the structure caused by the newly cast element being restrained by
other members and reaching a higher than normal temperature at the point where it sets and
obtains tensile strength and stiffness.
6.6.4 Placing Concrete

Do not place superplasticised concrete that exhibits a non-homogeneous structure or segregation during
the slump test. Low slump/spread ratios may be an indication of a tendency for concrete to segregate.
Provide an adequate system of lighting over the area of the site if concrete is to be placed at night.
Do not place concrete if its temperature exceeds 35 degrees Celsius.
Place and compact concrete within the following time after the addition of the mixing water to the mix:
Maximum Time To Place Concrete
Concrete Temperature at time of Placing Maximum time (minutes)
25 deg. C - 28 deg. C 75
28 deg. C - 32 deg. C 60
32 deg. C - 35 deg. C 45
Place concrete in a continuous operation between construction joints so that the face of the concrete is in
a plastic state when succeeding concrete is placed against it.
Do not allow concrete to free-fall from a height greater than 1.5 metres.
Keep tremie tubes full of concrete and the discharge ends completely submerged in newly placed
concrete at all times during placing.
Place all concrete in the dry unless otherwise approved.

6.6.5 Concrete Pumping

Pump the initial discharge of concrete to waste until a consistent workable mix is discharged.
Do not use aluminium delivery pipes.

6.6.6 Placing Concrete Under Water

Do not place concrete in moving or running water.

Ensure that concrete does not free-fall any distance through water.
Keep the top surface of the concrete as nearly level as possible.
Do not tamp or vibrate.
Remove laitance, the weak surface concrete, and scrabble the interface back to sound concrete after
placing the concrete underwater and before placing any subsequent concrete. Place the subsequent
concrete in the dry.
Use either a tremie or bottom dump bucket.
Submit details of the proposed methods and equipment for approval.
Do not use tremies that are not watertight or sufficiently large to permit the free flow of concrete.
Prevent water entering the tremie tube at all times.
Maintain a positive pressure head of concrete over the surrounding water.
Use a bucket that:
cannot be discharged until it rests on the surface upon which the concrete is to be placed,
has bottom doors that open downwards and outwards, and
is open at the top.
Lower and withdraw bucket slowly to avoid backwash and movement of water over surfaces of fresh
concrete.
6.6.7 Internal Vibration

Use vibrators having a frequency not less than 150 Hertz and a vibration intensity sufficient to visibly
affect concrete over a radius of at least 300 mm.
Unless otherwise approved, provide:
1 vibrator for each 4 cubic metres of concrete placed per hour,
at least 1 reserve, and
1 reserve for every 4 working vibrators.
Keep the vibrator inserted until the whole of the concrete in the immediate vicinity is vibrated full depth,
but do not leave stationary for more than 30 seconds.
Insert at spacings of not more than 400 mm.
Do not allow vibrators to rest on reinforcement.
Do not use vibrators to transport concrete in the forms.
Penetrate into the previous layer to knit successive layers of fresh concrete together.

6.6.8 External Vibration

Use formwork vibrators having vibration frequencies exceeding 80 Hertz.

Match adjacent vibrators so that they do not cancel out each other.

6.6.9 Vibrating Screeds

Use screeds with a vibration frequency exceeding 70 Hertz.

Move them at between 0.5 and 1 metre per minute.

6.7 CONCRETE CURING

6.7.1 General

Apply plastic sheeting or other materials to protect the concrete against drying out in addition to the
curing measures.
Protect and cure all exposed surfaces immediately after the concrete has taken its initial set.
Maintain all surfaces (including those within loosened formwork) in a moist condition by:
flooding,
continuous spraying with water, or
other methods approved by the Superintendent.
Prevent staining during the curing process of all concrete surfaces that will be visible in the completed
works.
Continuously maintain the protection and curing of each element for the minimum time specified by
AS 3600 to provide the concrete with a durability corresponding to the most severe exposure
classification applying to any of its surfaces.

6.7.2 Curing Compounds Hold Point

Hold Point - Do not use curing compounds in lieu of moist curing without the written approval of the
Superintendent. Approval will only be given in special circumstances.

6.7.3 Accelerated Curing Using Steam

Remove ungrouted post-tensioning tendons from their ducts before applying steam to a member.
Allow a delay period after completion of concreting, then apply steam.
The delay period is to allow the concrete to gain sufficient tensile strength to resist the thermal expansive
forces caused by steaming.
Use a delay period of:
40/t hours when the temperature inside the enclosure increases at a uniform rate and is controlled to
within 5 degrees Celsius of the predicted temperature at any time, or
60/t hours when the temperature is not controlled as accurately:
Where: t = the concrete temperature in degrees Celsius immediately after completion of concreting.
Modify this delay period for subsequent units if application of steam causes cracking.
Continue steaming until attaining the:
structurally required and specified "transfer" strength, and
the minimum concrete strength at completion of curing specified by AS 3600 (to provide the concrete
with a durability corresponding to the most severe exposure classification applying to any of its
surfaces).
Ensure that the temperature variation between any two locations inside the steam enclosure is less than
5 degrees Celsius.
Maintain 100 per cent relative humidity inside the steam enclosure.
Do not discharge steam directly onto the concrete or formwork.
Prevent the air temperature inside the enclosure rising (or falling) faster than 24 degrees Celsius per
hour.
Prevent the air temperature inside the enclosure exceeding 80 degrees Celsius.
Do not remove the enclosure until the unit is cooler than 40 degrees Celsius above ambient air
temperature.
Do not transfer prestress unless the units are cooler than 60 degrees Celsius.
Do not expose the unit to ambient air temperatures during steaming for more than the brief period
necessary to permit form stripping and removal from the forms.
Provide accurate instruments for controlling, and graphically recording, the temperature inside the
enclosure during the whole of the steaming operation.
Provide sufficient instruments and place them not more than 10 metres apart so as to record the variation
in temperature within the enclosure.
Protect the instruments against unauthorised access.
Place associated concrete cylinders:
within the enclosure,
adjacent to the lower face of the unit,
midway between steam entry points, and
clear of steam lines and steam jets.

6.8 MISCELLANEOUS

6.8.1 Construction Joints Hold Point

Hold Point - Submit details of all proposed construction joints for approval if they are not shown on the
drawings.
Approval will not be given if it is considered that the joint location or its detailing detracts from the
appearance of the finished structure.
Immediately prior to placing concrete against a construction joint:
 retighten the forms,
roughen the joint surface to so that it comprises clean, dense concrete of the specified strength, and
thoroughly moisten the joint surface.
An "exposed aggregate finish for unformed surfaces" is an acceptable technique and degree of
roughness.

6.8.2 Deck Concrete

Provide camber of the screeds to allow for deflection of the beams under the weight of the deck concrete.
Provide additional concrete and uniformly raise the finished deck surface if necessary to ensure that the
deck thickness is everywhere greater than the minimum shown on the drawings.

6.8.3 Concreting of Anchorage Recesses

Do not flame cut tendons within 50 millimetres of the anchorages.

Prevent the flame playing on anything within 25 millimetres of the anchorage.
Prepare the interior surfaces of the anchorages recesses and place concrete as specified for the repair of
defective surface finishes.
Use approved shrinkage compensated cement.

6.8.4 Concrete Bearing Pedestals

Cast them:
monolithically with the substructure concrete, or
cast a construction joint set more than 25 mm below the top of the supporting concrete, scabble the
construction joint, apply an approved bonding agent, and then cast the pedestal, or
as detailed on the drawings.
Do not cast separate pedestals unless the concrete substrate:
has been prepared in a manner agreed by the Superintendent,
has been inspected and approved by the Superintendent, and
is cool.
Moist cure in accordance with the requirements of this Specification for 7 days.
Do not load the pedestals until the concrete has achieved the specified strength.

6.8.5 Mortar Bearing Pedestals

Use a mixture of sand and cement mixed in a ratio of 3 parts sand to 1 part cement.
Use the minimum water possible consistent with achieving thorough mixing and sufficient workability for
placing.
Scabble the supporting concrete surface, moisten it, apply an approved bonding agent, and then cast the
pedestal.
Compact the mortar by hammering.
Trowel the surface to at least 25 mm beyond the nearest edge of bearing.
Finish edges to neat inclined faces.
Do not cast pedestals unless the concrete substrate:
has been prepared in a manner agreed by the Superintendent,
has been inspected and approved by the Superintendent, and
is cool.
Moist cure in accordance with the requirements of this Specification for 7 days.
Do not load the pedestals within 10 days of casting.

6.9 CONCRETE FINISHES

6.9.1 General

Refer to the section on formwork for specification of formed surface finishes.

Provide uniform colour and texture within each class of surface finish.
Remove free surface water during final screeding of unformed surfaces.
Do not place a topping of mortar after the concrete has set.
The following surface finishes are specified:
Finish S2 - Wood Floated
Finish S4 - Broomed
Finish S5 - Carborundum Surfaced
Sandblast Finish
Brush
Light
Medium
Heavy
Tooled and Bush Hammered Finish
Light
Medium
Heavy
Exposed Aggregate Finish for Unformed Surfaces
Supply an approved one metre square test panel for each class of surface finish (except S2, S4 and S5)
required to be applied in the work.
Make the panels:
in the presence of the Superintendent,
out of identical materials to be used in the works, and
using the same techniques and timings as in the works.
Construct as many test panels as is required to obtain one that has the colour, and the uniformity, and
the quality of surface texture required by the Superintendent.
Construct and use these panels for quality control as specified in AS 3610.
Apply the following unformed surface finishes
Schedule of Unformed Surface Finishes
Surface Class of Finish Generally S2
Surfaces of Bearing Pedestals S2
Deck surfaces which will be sealed or have a bituminous wearing surface applied. S4
Top surfaces of steps and footways that will not receive any other surfacing. S5
6.9.2 Finish S2 - Wood Floated Finish

Provide a uniform even surface free of screed marks.

6.9.3 Finish S4 - Broomed Surface Finish

Use the following sequence:

(a) Apply surface finish S2.
(b) Wait for the concrete to set sufficiently.
(c) Roughen the surface of the concrete by drawing an approved type broom across
and produce regular marks approximately 3 mm deep.

6.9.4 Finish S5 - Carborundum Surfaced

Apply finish S2.

Dust the surface with 1.5 kg per square metre of Carborundum grit of size not less than 180.

6.9.5 Sandblast Finish

Use wet sandblasting.

Erect tarpaulins around the sandblasting operation where sandblasting operation is considered to be a
nuisance or dangerous.
Provide the specified grade of sandblast finish.
The following are the available finish grades:
(a) Brush
Remove the surface laitance and expose the cement matrix.
(b) Light
Expose the fine aggregate and some large aggregate.
Maintain uniform colour.
Keep the projection of the large aggregate to less than 2 millimetres.
(c) Medium
Expose the large aggregate, but keep its projection to less than 4 millimetres.
(d) Heavy
Expose the large aggregate, but keep its projection to less than 6 millimetres.

6.9.6 Tooled and Bush Hammered Surface Finish

Hammer the concrete surface to fracture and dislodge the surface mortar, and to chip or fracture the
aggregate.
Provide the specified grade of bush-hammered finish.
The following are the available finish grades:
(a) Light
Break the concrete surface to remove surface mortar without fracturing the coarse aggregate (usually
achieved by the use of a combed head roller chisel, or disc bush hammer).
(b) Medium
Expose the coarse aggregate pattern but without pitting or spalling the concrete.
(c) Heavy
 Jack pick the concrete surface to spall substantial lumps of concrete surface and achieve a coarse
texture.

6.9.7 Exposed Aggregate Finish for Unformed Surface

Treat the surface of the fresh concrete with a surface retarder and subsequently water-wash or wire
brush it to remove the retarded mortar.
Submit details of the proposed techniques and manufacturer's literature to Superintendent for approval.
Ensure that the specified concrete cover to steel reinforcement is maintained after the surface finish has
been applied.
Prevent the retarder from contaminating the body of the concrete.
Remove loose aggregate and laitance.
Clean the surface with an air jet on completion, and moist cure it.
Water-wash within:
8 to 18 hours of casting if the ambient air temperature is less than 20 degrees Celsius, or
6 to 16 hours of casting if the ambient air temperature is more than 20 degrees Celsius.
Wire-brush within 24 to 48 hours after casting the concrete, and lightly wash with clean water.

6.10 TOLERANCES IN CONCRETE BRIDGEWORKS

Conform to the tolerances in the appropriate Australian Standard except where the following apply.
Construct to within the following maximum tolerances unless otherwise specified:

6.10.1 In-Situ Girders, Cross-heads, Columns, Piers and Walls

Misplacement from the specified position of the top of columns, piers, walls, girders, or similar parts:
10 mm.
Variation of Reduced Levels of the top of piers, walls, girders, or similar parts: +/- 5 mm.
Variation of Reduced Levels of bearing areas: +/- 3 mm.
Permissible surface irregularities of bearing surfaces over contact area when the lesser of measured with
a straight edge: +/- 1 mm or +/- 0.5 mm per 100 mm.

6.10.2 Precast Concrete Girders and Deck Slabs

Make allowance for elastic shortening of prestressed units. The expected hog is shown on the drawings;
however this can vary quite significantly.
The deck unit or girder cross section shall be accurate to within 5mm.
The overall length of a prestress concrete deck unit or girder and length from centre to centre of the
bearings shall not vary more than 0.06% from the specified length of the length with a maximum variation
of 20mm. The location and diameter of any transverse holes and cast in fittings shall not vary by more
than 5mm from the specified dimensions.

6.10.3 Precast Prestressed Concrete Formwork Slabs

Variation in thickness: + 3 mm, - 0 mm.

6.10.4 Bearing Plates for Concrete Beams

The plane of the bearing plates or bearing surfaces shall not vary from that shown on the Drawings by
more than the lesser of 0.5 mm per 100 mm, or 1 mm, in any direction.
6.11 DEFECTIVE CONCRETE AND MATERIALS

Concrete which is not placed, cured, or finished as specified, or does not have the specified strength,
shall be considered defective.
Bear all costs, expenses, and delays resulting from the rejection of concrete and the necessity to load
test, remove and replace it, strengthen the structure, or waterproof the structure.
Durability rather than structural strength is often the prime concern, and load testing to attempt to
compensate for non-conforming test results shall only be permitted at the discretion of the
Superintendent.
Concrete which does not have the specified surface finish or is not sound, dense and durable, crack-free
or does not possess other specified properties, shall also be deemed defective.
Remove and replace defective concrete.
Remove the concrete to a point agreed with the Superintendent at which a visually and structurally
acceptable construction joint can be made, and the defective element rebuilt.
Repair defective surface finishes if approved by the Superintendent: approval will not be given if the
defective area is too extensive or the techniques proposed are not adequate to ensure a visually
acceptable and durable repair.
Refer to the formwork section for specification of the repair of defective surface finishes and small areas
of repair.
Remove bulges and abrupt irregularities by bush hammering and grinding until the surface is within the
required tolerances.
Seal cracks by injecting with epoxy resin in accordance with the manufacturer's recommendations.
Clean and reinstate the surface to at least the specified standard of finish.
CONCRETE AND REINFORCEMENT