SPECIFICATION FOR CIVIL

ENGINEERING WORKS

Series 1700: Structural Concrete

Document Number: HS2-HS2-CV-SPE-000-011700

Revision Author Checked Approved Date Reason for revision

by by approved
P01 EDP eB review John Irwin May 2017 First issue
P02 Don eB review John Irwin July 2018 ‘Overseeing Organisation’ replaced by
Wimpenny HS2 minor clarifications/corrections
P03 John Irwin eB review John Irwin December Change “Lead Designer” to
12th 2019 “Contractor’s Engineering Director” as
agreed with supply chain

This document contains proprietary information. No part of this document may be reproduced without prior written consent from the Chief
Executive Officer, HS2 Ltd.
SECURITY CLASSIFICATION: OFFICIAL
 VOLUME 1 HS2 SPECIFICATION FOR CIVIL ENGINEERING WORKS

SERIES 1700
STRUCTURAL CONCRETE
Contents

1701 Concrete - General..................................... 1

1702 (P03) Concrete - Constituent Materials....... 1
1703 Concrete - Exposure Classes...................... 3
1704 (P03) Concrete - General Requirements ..... 3
1705 (P03) Concrete - Requirements for Designed
Concrete ............................................................... 4
1706 Concrete - Production ................................. 4
1707 Concrete - Conformity and Identity Testing . 4
1708 Concrete - Surface Finish............................ 4
1709 (Not Used)................................................... 6
1710 (P03) Concrete - Construction General ....... 6
1711 (P03) Concrete - Grouting and Duct Systems
for Post-tensioned Tendons ................................ 12
1712 Reinforcement - Materials ......................... 16
1713 Carbon Steel Reinforcement and Stainless
Steel Reinforcement - Bar Schedule Dimensions -
Cutting and Bending ........................................... 17
1714 (P03) Reinforcement - Fixing..................... 17
1715 Reinforcement - Surface Condition............ 18
1716 (P03) Reinforcement - Laps and Joints ..... 18
1717 Reinforcement - Welding........................... 18
1718 Prestressing Tendons - Materials .............. 18
1719 Prestressing Tendons - Handling and
Storage ............................................................... 18
1720 Prestressing Tendons - Surface Condition 19
1721 Prestressing Tendons - Straightness......... 19
1722 Prestressing Tendons - Cutting ................. 19
1723 Prestressing Tendons - Positioning of
Tendons, Sheaths and Duct Formers.................. 19
1724 (P03) Prestressing Tendons - Tensioning . 19
1725 Prestressing Tendons - Protection and Bond
........................................................................... 21
1726 Stainless Steel Dowels - Materials ............ 21
1727 Inspection and Testing of Structures and
Components ....................................................... 22
1728 (P03) Geometrical Tolerances................... 22
1729 Anti-Graffiti Coating.................................... 26

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STRUCTURAL CONCRETE

1701 Concrete - General

Specification of Concrete
1 This Series is part of the Specification for Civil Engineering Works. Whilst this Series is particularly relevant to the
subject matter in its title, it must be read in conjunction with the general requirements in Series 000 and 100 and with all
other Series relevant to the Specification for the particular works to be undertaken.

2 Concrete shall conform to the requirements of Technical Standard – Materials and Durability (HS2-HS2-CV-STD-
000-000003) and BS 8500 Parts 1 and 2. Unless otherwise described in contract specific Appendix 17/4, concrete shall be
specified as designed concrete. The contract specific requirements for the structural concrete in the permanent works are
given in contract specific Appendix 17/1.

Designed Concrete
3 The specification for designed concrete defined in BS 8500-1 shall be as described in this Specification and contract
specific Appendix 17/1 and shall contain:

(a) the basic requirements given in 4.3.2 of BS 8500-1;

(b) the additional requirements given in 4.3.3 of BS 8500-1 where described in this Specification and contract
specific Appendix 17/1.

Implementation of BS EN 13670
4. The execution of concrete structures shall be in accordance with BS EN 13670 as complemented by this
Specification. The provisions of this Specification apply to both in situ and precast concrete, unless noted otherwise.

Execution Class
5. The works shall be built in accordance with Execution Class 3 as defined in BS EN 13670 unless otherwise described
in contract specific Appendix 17/4.

Inspection Requirements
6. Inspection for materials and products and inspection for execution of works, as well as documentation of inspection,
shall be in accordance with BS EN 13670, as complemented by this Specification and Technical Standard – Materials and
Durability (HS2-HS2-CV-STD-000-000003). Requirements for the inspection and testing of structures are given in
contract specific Appendix 17/4. When described in Appendix 17/4 inspection of concrete works shall be executed by an
organisation independent of the Contractor.

1702 Concrete - Constituent Materials

Cement and combinations
1 Cement types as defined in BS 8500 (see Table A.6 of BS 8500-1 or Table 1 of BS 8500-2) shall comprise one of the
following, unless otherwise described in contract specific Appendix 17/4:

CEM I, CEM II/A-S, CEM II/A-L, CEM II/A-LL, CEM II/A-D, CEM II/B-S, CEM II/A-V, CEM II/B-V, CEM
III/A, CEM III/B, CEM IV/B and sulfate-resisting Portland cements CEM I-SR 0 and CEM I-SR 3 conforming to BS
EN 197-1.

Combinations as defined in BS 8500 shall comprise one of the following, unless otherwise described in contract specific
Appendix 17/4:

CIIA-S, CII A-D, CIIB-S, CIIA-L, CIIA-LL, CIIA-V, CIIB-V, CIIIA, CIIIB and CIVB-V.

Cements shall conform to BS EN 197-1. Evidence of compliance with the harmonised part of BS EN 197-1 with respect
to product performance shall be demonstrated by CE marking and a Declaration of Performance where the declared
performance for the essential characteristics given in Annex ZA of that Standard is equal or greater than the performance
level required for the intended use of the cement.

Ground granulated blastfurnace slag, fly ash and silica fume shall conform to BS EN 15167-1, BS EN 450-1 and BS EN
13263-1, respectively. Metakaolin shall comply with Clause 5.2.3.3 of BS EN 197-1. Evidence of compliance with the

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harmonised part of those Standards with respect to product performance shall be demonstrated by CE marking and a
Declaration of Performance where the declared performance for the essential characteristics given in Annex ZA of those
Standards is equal or greater than the performance level required for the intended use of the constituent.

Limestone fines shall conform to BS 7979.

Alkali-activated cementitious material shall comply with PAS 8820.

Aggregates
2 Unless otherwise specified in contract specific Appendix 17/4, aggregates shall conform to BS EN 12620 (for
normal and heavy weight aggregates) and BS EN 13055-1 (for lightweight aggregates) and to the requirements of 4.3 of
BS 8500-2 except that recycled concrete aggregate (RCA) and recycled aggregate (RA) should be in accordance with the
Technical Standard – Materials and Durability (HS2-HS2-CV-STD-000-000003).

Evidence of compliance with the harmonised part of BS EN 12620 and BS EN 13055-1 with respect to product
performance shall be demonstrated by CE marking and a Declaration of Performance where the declared performance for
the essential characteristics given in Annex ZA of that Standard is equal or greater than the performance level required for
the intended use of the aggregate, with the System of Assessment and Verification of Consistency of Performance
(AVCP) as defined in PD 6682-1 and PD 6682-4 for aggregates conforming to BS EN 12620 and BS EN 13055-1,
respectively.

The flakiness index of the coarse aggregate when determined by the method described in BS EN 933-3 shall not exceed
FI35 except when natural, uncrushed aggregates are used for concrete of strength classes lower than C32/40, when the
flakiness index shall not exceed FI50. No flakiness index limit is required for strength class C12/15 concrete or below.

When required, the resistance to fragmentation of the coarse aggregate, determined in terms of the Los Angeles
coefficient as specified in BS EN 1097-2 and declared in accordance with the relevant category specified in Table 16 of
BS EN 12620, shall meet the requirements for LA40. Aggregates with LA coefficient values above 40 may also perform
satisfactorily in normal concrete but their strength performance shall be established in concrete trials before use.

Chloride levels of aggregate shall be established from testing using the Volhard reference method in BS EN 1744-1, or
other method calibrated against this reference method. Where the aggregate chloride level has been established as
minimal, that is less than the detection level of 0.002%, typical for land based materials, then this value may be used.
Where there is a significant chloride level, the value shall be established as set out in 5.2.8 of BS EN 206.

Aggregates shall be selected as to satisfy the requirements in sub-Clause 1704.5 for the control of alkali-silica reaction.

Admixtures and Pigments

3 Admixtures shall conform to BS EN 934-2 and shall comply with 4.5 of BS 8500-2 and the requirements of Clause 5 of
BS EN 206 unless otherwise described in contract specific Appendix 17/4. Evidence of compliance with the harmonised
part of BS EN 934-2 with respect to product performance shall be demonstrated by CE marking and a Declaration of
Performance where the declared performance for the essential characteristics given in Annex ZA of that Standard is equal
or greater than the performance level required for the intended use of the admixture. Where a specified coloured concrete
requires a pigment, the pigment shall conform to BS EN 12878.

(P03) In all cases the Contractor shall record the following information, which shall be subsequently supplied to the
Contractor’s Engineering Director in accordance with the requirements of BD 62 ‘As built, Operational and Maintenance
Records for Highway Structures’ (DMRB 3.2.1):

(a) the detrimental effects caused by adding a greater or lesser quantity of admixture or pigment;
(b) the chemical name(s) of the main active ingredient(s);
(c) whether or not the admixture leads to the entrainment of air.
This clause shall also apply to other non-highway structures constructed under the powers of the High Speed Rail Act
(2017).

Fibres for concrete

4 The use of fibres for concrete shall be in accordance with BS EN 206.
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1703 Concrete - Exposure Classes

Selection of Exposure Classes
1 The exposure classes shall be as described in contract specific Appendix 17/1.

1704 Concrete - General Requirements

Compressive Strength Class of Concrete
1 The minimum requirements for the strength and durability of the concrete in the hardened state should be decided by
the designer from the requirements of the Technical Standard – Materials and Durability (HS2-HS2-CV-STD-000-
000003), relevant structural design code and the guidance in NG1704, but if in addition a special property or surface
finish is required, these minimum requirements may have to be considerably exceeded.

Minimum Cement Content and Maximum Water/Cement Ratio

2 The cement content shall be not less than, and the water/cement ratio shall be not greater than, the values described in
contract specific Appendix 17/1.

Maximum Cement Content

3 The cement content shall not exceed 550 kg/m3 unless otherwise described in contract specific Appendix 17/1.

Maximum Chloride Content

4 The chloride content class shall conform to the following requirements:

TABLE 17/1: Chloride content classes

Type or use of concrete Chloride content Maximum total chloride content
class expressed as % of chloride ion by mass
of cement (inclusive of ggbs or fly ash
when these are used as cement)
Prestressed concrete, heat-cured concrete Cl 0,10 0.10%
containing embedded metal
Concrete containing embedded metal and Cl 0,20 0.20%
made with sulfate-resisting Portland cements
CEM I-SR 0 and CEM I-SR 3 conforming to
BS EN 197-1
Concrete containing embedded metal and Cl 0,30 0.30%
made with other permitted cements
Concrete containing embedded metal and Cl 0,20 0.20%
exposed to XD1, XD2 or XD3 conditions

Control of Alkali-Silica Reaction

5 The provisions given in 5.2 of BS 8500-2 shall be applied to minimize damaging alkali-silica reaction.

Extremely reactive aggregates, comprising those aggregates containing detectable quantities of opal, glass and calcined
flint, shall not be used alone or in combination with other aggregates. The definition of rock types shall be as in BS EN
932-3.

Buried Concrete Exposed to Sulfates

6 Choice of concrete and additional protective measures (APMs) shall comply with the requirements of BS 8500-1 for the
design chemical (DC) class described in contract specific Appendix 17/1.

Early Thermal Cracking

7 (P03) The execution of concrete structures shall conform to the assumptions made in the design to control early
thermal cracking and described in contract specific Appendix 17/1, unless otherwise agreed with the Contractor’s
Engineering Director.

Cover to Reinforcement
8 (P03) The Contractor shall provide certificates of compliance with respect to cover to reinforcement and detailed
records of measured covers to the Contractor’s Engineering Director before concrete is placed.

Assessing Cover after Concreting

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9 As described in Appendix 17/4 the cover after concreting shall be assessed in accordance with Technical Standards –
Materials and Durability (HS2-HS2-CV-STD-000-000003).

1705 Concrete - Requirements for Designed Concrete

Conformity Criteria
1 The conformity criteria shall be in accordance with BS EN 206, BS 8500, and Technical Standard – Materials and
Durability (HS2-HS2-CV-STD-000-000003).

Suitability of Proposed Constituent Material Proportions

2 (P03) The Contractor shall record, prior to the supply of any designed concrete, the following information which
shall be subsequently supplied to the Contractor’s Engineering Director in accordance with the requirements of BD 62:
(i) the nature and source of each material;
(ii) either:
(a) appropriate existing data as evidence of satisfactory previous performance for target mean strength,
current margin, consistence and water/cement ratio; or
(b) full details of initial tests carried out in accordance with Annex A of BS EN 206;
(iii) the quantities of each constituent material per cubic metre of fully compacted concrete.
Assessment of the concrete in accordance with this sub-Clause shall be carried out for each different source of material
and for any change in the quantities of each constituent material (except for changes in cement content of not more than
20 kg/m3 and pro-rata changes in aggregate contents where a single assessment is required).

1706 Concrete - Production

Production Control
1 All concrete shall be subject to production control as specified in Clause 9 of BS EN 206 and Clause 13 of BS 8500-
2, and in accordance with the requirements of Clause 104 and Technical Standard – Materials and Durability (HS2-HS2-
CV-STD-000-000003).

Consistence At Delivery
2 In general water or admixtures shall not be added to concrete delivered to site following initial mixing in accordance
with the mix design. Water or admixtures may only be added in special circumstances under the direction of the concrete
producer and used to bring the consistence to the specified value provided that the limiting values, permitted by the
Specification, are not exceeded. The quantity of any additional water or admixture added to the mix shall be recorded on
the delivery ticket in all cases along with name of the organisation and person authorising the additions and the record of
sub-Clause 1705.2 shall be amended accordingly.

Self-Compacting Concrete (SCC)

3 The use of self-compacting concrete shall be in accordance with BS EN 206 and BS 8500.

1707 Concrete - Conformity and Identity Testing

General
1 Sampling and testing of fresh and of hardened concrete shall comply with BS EN 206 unless otherwise described in
contract specific Appendix 17/4, and shall be as scheduled in contract specific Appendices 1/5 and/or 1/6 as appropriate, in
accordance with Clause 105.

Identity Testing
2 Where identity testing for compressive strength is required, as described in contract specific Appendix 17/4, it shall
be in accordance with the requirements given in Annex B of BS EN 206 and Annex B of BS 8500-1. Where identity
testing for slump, flow, air content and density on individual batches of concrete is required, as described in contract
specific Appendix 17/4, it shall be in accordance with Annex B of BS 8500-1. Identity testing shall be as scheduled in
contract specific Appendix 1/5 and/or 1/6.

1708 Concrete - Surface Finish

Trial Panels
1 When required in contract specific Appendix 17/3 and before commencing concrete works the Contractor shall
prepare a trial panel of a suitable size that will demonstrate that the required surface finish can be achieved by the
methods proposed. Trial panels shall also be subject to inspection for surface defects and subject to durability testing in
accordance with Technical Standard – Materials and Durability (HS2-HS2-CV-STD-000-000003).
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The panel of concrete shall contain reinforcement representative of the reinforcement sizes and spacings in the sections of
the permanent works the panel represents and shall be filled with the concrete proposed for the works the trial panel
relates to compacted by the method to be used in the works. As soon as practicable after compaction, the formwork shall
be removed to check that the required surface finish and compaction has been achieved.

Reference panels have also been produced showing typical Class F2 and F4 Surface finishes made with local materials in
each region of the UK and they can be viewed at various sites throughout the UK.

Control of Colour
2 When stated in contract specific Appendix 17/1 each constituent material shall be obtained from a single consistent
source. The aggregates shall be free of any impurities that may cause staining. The mix proportions and the grading,
particularly of the sand (i.e. fine aggregate), shall be maintained constant. The same type of formwork facing material,
surface finish and surface treatments shall be used in formwork throughout similar exposed areas.

Release Agents
3 Release agents for the formwork shall enable the formwork to be removed without damage to the concrete surface.
Where a concrete surface is to be permanently exposed, only one agent shall be used throughout the entire area. Release
agents shall be applied evenly and shall not be permitted to come into contact with reinforcement, prestressing tendons
and anchorages; contamination from release agents shall be removed from such areas.

Where the concrete is to receive an applied finish, or surface impregnation, release agents shall be compatible with the
particular material and any associated process.

Surface Finishes for Concrete

4 (i) Formed Surfaces - Classes of Finish

Formwork as described in sub-Clause 1710.2 shall be capable of producing the following finishes where
required in the works:

Class F1. A dense finish with no grout or mortar loss with the specified cover to embedded metal and
achieving the specified dimensional tolerances.

Class F2. As the requirements of F1 and the irregularities in the finish shall be no greater than those obtained
from the use of wrought thicknessed square edged boards arranged in a uniform pattern. The finish is intended
to be left as struck but imperfections such as fins and surface discolouration shall be made good.

Class F3. As the requirements of F1 and the resulting finish shall be smooth and of uniform texture and
appearance. The formwork lining shall leave no stain on the concrete and shall be so joined and fixed to its
backing that it imparts no blemishes. It shall be of the same type and obtained from only one source
throughout any one structure. The Contractor shall make good any imperfections in the finish. Internal ties and
embedded metal parts shall not be used.

Class F4. The requirements for Class F4 are as for Class F3 except that internal ties and embedded metal parts
shall be permitted. The ties shall be positioned only in rebates or in other positions as described in contract
specific Appendix 17/3.

Class F5. The resulting finish shall be smooth and of uniform texture. Any blemishes and imperfections, such
as discolouration and fins, shall be made good. Provision for the embedment of metal parts in the permanent
works on a regular spacing, shall be allowed.

Other classes. The finishes shall comply with the specific requirements described in contract specific Appendix
17/3.
Permanently exposed concrete surfaces to all Classes of finish other than F1 shall be protected from rust marks
and stains of all kinds.

Unless otherwise described in contract specific Appendix 17/3, all formwork joints for all classes of finish
other than F1 shall form a regular pattern with horizontal and vertical lines continuous throughout each
structure and all construction joints shall coincide with these horizontal or vertical lines.
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Unless otherwise described in Appendix 17/3 all exposed concrete edges shall either be
chamfered at 25mm x 25mm or be rounded with a 30mm radius.

(ii) Unformed Surfaces - Classes of Finish

Class U1 finish. The concrete shall be levelled and screeded to produce a uniform surface to the profile shown
on the drawings. No further work shall be applied to the surface unless it is used as a first stage for another
class of finish.

Class U2 finish. After the concrete has hardened sufficiently, the Class U1 finish shall be floated by hand or
machine sufficiently only to produce a uniform surface free from screed marks.

Class U3 finish. When the moisture has disappeared and the concrete has hardened sufficiently to prevent
laitance from being worked to the surface, a Class U1 finish shall be steel-trowelled under firm pressure to
produce a dense, smooth uniform surface free from trowel marks.

Class U4 finish. The concrete shall be levelled and screeded to produce a uniform surface. When the concrete
has sufficiently hardened and the bleed water evaporated the surface shall be trowelled to produce a hard dense
surface free from screed marks and exposed aggregate. Finally the surface shall be lightly textured with a
wooden float or equivalent. Alternatively the concrete shall be levelled, screeded and floated to produce a
uniform surface and immediately before the waterproofing operation this surface shall receive surface
preparation by water jetting or grit blasting to provide a lightly textured finish. The finished surface shall not
deviate from the required profile by more than 10 mm over a 3 m gauge length or have any abrupt
irregularities more than 3 mm.

Class U5 finish. The concrete shall be levelled and screeded to produce a uniform finish. When the concrete
has sufficiently hardened to prevent laitance being worked to the surface it shall be floated to produce a
surface free from screed marks and exposed aggregate. Finally the surface shall be textured to suit the
requirements of the particular waterproofing and surfacing system. The accuracy of the finished surface shall
be such that it does not deviate from the required profile by more than 5 mm over a 3 m gauge length or have
any abrupt irregularities.

Other classes. The finishes shall comply with the specific requirements described in contract specific Appendix
17/3.

1709 (Not Used)

1710 Concrete - Construction General

Construction Joints
1 The position of construction joints shall be as shown on the drawings and at additional positions determined by the
Contractor in accordance with the requirements of contract specific Appendix 17/4. When concrete is placed in vertical
members, walls, columns and the like, the lifts of concrete shall finish level or, in sloping members, at right angles to the
axis of the members, and the joint lines shall match features of the finished work, if possible, or be formed by grout
checks. Kickers shall be constructed integrally with the lift of concrete below.

Concreting shall be carried out continuously up to construction joints.

Unless interface shear calculations in accordance with BS EN 1992-2 (Clause 6.2.5 of BS EN 1992-1-1) show that a non-
prepared surface between concrete cast at different times is sufficient for structural purposes, construction joints shall be
prepared in either of the following ways:

(i) When the concrete is self-supporting but still sufficiently green, the formwork shall be removed, as necessary
to expose the construction joint, subject to the requirements of sub-Clause 5 of this Clause. The concrete
surface shall be sprayed with a fine spray of water or brushed with a stiff brush, just sufficiently to remove the
outer mortar skin and expose the larger aggregate without disturbing it. Alternatively where this preparation
proves impracticable the hardened surface skin and laitance shall be removed by grit blasting or a needle gun.
Hardened surfaces shall not be hacked.

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(ii) By the use of proprietary steel open-mesh permanent formwork intended for use in construction joints.

Retarding agents shall not be used unless permitted in contract specific Appendix 17/4.

The joint surface shall be clean and damp but free of standing water immediately before any fresh concrete is placed
against it.

Falsework and Formwork

2 (i) Design and construction. The formwork shall be sufficiently rigid and tight to prevent loss of grout or mortar
from the concrete at all stages and for the appropriate method of placing and compacting. The falsework and
formwork shall be so arranged as to be readily dismantled and removed from the cast concrete without shock,
disturbance or damage.

Where necessary, the falsework and formwork shall be so arranged that the soffit form, properly supported on
props only, can be retained in position for such period as may be required by maturing conditions as described
in sub-Clause 1710.4(ii). If the component is to be prestressed whilst still resting on the soffit form, provision
shall be made to allow for elastic deformation and any variation in weight distribution. Where it is intended to
re-use formwork it shall be thoroughly cleaned and made good.

Internal metal ties which require being withdrawn through hardened concrete shall not be used where each
face is permanently exposed. Where internal metal ties are left in they shall be provided with cover of at least
50mm or depth of cover equivalent to the adjacent reinforcement, whichever is the greater. The jointing faces
of the pocket shall be prepared with an exposed aggregate finish and dampened immediately prior to mortar
filling.

(ii) Cleaning and treatment of forms. The faces of the forms in contact with the concrete shall be clean and treated
with a suitable release agent, where applicable as described in sub-Clause 1708.3. Immediately before
concreting, all forms shall be thoroughly cleaned out. The source of any compressed air used for the clearing
of foreign matter from formwork shall be free from oil and other contaminant.

(iii) Projecting reinforcement and fixing devices. Where holes are needed in forms to accommodate projecting
reinforcement or fixing devices, care shall be taken to prevent loss of grout when concreting or damage when
striking forms.

(iv) Permanent formwork or special formwork shall be in accordance with BA33/90 and CIRIA 558 and shall
comply with the contract specific Appendix 17/4.

Transporting, Placing and Compacting

3 Concrete shall be transported and placed so that contamination, segregation or loss of the constituent materials does
not occur, in accordance with Clause 14 of BS 8500-2.

Concrete, when deposited, shall have a temperature of not less than 5°C. Where the concrete is made using CEM I or a
CEM II/A cement the concrete temperature shall not be more than 30°C. Where the concrete is made using a CEM II/B or
a CEM III cement, or equivalent combination, the concrete temperature shall not be more than 35°C. The temperature of
fresh concrete shall be measured in accordance with BS 8500-2. Fresh concrete shall not be placed against in situ concrete
that has been in position for more than 30 minutes unless a construction joint is formed as described in sub-Clause 1 of
this Clause.

(P03) Where lightweight aggregate concrete is to be pumped, the Contractor shall demonstrate to the satisfaction of the
Contractor’s Engineering Director that pumping will have no significant effect on the strength of the hardened concrete.

No concrete shall be placed in flowing water. Underwater concrete shall be placed in position by tremies or by pipelines
using methods to ensure the requirements of this Specification are met.

When concreting bridge decks of substantial thickness to avoid layering of concrete, the whole thickness shall be placed
in one pass. In deck slabs where void formers are used, adequate means to prevent flotation shall be employed and care
taken to ensure adequate compaction of the concrete placed beneath the void formers.

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Where the minimum dimension of a concrete section to be placed at a single time is greater than 600 mm measures shall
be taken to reduce the adverse effects of high temperatures in the concrete or to reduce the temperature of concrete to
prevent high temperatures having an adverse effect on the finished concrete.

Concreting operations shall not displace reinforcement, tendon ducts, tendon anchorages or formwork, or damage the
faces of formwork.

Concrete shall be thoroughly compacted by vibration during the operation of placing, and thoroughly worked around the
reinforcement, tendons or duct formers, around embedded fixtures and into corners of the formwork to form a solid mass
free from voids. When vibrators are used to compact the concrete, vibration shall be applied continuously during the
placing of each batch of concrete until the expulsion of air has practically ceased. A sufficient number of vibrators in
serviceable condition shall be on site to ensure that spare equipment is always available in the event of breakdowns.
Vibration shall not be applied by way of the reinforcement. Where vibrators of the immersion type are used, contact with
reinforcement and inserts shall be avoided as far as is practicable.

Self-compacting concrete shall be designed to be compatible with the intended application (eg. piling and diaphragm
walling), including any constraints due to the reinforcement and placing method. It shall be capable of self-weight
compaction without segregation and excessive bleeding. Viscosity, passing ability and segregation resistance shall be
assessed to BS EN 206.

Concrete shall not be subjected to disturbance between 4 hours and 24 hours after compaction except that re-compaction
of the upper layers of deep lifts to prevent or anneal settlement cracking may be carried out. Whenever vibration has to be
applied externally, the design of formwork and disposition and operation of vibrators shall ensure efficient compaction
and the avoidance of surface blemishes.

There shall be no excess water on the top surface on completion of compaction.

Slipforming shall be performed with appropriate equipment using methods to ensure that the requirements of this
Specification are met.

Removal of Formwork and Falsework

4 (i) General. Falsework and formwork shall be removed in a manner that does not damage the concrete, and at
times to suit the requirements for its curing and to prevent restraint that may arise from elastic shortening,
shrinkage or creep.
(ii) Timing of removal for cast in situ concrete. Where the concrete compressive strength is confirmed by tests on
concrete cubes stored under conditions that simulate the field conditions, formwork supporting concrete in
bending may be removed when the cylinder/cube strength is 12/15MPa or the strength needed by the design,
whichever is the greater. For ordinary structural concrete made with Portland cement (CEM I) or sulfate-
resisting Portland cements (CEM I-SR 0 or CEM I-SR 3) of strength class 42.5 or above, in the absence of
control cubes the period before removal shall be in accordance with the minimum periods given in Table 17/2.

TABLE 17/2: Minimum Period Before Removing Falsework and Formwork (CEM I or CEM I-SR Concrete)
Minimum Period Before Removal
Surface temperature of concrete:
16°C 7°C t°C (any temperature between
0°C and 25oC)

Vertical formwork to columns, 12 hours 18 hours 300/(t+10) hours

walls and large beams
Soffit formwork to slabs 4 days 6 days 100/(t+10) days
Props to slabs 10 days 15 days 250/(t+10) days

Soffit formwork to Beams 9 days 14 days 230/(t+10) days

Props to beams 14 days 21 days 360/(t+10) days

(P03) Where surface temperatures of concrete fall outside or are likely to fall outside the above temperature ranges
agreement shall be reached between the Contractor and the Contractor’s Engineering Director on appropriate removal
times.}

Curing of Concrete

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5 (i) General. Curing Classes 3 and Class 4 in accordance with Clause 8.5 of BS EN 13670 shall be used for
Consequence Class 2 and Class 3 structures respectively in accordance with BS EN 1990 unless otherwise
specified in contract specific Appendix 17/4. Additional special curing requirements may be given in contract
specific Appendix 17/4.

Immediately after compaction and thereafter for the duration of applied curing, except where elevated
temperature curing is used, concrete shall be protected against harmful effects of weather, including rain, rapid
temperature changes, frost, and from drying out. The method of curing shall provide a suitable environment for
the concrete to mature and prevent loss of moisture harmful to the quality of the concrete.

(P03) Where the Contractor proposes to use a curing liquid, compound or membrane on surfaces on which a
waterproofing system is to be laid, it shall be completely removable. The Contractor shall keep records of all
curing liquids, compounds and membranes and the areas of subsequent removal; such records shall be
subsequently supplied to the Contractor’s Engineering Director in accordance with the requirements of BD 62.

(ii) Accelerated curing. Where accelerated curing is proposed, the influence on the performance of the concrete,
and in particular thermal cracking, early and later strength and durability, shall be established by trials.

(a) The formwork may be generally heated to no more than 20°C prior to the placing of concrete.
(b) Once placing is complete the concrete shall be left for 4 hours without additional heating. The concrete
temperature can then be raised at a maximum rate of 10°C per ½hour.
(c) The concrete temperature shall at no time exceed 70°C.
(d) The rate of subsequent cooling shall not exceed the rate of heating.
(e) Cubes shall be manufactured and cured under identical conditions to those to which the concrete is
subjected.

Cold Weather Work

6 When concrete is placed at air temperatures below 2°C, the following requirements shall be met:

(i) The aggregates and water used in the mix shall be free from snow, ice and frost.

(ii) The surface temperature of the concrete at the time of placing shall be at least 5°C. Where the concrete is
made using CEM I or a CEM II/A cement, the concrete temperature shall not be more than 30°C. Where the
concrete is made using a CEM II/B or a CEM III cement, or equivalent combination, the concrete temperature
shall not be more than 35°C.

(iii) The surface temperature of the concrete shall be maintained at not less than 5°C until the concrete reaches a
strength of 5 N/mm² as determined by tests on cubes that were cured under identical conditions to the
structural concrete.

(iv) Before placing concrete, the formwork, reinforcement, prestressing steel and any surface with which the fresh
concrete will be in contact shall be free from snow, ice and frost.

(v) Cement shall not be allowed to come into contact with water at a temperature greater than 60°C.

Hot Weather Work

7 During hot weather the Contractor shall ensure that the constituent materials of the concrete are sufficiently cool to
prevent the concrete from stiffening in the interval between its discharge from the mixer and compaction in its final
position.

Cement shall not be allowed to come into contact with water at a temperature greater than 60°C.

Precast Concrete Construction

8 (i) General

Precast concrete elements to be used in the works shall comply with the Technical Standard –
Materials and Durability (HS2-HS2-CV-STD-000-000003). They shall also meet the following Product Standards
as appropriate:
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(a) Bridge deck elements shall comply with BS EN 15050.

(b) Foundation piles shall comply with BS EN 12794.
(c) Box culverts shall comply with BS EN 14844.
(d) Retaining wall elements shall comply with BS EN 15258.
(e) Masts and poles shall comply with BS EN 12843.

All precast concrete elements to be used in the works that fall within the scope of a Product Standard shall be
supplied in accordance with that Standard. Precast elements that are outside the scope of a Product Standard shall
conform to BS EN 13369 ‘Common rules for precast concrete products’, unless otherwise described in contract
specific Appendix 17/7.

Where there is conflict between the Technical Standard – Materials and Durability (HS2-HS2-CV-STD-000-
000003) and a Product Standard or BS EN 13369, then the Technical Standard shall take precedence.

Where minor site manufactured precast elements do not conform to any product standard or BS EN 13369
manufacture and construction operations shall comply with the provisions of BS EN 13670 and with this
Specification.

For precast products, the manufacturing requirements as detailed in their relevant Product Standard or in BS EN
13369 shall be complied with; the construction operations from the reception at the site or, if site manufactured,
from removal from the forms, shall comply with the provisions of BS EN 13670 and with this Specification. Where
precast products are manufactured in temporary plants on site, the production shall be protected against adverse
weather conditions and production control shall satisfy the requirements of Clause 6 of BS EN 13369.

(ii) Manufacture of precast products

Precast products shall be suitable for their intended use and place of installation in the works. The relevant Product
Standard for each precast product to be used shall be as identified in contract specific Appendix 17/7. Where there is
no relevant Product Standard, reference to manufacture in accordance with BS EN 13369 shall be as quoted in
contract specific Appendix 17/7.

Where a precast product is to be manufactured in accordance with a Product Standard, evidence of compliance with
the harmonised part of the Product Standard with respect to product performance shall be demonstrated by CE
marking and a Declaration of Performance where the declared performance for the essential characteristics given in
Annex ZA of that Standard is equal to or greater than the performance level required for the intended use of the
precast product.

The minimum set of information to be included with the CE marking and labelling in accordance with Annex ZA of
the Product Standard shall be as required in contract specific Appendix 17/7.

(iii) Manufacture of precast concrete elements not conforming to any Product Standard or to BS EN 13369

(P03) The Contractor shall give reasonable notice to the Contractor’s Engineering Director in advance of the date
of commencement of manufacture and casting of each type of element to permit inspection of the manufacturing
facility. A copy of all 28-day cube test results relating to the work, as scheduled in contract specific Appendix 1/5,
shall be made available by the Contractor to the Contractor’s Engineering Director in accordance with Clause 105.

(P03) For all prestressed elements, the Contractor shall provide to the Contractor’s Engineering Director, not
more than 7 days after the transfer of stress, a certificate showing the force and extension in the tendons after they
were anchored, the strength and age of test cubes cast as described in sub-Clauses 1724.3 and 1724.4 and the
minimum age in hours of the concrete at the time the stress was applied to the element.

For all prestressed pretensioned elements the length, cross-section dimensions and straightness of precast concrete
shall be measured, as far as practicable, at 28 ± 2 days after casting. If earlier measurement is required, the
manufacturer should allow for further shrinkage and creep between the time of measurement and 28 days, based on
recorded experience.

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All elements shall be indelibly marked to show the element mark as shown on the drawings, the weight of the
element, the production line on which they were manufactured, the date on which the concrete was cast and, if
they are of symmetrical section, the face that will be uppermost when the element is in its correct position in the
works. The markings shall be so located that they are not exposed to view when the element is in its permanent
position.

(iv) Requirements for all precast elements (including precast products)

(a) General. Where tests are to be carried out, no elements to which the tests relate shall be dispatched to the
site until the tests have been satisfactorily completed. In the case where elements are manufactured in
temporary plants on site, they shall not leave the designated production area until the tests have been
satisfactorily completed.

Unless interface shear calculations in accordance with BS EN 1992-2 (Clause 6.2.5 of BS EN 1992-1-1)
show that a non-prepared surface between concrete cast at different times is sufficient for structural
purposes, the vibrated top surface of precast concrete elements which will subsequently receive in situ
concrete shall be further prepared using one of the following methods and therefore considered as
“Rough” in accordance to Clause 6.2.5 of BS EN 1992-1-1:

Class 1 surface preparation. The surface finish shall be in accordance with sub-Clause 1710.1.

Class 2 surface preparation. The hardened surface shall be jetted with air or water to remove laitance and
all loose material and no further roughening shall then be carried out (rough as cast).

The surface classification and the method of preparation shall be shown on the drawings.

(b) Handling. Elements shall be lifted or supported at points described in contract specific Appendix 17/7 and
shall be handled and placed without impact. Additional constraints on the support, restraint and dynamic
loading during handling or transport are described in contract specific Appendix 17/7. The Contractor shall
incorporate, in the erection specification in accordance with BS EN 13670, the requirements of the lifting
scheme for the precast concrete elements.

(c) Storage. When elements are stored, they shall be firmly supported only at the points described in contract
specific Appendix 17/7. Where elements are stacked several units high, packings shall be vertically above
each other to prevent additional bending stresses in the elements, and the maximum height of the stack
and any provision required to maintain stability shall be as described in contract specific Appendix 17/7.
The accumulation of trapped water and deleterious matter in the units shall be prevented. Care shall be
taken to avoid rust staining and efflorescence. Where disfigurement would be detrimental, packing pieces
shall not discolour or otherwise permanently damage the elements.

(d) Protection. At all stages of construction, precast concrete elements and other concrete associated
therewith shall be properly protected to prevent damage to permanently exposed concrete surfaces,
especially arrises and decorative features.

(e) (P03) Placing and adjustment. An erection specification shall be prepared by the Contractor in
accordance with BS EN 13670 and it shall be submitted for acceptance of the Contractor’s Engineering
Director at least 4 weeks prior to the delivery of the elements. The method of assembly and erection
shall comply with any particular requirements in contract specific Appendix 17/7 and form part of the
erection specification.

(f) Requirements for placing and adjustment of composite slab bridges. In a composite slab bridge where
precast beams are laid side by side with minimal gaps to form a deck, the difference in soffit level
between adjacent units before the in situ concrete is placed shall nowhere exceed 5 mm for units up to 5
m in length or 10 mm for longer units, and the width of the deck soffit shall be within + 25 mm of that
shown on the drawings; furthermore, the width of the gap between individual beams shall not exceed
twice the nominal gap shown on the drawings. The alignment of transverse holes shall permit the
reinforcement or prestressing tendons to be placed without distortion. In adjacent spans, the continuity of
line of the outside beams shall be maintained.

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The in situ concrete in composite slab bridges shall be placed in such a sequence that the advancing edge
of the freshly deposited concrete over the full width of the deck, between longitudinal construction joints,
is approximately parallel to the deck supports. Precast beams shall be prevented from moving laterally
during the placing of the in situ concrete.

(g) Jointing and completion works. The composition and water/cement ratio of the in situ concrete or mortar
used in any connection and in the packing of joints shall be in accordance with the erection specification.
Levelling devices shall only be released or removed, in accordance with the erection specification when
the structural connection is complete and has achieved sufficient strength.

Care shall be taken to ensure that the in situ material is thoroughly compacted.

When using proprietary jointing materials, the manufacturer’s recommendations and any particular
requirement in contract specific Appendix 17/7 for the application and methods shall be strictly followed to
ensure full compatibility between the joint type and size and the sealing method.

1711 Concrete - Grouting and Duct Systems for Post-tensioned Tendons

Planning, Trials and Basic Requirements
1 Site operations, including duct installation, stressing and grouting, shall be carried out by organisations certificated in
accordance with the requirements of the CARES product acceptance scheme for the Supply and Installation of Post-
tensioning Systems in Concrete Structures (PT1), or an equivalent scheme. Post-tensioning systems shall be in accordance
with Clause 7.2 of BS EN 13670. The system shall have the intended use category and shall meet any performance
requirement stated in contract specific Appendix 17/6. The performance characteristics of the post-tensioning system shall
be demonstrated by CE marking and a Declaration of Performance where the declared performance for the product
characteristics is equal or greater than the performance level required for the intended use of the product.

Precast segmental construction using an internal grouted tendon system is not permitted except as indicated in Technical
Standard –Materials and Durability (HS2-HS2-CV-STD-000-000003).

Grouts for protection of prestressing tendons shall be as required in contract specific Appendix 17/6 and defined in sub-
Clause 1711.2. Grease and wax for post-tensioned unbonded tendons shall be as required in Clause 1725.

Unless otherwise agreed with the Project Manager, the Contractor shall undertake full-scale trials of the grouting
operations as required in the Contract for duct installation, testing, concreting, grouting and any other associated
requirements in accordance with the details described in contract specific Appendix 17/6. The trials are required to
demonstrate that the grouting methods and procedures proposed by the Contractor shall ensure that grout fills the ducts
and surrounds the prestressing steel.

(P03) The Contractor shall submit for acceptance of the Contractor’s Engineering Director, a detailed method statement,
at least 4 weeks prior to use in any trials or in the works, covering proposed materials, ducts, anchorage and vent
arrangements, personnel, equipment, grouting procedures and quality control. The method statement shall also describe
arrangements for storage and protection of materials (tendons etc.) on site, in the time between delivery and grouting.

(P03) Where full scale trials are required, these shall be carried out at least 56 days before the planned commencement of
fixing ducts for prestressing for the permanent works unless specified otherwise in contract specific Appendix 17/6. The
trials shall incorporate all relevant details of ducts, vents, duct supports, prestressing anchorages and couplers,
prestressing strands, grout inlets and outlets. The tendons shall be sufficiently tensioned such that the strands within the
duct take up a representative alignment. All systems, methods and materials are to be those proposed for the permanent
works and shall have been submitted to the Contractor’s Engineering Director as part of the detailed method statement
required. After three days the Contractor shall carefully cut or core the trial section to expose cross sections and
longitudinal sections of the duct, anchorages and any other locations where required, or as further directed by the
Contractor’s Engineering Director, to demonstrate that the duct is satisfactorily grouted. A report shall be prepared by the
Contractor giving full details of the trial, testing results and photographs of the exposed sections and submitted to the
Contractor’s Engineering Director.

(P03) Grouting of the ducts shall be shown to leave no void which has either a dimension greater than 5% of the duct
diameter measured in the radial direction of the duct or which poses a risk to the protective system. The location of any
voids with respect to grout vents and their adequate grouting and subsequent sealing, and the disposition of the steel

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tendons within the body of the grout shall be reported in writing by the Contractor to the Supervisor within 24 days.
Prestressing for the permanent works shall not be permitted without the prior written acceptance of the grouting
procedures by the Contractor’s Engineering Director and formal acceptance of the results of the grouting trial.

Irrespective of whether the Contract requires full-scale grouting trials, the Contractor shall carry out a materials suitability
assessment in accordance with sub-Clause 1711.2. Inspection and conformity of grouting works, including requirements
prior, during and after grouting shall be in accordance with Section 9 of BS EN 446 for Execution Class 3.

Grout Materials, Batching and Mixing

2 Grouting materials and procedures shall be in accordance with BS EN 445, BS EN 446 and BS EN 447 and FIB
Bulletin 20.

The properties of the grout, made with the materials, and using the plant and personnel proposed for use on site, shall be
assessed for suitability for the intended purpose by the Contractor in accordance with 6.1 of BS EN 446. This assessment
shall be carried out sufficiently in advance of grouting operations to enable adjustments to be made in use of materials or
plant or personnel. The assessment shall consist of the preparation of the grout, made with the materials, and using the
plant and personnel proposed for use on site, and the testing of it in accordance with sub-Clause 1711.3. The preparation
shall be carried out under representative conditions of temperature expected on site. If grouting operations are likely to
cover different seasons, the assessment shall be carried out for the expected range of temperatures.

(P03) No departures from the sources of the materials and procedures approved as a result of satisfactory trials will be
permitted without the written approval of the Contractor’s Engineering Director.

When pre-bagged grouts are used, they shall be obtained from companies holding a valid CARES product acceptance
scheme certificate for the production of pre-bagged grouts complying with the requirements of BS EN 445, BS EN 446
and BS EN 447 (PT10), or an equivalent scheme.

All bagged materials shall be weighed before use, unless clearly weight marked with stated tolerance.

Admixtures
Admixtures shall be used where required to achieve a low water/cement ratio and impart good fluidity, minimum bleed
and volume stability or expansion to the grout to comply with sub-Clause 1711.3. For site batched grout, admixtures shall
be added on site during the mixing process and used in accordance with the manufacturer’s recommendations. For pre-
bagged grout the admixtures shall form a pre-blended component.

(P03) Admixtures are divided into two types, expanding and non-expanding and they may be used to obtain the required
grout performance. Admixtures used in combination shall be checked for compatibility by the Contractor, and reported to
the Contractor’s Engineering Director for acceptance.

Admixtures shall not contain substances in quantities that will adversely affect the grout or cause the grout to promote
corrosion of the prestressing steel by rusting, pitting, stress corrosion or hydrogen embrittlement.

The admixture shall not segregate, shall be uniform in colour and the composition shall not change. Admixtures shall
comply with BS EN 934-4; evidence of compliance with the harmonised part of BS EN 934-4 with respect to product
performance shall be demonstrated by CE marking and a Declaration of Performance where the declared performance for
the essential characteristics given in Annex ZA of that Standard is equal or greater than the performance level required for
the intended use of the admixture.

(P03) The optimum dosage of any admixture shall be determined by trial mixes with the cement to be used in the grout.
This dosage shall be expressed as percent by mass of the cement. It shall be within the range recommended by the
supplier and shall not exceed 5% by mass of the cement. The method of measuring dosage and checking weights shall
comply with this sub-Clause or as otherwise agreed with the Contractor’s Engineering Director.

Batching and Mixing

All materials shall be batched by mass except the mixing water and liquid admixtures which may be batched by mass or
by volume. Bagged materials shall be weighed before use, unless clearly weight marked with stated tolerance. The
accuracy of batching shall be or have been (in case of pre-bagged materials):

± 2% for dry materials, cement and admixtures

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± 1% for mixing water

of the quantities specified. The total amount of mixing water shall include the water content of liquid admixtures.Where
proprietary pre-bagged grouts are used, they shall be mixed in accordance with the manufacturer's instructions.

Depending upon environmental or material influence (e.g. temperature, configuration of the tendon and properties of the
materials used), the water/cement ratio shall be kept as low as possible having regard to the required plastic properties of
the grout (see sub-Clause 1711.3). Actual water/cement ratios shall be recorded.

The material shall be mixed to produce a homogeneous grout and kept in slow continuous agitation until pumped into the
duct. Unless manufacturers specify otherwise, water shall be added to the mixer first, followed by the dry materials which
may be added as a whole or in part in sequence until the total quantities are added. The minimum mixing time determined
from grouting trials shall be adhered to.

The temperature of freshly mixed grout shall be between 5oC and 30oC. The maximum temperature may be increased
provided trials demonstrate that the grout meets the requirements of sub-Clause 1711.3.

Properties, Performance and Testing of Grout

3 The properties and performance requirements for grout shall be in accordance with Section 6 of BS EN 447. The
requirements for suitability testing shall be in accordance with Section 6 of BS EN 446. Test methods are described in BS EN
445. Test requirements for grout during grouting shall be in accordance with Section 9 of BS EN 446 for Execution Class 3.

Duct Systems
4 Ducts shall be in accordance with the recommendations of FIB Bulletin 75. The system of ducts, duct connectors,
grouting connections, vents, vent connections, drains, transitions to anchorages and caps for anchors shall form a
complete encapsulation for the tendons which is resistant to the ingress of air and water. Ducts shall be of plastic and shall
not degrade during the expected life of the structure. The system shall be fully compatible with the prestressing
anchorages, couplers and other details. Where ducts are non-conductive, metal parts of anchorages shall be electrically
bonded to the adjacent reinforcement at each end of the tendon and electrical continuity of the structure over the length of
the tendon shall be confirmed by testing. All ducts shall be kept free from standing water at all times and be thoroughly
clean before grouting.

The following air pressure tests shall be carried out on site unless specified otherwise in contract specific Appendix 17/6.

Duct Assembly Verification Tests

Each complete duct system including vents, anchorages, anchorage caps, and where appropriate couplers and their
connections, shall be air-pressure tested before concreting. Testing to a pressure of 0.01N/mm2 unless otherwise specified
in contract specific Appendix 17/6, shall demonstrate that the system is undamaged and has been correctly assembled.
The testing shall demonstrate that a loss of pressure no greater than 10% occurs after 5 minutes.

The minimum manufactured wall thickness of ducting for internal tendons shall be 2 mm. The duct rigidity and type and
spacing of fixings and supports shall be such as to maintain line, position and cross section shape during concreting. Local
deformation of the duct at supports shall be avoided.

For external tendons the minimum wall thickness shall be 4 mm for durability, or such thicker wall as required to
withstand grouting pressures of the particular duct configuration.

The Contractor shall provide evidence of testing to demonstrate the following requirements:

(i) Wall thickness of ducts for tendons after tensioning of the tendons shall be not less than 1.5mm unless
specified otherwise in contract specific Appendix 17/6.
(ii) For internal tendons the duct shall transmit full bond strength from the tendons to the surrounding concrete
over a length no greater than 50-100 duct diameters or other such requirement as given in contract specific
Appendix 17/6.

Vents
Vents providing an air passage of at least 15 mm internal diameter shall be provided at the anchorages and in the troughs
and crests and beyond each intermediate crest in the direction of flow of the grout at the point where the duct is one half

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diameter lower than the crest, (but no further than 1m from the crest), unless otherwise described in contract specific
Appendix 17/6. The maximum spacing of vents shall be 15m unless specified otherwise in contract specific Appendix
17/6.

The vent diameter and spacing may be varied in full-scale trials demonstrating the suitability of alternatives. The vents
shall be rigidly connected to the ducts, and shall be capable of being closed and re-opened. Holes in the ducts shall be at
least the internal diameter of the vents and shall be formed before pressure testing.

For external tendons the arrangement and detailing of the vents at positions within deflectors/diaphragms shall be proven
by detailed testing.

Vents on each duct shall be identified by labelling and shall be protected against damage at all times.

Vents at high points shall extend to a minimum of 500 mm above the highest point on the duct profile unless described
otherwise in contract specific Appendix 17/6.

Grouting Equipment
5 Grouting equipment shall comply with the requirements of Section 7 of BS EN 446.

The equipment shall be capable of maintaining pressure on completely grouted ducts and shall be fitted with a valve that
can be locked off without loss of pressure in the duct.

During the grouting operation the Contractor shall provide adequate flushing-out plant to facilitate complete removal
of the grout in the event of a breakdown of the grouting equipment or other disruption before the grouting operation
has been completed. Stand-by and emergency equipment shall be provided.

All equipment shall be kept free from build-up of adhering materials.

Grouting Procedures
6 Grouting procedures shall comply with the requirements of Section 8 of BS EN 446 and reflect the supplementary
recommendations of FIB Bulletin 20.

(P03) Grouting of the ducts shall be carried out within 14 days of installation of the tendon or as soon as is practicable
thereafter, in which case additional measures shall be taken to avoid corrosion of the prestressing steel. The Contractor’s
Engineering Director’s written agreement to commence grouting operations shall be obtained.

(P03) During grouting operations, once the fluidity of the grout flowing from the vents is the same as the grout being
injected (to within the limits specified in BS EN 447, as per 8.4 of BS EN 446), 5 litres of grout at each vent, or such
other requirement of contract specific Appendix 17/6, shall be vented into a clean receptacle and then discarded. The
volume of all grout that is expelled shall be measured. The opening shall be firmly closed. All vents shall be closed in a
similar manner one after another in the direction of the flow except that at intermediate crests the vents immediately
downstream shall be closed before their associated crest vent. The injection tubes shall then be sealed off under pressure
with a pressure of 0.5 N/mm2 being maintained for at least one minute. Grout vents at high points shall be reopened
immediately after 1 minute, while the grout is still fluid. Any escape of air, water or grout shall be recorded and reported
immediately to the Contractor’s Engineering Director. A further pumping of grout shall then be carried out to expel bleed
water – and/or entrapped air. This shall be carried out with the vents open one at a time sequentially in the direction of
grouting with a further 5 litres being released at each vent. In the event of disagreement over the quality of the vented
grout, testing shall be undertaken immediately by the Contractor. Finally, when all outlets are closed the grout pressure
shall be maintained for at least one minute to confirm there is no unintended loss due to leakage.

The filled ducts shall not be subjected to shock or vibration for at least 24 hours from the time of grouting.

(P03) When the grout has set, the grout vents shall be temporarily reopened. If voids are apparent on inspecting vents at
end caps, the Supervisor may require all or some of the end caps to be removed to demonstrate that they are satisfactorily
filled with grout. End caps which have been removed shall then be replaced and permanently sealed against ingress of
contaminants, such sealing to be proved to the Contractor’s Engineering Director.

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(P03) If the method of demonstrating filling of the anchorage caps involves their removal, a photographic record shall be
made by the Contractor. The record shall clearly identify the individual anchorages, and shall be included in the report to
the Contractor’s Engineering Director.

(P03) If, in the opinion of the Contractor’s Engineering Director, there is doubt that the ducts or any part of the system
are not satisfactorily filled with grout, the Contractor’s Engineering Director may require investigations to be carried out.

(P03) The Contractor shall keep full records of grouting for each duct in accordance with the certification scheme
requirements for the installation of post-tensioning systems. Copies of these records shall be supplied to the Contractor’s
Engineering Director within 24 hours of completing grouting to each duct.

On completion of grouting, grout vents shall be positively sealed and waterproofed by a means additional to but separate
from the concrete waterproofing.

Grouting During Cold or Hot Weather

7 Requirements for grouting in cold or hot weather are given in 8.3 of BS EN 446.

When the ambient temperature is expected to fall below 5°C, accurate records shall be kept by the Contractor of the
maximum and minimum air temperatures, and the temperatures of the structural elements adjacent to the ducts to be
grouted.

(P03) When heating is considered appropriate, methods of heating shall be to the acceptance of the Contractor’s
Engineering Director. Ducts shall not be warmed with steam.

Void Grouting
8 Void grouting is the injection of grout into voids left in tendon ducts after the original grout has hardened and shall not be
confused with regrouting, which means the reinjection of grout into ducts while the original grout is still fluid. Where the use
of void grouting is proposed, it shall be subject to the approval of the Supervisor.

1712 Reinforcement - Materials

Hot Rolled and Cold Worked Carbon Steel Bars
1 All hot rolled and cold worked steel bars shall conform to BS EN 10080 and BS 4449 Grades B500B or B500C.
Reinforcement shall be cut and bent in accordance with BS 8666. The bars shall be obtained from and cut and bent by
organisations holding a valid CARES product acceptance scheme (or equivalent scheme) certificate of approval for the
production and supply of steel for the reinforcement of concrete (see also Clause 1712.8).

2 Hot rolled and cold worked carbon steel bars shall conform to BS EN 10080 and BS 4449 except that no bar shall
contain a flash weld.

Steel Wire
3 Steel wire shall only be used in precast concrete elements and shall be ribbed Grade 500 conforming to BS EN 10080
and BS 4482 . Steel wire shall have a minimum nominal diameter of 8 mm and shall be obtained from organisations
holding a valid CARES product acceptance scheme (or equivalent scheme) certificate of approval for the production and
supply of steel wire (see also Clause 1712.8).

Steel Fabric
4 Steel fabric reinforcement shall be Grades B500A, B500B or B500C conforming to BS EN 10080 and BS 4483.
Steel fabric reinforcement shall be cut and bent in accordance with BS 8666. Steel fabric reinforcement shall have a
minimum nominal bar size of 6 mm (8 mm for Grade B500A) and shall be obtained from organisations holding a valid
CARES product acceptance scheme (or equivalent scheme) certificate of approval for the production and supply of steel
fabric reinforcement (see also Clause 1712.8). Steel fabric reinforcement shall be delivered to site in flat mats or pre-bent.

Stainless Steel Reinforcement

5 All stainless steel reinforcement shall conform to BS 6744 and shall be cut and bent in accordance with BS 8666 and
shall be obtained from organisations holding valid CARES product acceptance scheme (or equivalent scheme) certificates
of approval for the production and supply of stainless steel reinforcement (see also Clause 1712.8).

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6 Stainless steel reinforcement shall be ribbed Grade 500 conforming to BS 6744 and the additional properties
described in contract specific Appendix 17/4.

Bond Strength
7 For hot rolled and cold worked carbon steel bars, and for steel fabric reinforcement, the bond property requirements
of BS 4449 shall be complied with based on the surface geometry requirements of that standard. For steel wire, the bond
property requirements of BS 4482 shall be complied with based on the surface geometry requirements of that standard.

Traceability and Identification of Reinforcement

8 Any product acceptance scheme shall ensure that materials used in reinforcing bars are traceable from their initial
production casts, through rolling and other treatments to delivery on site of straight bar or cut and bent steel. The marking
system on reinforcement shall be secure, clear and unambiguous. Marking must also identify the grade of a reinforcement
bar both in terms of strength and ductility. Materials complying with the requirements given in Clauses 1712.1 to 6 and
supplied in accordance with the CARES product acceptance scheme or equivalent scheme shall be deemed to meet the
requirements for traceability and identification of materials described above.

1713 Carbon Steel Reinforcement and Stainless Steel Reinforcement - Bar Schedule Dimensions -
Cutting and Bending
1 The bar schedules are based on the dimensions of the concrete and the nominal cover to the reinforcement shown on
the drawings. The reinforcement shall be cut and bent within the tolerances given in BS 8666 but this shall not relieve the
Contractor of his responsibility for the correct fit of the reinforcement and the achievement of the required cover as
described in Clause 1714. The mandrel diameter for bending bars shall comply with Clause 8.3 of BS EN 1992-1-1.

Bending of reinforcement at temperatures below 5°C or in excess of 100°C shall not be carried out.

Re-bending of carbon steel bars and fabric reinforcement shall not to be permitted.

Re-bending of stainless steel reinforcement bars shall not be permitted.

Site storage of reinforcement shall ensure that it is clear of the ground and covered with a waterproof sheeting or fixed
cover, in order to reduce contamination and excess corrosion prior to placement.

1714 Reinforcement - Fixing

1 Reinforcement shall be secured against displacement and tied together in accordance with BS 7973-2. The
positioning of reinforcement shall be within the tolerances given in sub-Clause 1728.3.

Bars in inner layers shall be located as shown on the drawings.

Welding of carbon steel reinforcing bars for fixing purposes shall be in accordance with Clause 1717. Welding of
stainless steel reinforcement bars shall not be permitted.

Cover shall be achieved by using spacers and chairs which meet the performance requirements of BS 7973-1. They shall
be designed so that they will not overturn or be displaced when the concrete is placed. Reinforcement spacers and chairs
shall be fixed in accordance with BS 7973-2.

Spacer blocks shall be factory produced proprietary products. Site produced or other non-proprietary spacers shall not be
used.

Wire cast in spacer block for the purpose of tying it to the reinforcement shall be as described below. Projecting ends of
ties or clips shall not encroach into the concrete cover.

Tying wires shall be 1.2 mm diameter stainless steel wire for bridge decks and exposed surfaces and any other locations as
described in contract specific Appendix 17/4. In other areas 1.6 mm soft annealed iron wire may be used. Stainless steel
tying wire shall be used when tying stainless steel reinforcement.

(P03) The Contractor shall provide access and carry out a cover measurement survey of all reinforced concrete surfaces
within the 4-week period following the removal of formwork. The cover measurement survey shall be carried out on a

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500 mm grid over the whole structure. A record of the survey shall be kept and subsequently supplied to the Contractor’s
Engineering Director in accordance with the requirements of BD 62.

1715 Reinforcement - Surface Condition

1 Immediately before concrete is placed around it, reinforcement shall be free from mud, oil, paint, retarder, release
agent, loose rust, loose mill scale, snow, ice, grease or any other substance that can be shown to have an adverse chemical
effect on the steel or concrete, or to reduce the bond between the steel and the concrete.

1716 Reinforcement - Laps and Joints

1 (P03) Laps and joints shall be made only where shown on the drawings, except in the case where additional laps or
splice bars are required and the Contractor’s Engineering Director’s approval has been obtained.

2 Where reinforcing bars are required to be coupled the coupling system shall have a current British Board of
Agrément Roads and Bridges Certificate or CARES product acceptance scheme Certificate of Product Assessment TA1-
A for use with Highway Structures or equivalent scheme and shall be sourced, applied and processed from organisations
holding relevant valid CARES product acceptance scheme (or equivalent scheme) certificate of approval. Couplers shall
comply with cover requirements of sub-Clause 1714.1.

1717 Reinforcement - Welding

General
1 Welded reinforcement, other than steel fabric reinforcement, shall not be incorporated in the permanent works unless
permitted in contract specific Appendix 17/4. When required, welding of reinforcing bars shall comply with the
requirements of Clause 3.2.5 of BS EN 1992-1-1, shall be carried out in accordance with BS EN ISO 17660 and be subject
to the demonstration of the satisfactory performance of trial joints. The Contractor shall demonstrate that at each location
the fatigue life, durability and other properties of the member are not adversely affected by the proposal.

Site welding of stainless steel reinforcement bars shall not be permitted.

Strength of Structural Welded Joints

2 The strength of all structural welded joints shall be assessed following tests on trial joints to establish the minimum
specified mechanical properties of the joint. Tests shall be carried out by an independent testing body appropriately
accredited as described in Clause 105.
1718 Prestressing Tendons - Materials
Steel Wires and Strands
1 Steel wires and strands shall comply with BS 5896 and shall be obtained from an organisation holding a valid
CARES product acceptance scheme certificate of approval for the production of prestressing steel wires and strands (PT6-
PT8), or equivalent scheme.

Cold Worked High Tensile Alloy Bar

2 Cold worked high tensile alloy steel bars for prestressed concrete shall comply with BS 4486 and shall be obtained
from an organisation holding a valid CARES product acceptance scheme certificate of approval for the production of
prestressing steel bars (PT7), or equivalent scheme.

Sampling and Testing

3 When it is proposed to use other than the lowest strength diameter wire or strand complying with BS 5896, the
following shall apply:

(i) A sample shall be taken from each reel of material proposed for use in the works.
(ii) A reel shall only be accepted if both the breaking load and the 0.1% proof load of the sample exceeds the
specified characteristic loads given in BS 5896.

4 Where scheduled in contract specific Appendix 1/5, the Contractor shall arrange for samples of the steel intended for
use in the permanent works to be tested at a testing laboratory appropriately accredited as described in Clause 105.

5 Testing of prestressing steel bar, wire and strand shall be performed in accordance with BS EN ISO 15630-3.

1719 Prestressing Tendons - Handling and Storage

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1 Prestressing tendons shall not be mechanically damaged, work-hardened or heated during handling. All prestressing
tendons shall be stored clear of the ground and protected from the weather, from splashes from any other materials, and
from splashes from the cutting operation of an oxy-acetylene torch, or arc-welding processes in the vicinity.

In no circumstances shall prestressing tendons after manufacture be subjected to any welding operation, or heat treatment
or metallic coating such as galvanizing. This does not preclude cutting as described in Clause 1722.

1720 Prestressing Tendons - Surface Condition

1 Prestressing tendons and internal and external surfaces of sheaths or ducts shall be clean and free from pitting at the
time of incorporation in the works. Slight surface rusting is generally acceptable, unless in environmentally severe sites
(marine or industrial).

1721 Prestressing Tendons - Straightness

Wire
1 Low relaxation and normal relaxation wire shall be in coils of sufficiently large diameter to ensure that the wire pays
off straight, except that in cases where straight as-drawn wire is not essential, wire in small-diameter coils (corresponding
to the diameter of the blocks in the drawing machine) may be used.

Strand
2 Prestressing strand, however manufactured, shall be in coils of sufficiently large diameter to ensure that the strand
pays off straight.

Bars
3 Prestressing bars as delivered shall be straight. Any small adjustments for straightness that are necessary on Site shall
be made by hand. Bars bent in the threaded portion shall be rejected. Any straightening of bars shall be carried out cold
but at a temperature of not less than 5°C. Any necessary warming shall be by means of steam or hot water.

1722 Prestressing Tendons - Cutting

1 All cutting of wire, strand or bar shall be carried out after gradual release of the tension in the tendons to be cut.
Cutting shall be executed using either:

(i) a high-speed abrasive cutting wheel, friction saw or equivalent mechanical method at not less than one tendon
diameter from the anchor; or
ii) an oxy-acetylene cutting flame, using excess oxygen to ensure a cutting rather than a melting action, not less
than 75 mm from the anchor. The temperature of the tendon adjacent to the anchor shall not be greater than
200°C. Neither the flame nor splashes from the cutting operations shall come into contact with the anchorages
or uncut tendons.

1723 Prestressing Tendons - Positioning of Tendons, Sheaths and Duct Formers

1 Tendons, sheaths and duct formers shall be accurately located and maintained in position both vertically and
horizontally as shown on the drawings. The position shall be within the tolerances given in sub-Clause 1728.3.

Where tendons are described in the Contract as debonded from the concrete they shall be covered with suitable sleeves.
The ends of the sleeves shall be taped to the tendon to prevent the ingress of grout.

Joints in sheaths shall be securely taped to prevent penetration of the duct by concrete or laitance, and ends of ducts shall
be sealed and protected after the stressing and grouting operations. Joints in adjacent sheaths shall be spaced at least 300
mm apart.

1724 Prestressing Tendons - Tensioning

General
1 All wires, strands or bars stressed in one operation shall be taken, where possible, from the same parcel. Each cable
shall be tagged with its number from which the coil numbers of the steel used can be identified. Cables shall not be
kinked or twisted. Individual wires and strands for which extensions are to be measured shall be readily identifiable at
each end of the member. No strand that has become unravelled shall be used. Strands of the same diameter but with
different strength grades must not be used in the same beam.
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Tensioning Apparatus
2 The tensioning apparatus shall meet the following general requirements:

(i) The means of attachment of the tendon to the jack or tensioning device shall be safe and secure.
(ii) Where two or more wires or strands are stressed simultaneously, they shall be approximately of equal length
between anchorage points at the datum of load and extension measurement. The degree of variation shall be
small compared with the expected extension.
(iii) The tensioning apparatus shall be such that a controlled total force is imposed gradually and no dangerous
secondary stresses are induced in the tendons, anchorage or concrete.
(iv) The force in the tendons during tensioning shall be measured by direct-reading load cells or obtained indirectly
from gauges fitted in the hydraulic system to determine the pressure in the jacks. Facilities shall be provided
for the measurement of the extension of the tendon and of any movement of the tendon in the gripping
devices. The load measuring device shall be calibrated to an accuracy within ± 2% and checked at frequent
intervals. The valid calibration records shall be available on site before tensioning starts. Elongation of the
tendon shall be measured to an accuracy within 2% or 2 mm, whichever is the greater.
(v) The tensioning equipment shall be calibrated before the tensioning operation and subsequently at frequent
intervals.

Pretensioning
3 Where pretensioning methods are used, the tension shall be fully maintained by some positive means during the
period between tensioning and transfer. The transfer of stress shall take place slowly to minimize shock.

(i) Straight tendons. In the long-line method of pretensioning, sufficient locator plates shall be distributed
throughout the length of the bed to ensure that the wires or strands are maintained in their proper position
during concreting. Where a number of units are made in line, they shall be free to slide in the direction of their
length and thus permit transfer of the prestressing force to the concrete along the whole line. In the individual
mould system, the moulds shall be sufficiently rigid to provide the reaction to the prestressing force without
distortion.
(ii) Deflected tendons. Where possible, the mechanisms for holding down or holding up tendons shall ensure that
the part in contact with the tendon is free to move in the line of the tendon so that frictional losses are
nullified. If, however, a system is used that develops a frictional force, this force shall be determined by test
and due allowance made. For single tendons the deflector in contact with the tendon shall have a radius of not
less than 5 times the tendon diameter for wire or 10 times the tendon diameter for strand, and the total angle of
deflection shall not exceed 15°. The transfer of the prestressing force to the concrete shall be effected in
conjunction with the release of hold-down and hold-up forces.

Unless otherwise described in contract specific Appendix 17/4, concrete shall not be stressed until it has reached at least
the age at which 2 test results from specimens taken from it (each obtained from the average of two test cubes made from
one concrete sample) attain the specified characteristic compressive strength at the time when the concrete is subjected to
the prestressing force. Testing shall be as described in Annex B.5 of BS 8500-1 and Annex B of BS EN 206. The samples
shall be taken as described in BS EN 12350-1 and the test cubes shall be made and tested as described in BS EN 12390-2
and BS EN 12390-3 respectively. They shall be cured in similar conditions to the concrete to which they relate. The
Contractor shall cast and test sufficient cubes to demonstrate that the required strength of the concrete at transfer has been
reached.

Post-tensioning
4 In addition to the present Clause, the installation of post-tensioning systems shall comply with the requirements of
Clause 1711.

(i) Arrangement of tendons. Where wires, strands or bars in a tendon are not stressed simultaneously, the use of
spacers shall be in accordance with the recommendations of the system manufacturer.
(ii) Anchorages. Prestressing anchorages for post-tensioning systems shall be in accordance with Clause 7.2 of BS EN
13670 and shall be supplied by organisation certificated with the CARES product acceptance scheme for the
Production and Supply of Prestressing Anchorages for Post-tensioning Systems (PT3), or an equivalent scheme.
Anchorages shall comply with the minimum performance requirements of BS EN 13391. For each anchorage

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system used in the works, the characteristic value for anchorage efficiency shall be not less than 95%.
Proprietary anchorages shall be handled and used strictly in accordance with the manufacturer’s instructions
and recommendations.
(iii) Deflected tendons. The deflector in contact with the tendon shall have a radius of not less than 50 times the
diameter of the tendon, and the total angle of deflection shall not exceed 15°.
(iv) Tensioning procedure. Before tensioning, the Contractor shall demonstrate that all tendons are free to move in
the ducts unless the geometry of the ducts makes this impracticable. Tensioning shall be carried out in such a
manner that the stress in the tendons increases at a gradual and steady rate. Tensioning shall not be carried out
at a temperature below 0°C.

Unless otherwise described in contract specific Appendix 17/4, concrete shall not be stressed until it has reached at least
the age at which 2 test results from specimens taken from it (each obtained from the average of two test cubes made from
one concrete sample) attain the specified characteristic compressive strength at the time when the concrete is subjected to
the prestressing force. Testing shall be as described in Annex B.5 of BS 8500-1 and Annex B of BS EN 206. The samples
shall be taken as described in BS EN 12350-1 and the test cubes shall be made and tested as described in BS EN 12390-2
and BS EN 12390-3 respectively. They shall be cured in similar conditions to the concrete to which they relate. The
Contractor shall cast and test sufficient cubes to demonstrate that the required strength of the concrete at transfer has been
reached.

The Contractor shall ensure that those carrying out the stressing are provided with particulars of the required tendon
loads, order of stressing and extensions. Allowance shall be made during stressing for the friction in the jack and in the
anchorage, although the former is not necessary when using load cells, and for draw-in of the tendon during anchoring.

Stressing shall continue until the required extension and tendon load are reached. The extension shall allow for any draw-
in of the tendon occurring at a non-jacking end, but measurement shall not commence until any slack in the tendon has
been taken up.

Immediately after anchoring, the forces in the prestressing tendons shall not exceed 70% of their characteristic strength.
During stressing the value may exceed 70% of their characteristic strength but shall not exceed 80%.

After the tendons have been anchored, the force exerted by the tensioning apparatus shall be decreased gradually and
steadily so as to avoid shock to the tendon or the anchorage. Full records shall be kept of all tensioning operations,
including the measured extensions, pressure-gauge or load-cell readings, and the amount of draw-in at each anchorage.
When requested copies of these records shall be provided within 24 hours of each tensioning operation.

(P03) Tendons shall not be cut within 3 days of their being grouted; however, in the case of deviation from the planned
performance during tensioning, cutting of the tendons, grouting and work which can impair the re-tensioning shall not take
place until the causes have been investigated and revised tensioning report has been approved by the Contractor’s
Engineering Director.

1725 Prestressing Tendons - Protection and Bond

1 The prestressing tendons shall be protected in their permanent positions from both mechanical damage and corrosion
as described in contract specific Appendix 17/4.

Grout and grouting operations for filling ducts and anchorages of post-tensioned bonded tendons (internal or external) shall
be in accordance with Clause 1711.

Grease and wax for the protection of sheaths and anchorages of unbonded tendons shall be in accordance with Clauses 7.2
and 7.6 of BS EN 13670.

Vents, grout inlets and outlets and anchorages shall be sealed to assure corrosion protection equivalent to that provided along
the tendon. Anchorage zones shall be protected from drainage water.

Unbonded tendons shall be sealed throughout their length against penetration of moisture.

1726 Stainless Steel Dowels - Materials

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1 Dowels shall be made from Steel Designation 1.4429 or 1.4436 and Grade 200 or 500 steel bars complying with BS
6744.

1727 Inspection and Testing of Structures and Components

General
1 Inspection and testing of structures and components shall be in accordance with BS EN 13670 for the designated
Execution Class (see Clause 1701) and carried out as described in contract specific Appendix 17/4 and as scheduled in
contract specific Appendices 1/5 and/or 1/6. The documentation of inspection shall be in accordance with BS EN 13670
and this Specification.

1728 Geometrical Tolerances

General
1 The tolerances given in Clauses 10.4 to 10.6 of BS EN 13670 and in its Annex have been derived specifically for
buildings and shall not be applied to highway works. Instead, the requirements of this Clause apply. The tolerances given
in this Clause are not cumulative. Further project specific tolerances shall be as described in contract specific Appendix
17/4 and on the drawings.

Reference System
2 (P03) The location of the reference grids or primary lines and levels for the overall positioning of the works shall be
agreed between the Contractor’s Engineering Director and the Contractor before the works are set out.

Sections
3 The dimensions of cross-section, the cover and position of reinforcement and prestressing tendons shall not deviate
more than the values given in Figure 17/1. With the exception of case (d) in Figure 17/1, these values do not apply to precast
concrete elements, which shall conform to the provisions for geometrical tolerances in BS EN 13369 and/or to the relevant
Product Standard as appropriate (see Clause 1710.8).

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No. Type of deviation Description Permitted deviation Δ

A Cross-sectional dimensions
li = Length of
cross-sectional
dimension

Applicable to
beams, slabs and
columns

For li < 150 mm ± 5 mm

li = 400 mm ± 10 mm
li ≥ 2500 mm ± 30 mm

with linear
interpolation for
intermediate
values

B Location of ordinary reinforcement

Cross Section h ≤ 150 mm, Δ(plus)= + 5 mm

h = 400 mm, Δ(plus) = + 10 mm

h ≥ 2500 mm, Δ(plus) = + 20 mm

with linear
interpolation
for intermediate
values
cmin = required minimum cover
cn = nominal cover = cmin + | Δ(minus) |
c = actual cover
All values of h Δ(minus) = Δcdev a)
Δ= permitted deviation from cn
h = height of cross-section

Requirement: cn + Δ(plus)> c > cn - | Δ(minus) |

a) Δcdev shall be in accordance with Technical Standard – Materials and Durability (HS2-
HS2-CV-STD-000-000003).

NOTE: Permitted plus-deviations for cover to reinforcement for foundations and concrete
members in foundations may be increased by 15 mm. The given minus-deviations apply.

C Lap-joints
l = Lap length - 0,06 l

d Location of prestressing duct

Longitudinal section y = Intended distance ± 5mm

to centreline of duct in
plan or elevation

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Figure 17/1 – Permitted Sectional Deviations

Permitted Deviations at Support Bearings

4 The position of bearings at supports shall not deviate more than the values given in Figure 17/2.

No. Type of deviation Description Permitted deviation

Δ
A Position of bearing axis of support when structural
bearings are used l = Intended The larger value,
distance from taken with the
all edges negative sign,
between
- l/50 and - 5mm

and not greater than

- 15 mm

but for columns not

greater than the
larger value, taken
with the negative
sign, between

- 15 mm and - h/600

where h = free
height of column

Figure 17/2 – Permitted deviations at support bearings

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Permitted Deviations for Columns and Walls

5 The dimensions of columns and walls shall not deviate more than the values given in Figure 17/3.

No. Type of deviation Description Permitted

deviation Δ
a Inclination of a column or wall

The larger of
h = free height h/600
or
15mm

b Curvature of a column or wall

The larger of
h/600
h = free height or
15mm

Figure 17/3 – Permitted deviations for columns and walls

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1729 Anti-Graffiti Coating

1. Coating System
The coating shall comprise a three coat system:
Coat Description Requirements
Sealer Anti-graffiti pigmented Composition Non-volatile media: Water miscible epoxy with
sealer requirements: polyamide cross-linking agent
Particular Gloss: 20 – 40% (60o head)
requirements: Colour: Class 2 match to BS 4800 shade 00 E
53 (black)
Intermediate Anti-graffiti Composition Non-volatile media: Polyol with aliphatic
polyurethane coloured requirements: isocyanate cross-linking agent
finish Particular Gloss: To be available in semi-gloss and gloss
(2 pack) requirements: with not less than 75% (20o head).
Minimum wet film thickness: 100 microns
Topcoat Anti-graffiti Composition Non-volatile media: Polyol with aliphatic
polyurethane coloured requirements: isocyanate cross-linking agent
finish Particular Gloss: To be available in semi-gloss and gloss
(2 pack) requirements: with not less than 75% (20o head).
Minimum wet film thickness: 75 microns

All components of the anti-graffiti coating system shall be obtained from the same manufacturer.

The anti-graffiti coating system shall have a minimum design life of 10 years. Anti-graffiti coating systems for concrete
shall be tested in accordance with the requirements of BS EN 1062. It is preferable for test data to be gathered and
supplied by an organisation independent of the manufacturer, however, data from a BS EN ISO9001/9002 registered
company may be accepted – where such data can be verified.

The anti-graffiti coating shall not adversely affect the durability of the structure as detailed in Technical Standard –
Materials and Durability (HS2-HS2-CV-STD-000-000003)

2. Surface Preparation
The anti-graffiti coating is to be applied to the concrete within 28 days of casting. The surface preparation of the concrete
shall comprise washing down to remove all traces of release agent, curing membrane etc. All laitance and loose material
shall also be removed. Following washing down the concrete shall be allowed to dry so that at the time of application of
the anti-graffiti coating the residual moisture content of the concrete shall be less than 7%.

3. Application
The anti-graffiti coatings shall be applied in strict accordance with the manufacturer’s instructions manufacturer’s
instructions.

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