OM NOTE NUMBER 004, AUGUST 1990

on any given site properties of materials used will vary over the
period of construction. This variability contributes to the
overall variation in the measured strength of concrete which
arises mainly from the aggregate water content during the day,
temperature changes and inaccurate batching of the component
materials, the production process (i.e. plant control, resulting
in changes from the intended mix proportions) and the sampling,
making and testing of concrete specilllens. It is difficult to
determine the proportion of the overall variation arising from
each of these sources .
The variation in concrete strength typically obtained from tests
at a site show more results close to the mean value and fewer at
the extremes. It is now accepted that the variation in concrete
strengths follows a normal distribution curve which is
characterized by two parameters, its mean m and its standard
deviations, the latter being a measure of variability.

s = sq.rt [sigma (X - m)2 I (n - 1)]

,,

where X = an individual result

n = the number of results
m = the mean of n results
sigma = summation

With poor control there is a wide scatter of results giving a high

standard deviation; the better the control the lower the standard
deviation.

Due. to the distribution of the results, there. is always the

possibility, however remote, that a result less than the specified
strength will be obtained. It has now become general practice to
specify not a mini.mum strength but a "characteristic strength".
below which a specified proportion of the test results, often
called "defectives", may be expected to fall. The characteristic
strength may be defined to have any proportion of defectives; BS
5328, BS 8110 have all adopted a 5 percent level of defectives for
concrete. Thus, the characteristic strength of concrete is
defined as "that value of strength below which 5 percent of the
population ot all possible strength measurements of the specified
concrete are expected to fall"
 OM NOTE NUMBER 004, AUGUST 1990

6. 1 Margins required for mix design

Because of the variability of concrete strength, the mix must be
designed to have a mean strength greater than the specified
characteristic strength by an amount termed the "margin". Thus

fm = fc + ks
where fm = the target mean strength
fc = the specified characteristic strength
s = the standard deviation
k = statistical constant

The statistical constant k is derived from the mathematics of the

normal distribution and increases as the proportion of defectives
is decreased; for example
k = 1.28 for 10 percent defectives
k = 1.64 for 5 percent defectives
k = 2.33 for 1 percent defectives

The magnitude of standard deviation s varies from site to site.

An analysis of tests results of project works in the Emirate show
a range of 4 - 5 N/mm2 for commonly used C30 grade concrete.
For concrete having a 5 percent defective level, k = 1.. 64 and
the margin is 1.64 s.
For a specified characteristic strength of 30 N/mrn2 and a
standard deviation of 5 N/mm2,
The margin = 1.64 x 5 = 8.2 N/rnm2,
Then, the target mean strength = 30 + 8.2 = 38.2 N/rnm2

The standard deviation may be specified for a given job based on

experience . In many cases there is information on standard
deviation to be expected (with&a3096Hready-mmxenete, for example).
The reliability of the value of the standard deviation increases
with the number of results used in its calculation and it is
generally recommended that at least 20, and preferably 40, results
are used.

6.2 Grades of concrete

Whether concrete is specified in terms of mix proportions or

performance, BS 5328 requires the specification of the quality of
concrete in terms of a 28-day characteristic strength grade but
BS 5328 also includes flexural and indirect-tensile strength
grades, Table numbers 1, 2 and 3 .
 DM NOTE NUMBER. 004, AUGUST 1990

6.2.1 Tension Strength

The main measure of the structural quality of concrete is its

compressive strength. While concrete is best employed in a manner
which utilizes its favourable compression strength , its tension
strength is also of consequence in a variety of situations .
The knowledge of tensile strength is of value in estimating the
load under which cracking will develop . The absence of cracking
is of considerable importance in maintaining the continuity of a
concrete structure and in many cases in the prevention of
corrosion of reinforcement . Cracking problems occur when diagonal
tension arising from shearing/torsional stresses develops, thus
the shear and torsion resistance of reinforced-concrete members
appears to depenc:i primarily on the tension strength of the
concrete. Also, the conditions under which cracks form and
propagate on the tension side of reinforced concrete flexural
members depends strongly on the tension strength . The most
frequent case of cracking is due to restrained shrinkage and
temperature gradients . An appreciation of the tensile strength of
concrete helps in understanding the behaviour of reinforced
concrete even though the actual design calculations do not in many
cases explicitly take the tensile strength into account.

6.2.1.1 Flexu;ral strength - Flexural Test

There are considerable experimental difficulties in determining

true tensile strengths for concrete. In direct tension test,
minor misalignments and stress concentrations in the gripping
devices are apt to mar the results. Tension properties have been
measured in te·rms of the modulus of rupture, i.e. , that computed
flexural tension stress at which a test beam of plain concrete
would fracture. Because this nominal stress is computed on the
assumption that concrete is an elastic material, and because this
bending stress is localised in the outermost fibers, it is apt to
be the larger than the strength of concrete in uniform axial
tension. It is thus a measure of, but not identical with, the
real actual tension strength. Nevertheless, the flexural test is
very useful.

In some types of construction, such as roads or airport runways,

mix design of concrete on the basis of flexural strength is
frequently preferred because flexural tension there is a critical
factor .

BS 1881 Part 118 describes the test method .

 OM NOTE NUMBER 004, AUGUST 1990

6.2 . 1 . 2 Indirect Tensile strength - Splitting Test

An indirect method of applying tension is in the form of splitting

a cylindrical specimen . The result of the so called split­
cylinder test has established itself as a measure of tensile
strength of concrete .
A 150mm X 300mm, concrete cylinder is inserted in a compression
testing machine in the horizontal position, so that the
compression is applied uniformly along to opposite generatrices.
It can be shown that in an elastic cylinder so loaded , a nearly
uniform tensile stress exists at right angles to the plane of load
application. Correspondingly, such cylinders, when tested, split
into two halves along that plane, at a stress which can be
computed . Because of local stress conditions at the load lines and
the presence of stresses at right angles to the aforementioned
tension stresses, the results of the split-cylinder tests likewise
are not identical with the true axial tensile strength.
Cubes can also be subjected to the splitting tests, the load being
applied through semi-cylindrical pieces resting against the cube
on centre lines of two opposing faces . The method yields the same
result as the splitting test on a cylinder . The splitting tests
are simple to perform and give more uniform results than the other
tension test. The strength determined in the splitting test is
believed to be closer to the true tensil.e strength of concrete
than the modulus of rupture .

ASTM Standard C496 and BS 1881 Part 117 cover these test methods

6.2 . 1.3 Correlation with compressive strength

Tensile strength, whichever way determined, does not correlate
well with the compression strength. It appears that for normal
weight aggregate concrete the tensile strength depends primarily
on the strength of bond between hardened cement paste and
aggregate. The shape of the coarse a9gregate particles affects
the relation between the water / cement ratio and the flexural
tensile strength . With a given water / cement ra.tio angular
aggregate produces a higher flexural tensile strength than rounded
or irregular aggregate. The compression strength, on the other
hand, is much less determined by these particular characteristics
and is sensibly independent of the shape of the aggregate
particles . Tensile strengths (N/mm2) of normal weight aggregate
concretes can be estimated from the following expressions

True tensile strength 0 . 24 to 0.40 sq.rt (fcu)

Indirect tensile strength 0.48 to 0.56 sq.. rt (fcu)
Flexural tensile strength 0.72 to 1 . 00 sq . rt (fcu)
Where, fcu is characteristic cube strength (N/mm2)
 OM NOTE NUMBER 004, AUGUST 1990

The smaller of the foregoing factors apply to high strength

concrete, and larger to the low strength concretes. These
approximate expressions show that the tension and compression
strengths are by no means proportional and that any increase in
compression strength, such as that achi eved by lowering the water­
cement ratio, is accompanied by a much smaller percentage increase
in tensile strength.

TABLE 1 - COMPRESSJVE STRENGTH TABLE 2 - FLEXURAL STRENGTH TABLE 3 - INDIRECT TENSILE STRENGTH

Concrete Characteristic Characteristic Characteristic

grede compressiv& strength Grade flexural strength Grade indirect tensile strength
at 28 days, N/111112 at 28 days, N/nrn2 at 28 days, N/nm2

C 7.5 7.5 F3 3.0 IT 2 2.0

C 10 10.0 F4 4.0 IT 2.5 2.5
C 12.5 12.5 F5 5.0 IT 3 3. 0

C 15 15.0
C 20 20.0
C 25 25.0
C 30 30.0
C 35 35.0
C 40 40.0
C 45 45.0
C 50 50.0
C 55 55.0
C 60 60.0

6.2.2 Selecting compressive trength Grade of Concrete

For reinforced concrete, the lowest grade should be C25 for

concrete made with norEal-weight aggregates.
For prestressed concrete, the appropriate grade of concrete should
be selected from the preferred grades. Grades C30 and C40 are the
minimum recommended for post-tensioning and pre-tensioning
respectively.
 OM NOTE NUMBER 004, AUGUST 1990

6.2.3 Selecting Tensile strength Grade of concrete

Though the standard BS 8110 : Structural Use of Concrete does ·not
directly specify the required tensile strength grade, the design
tensile stresses are specified in terms of characteristic
compressive strength as given by the expression (refer clause
6 . 2 . 1 . 3 above) namely,
Tensile strength = f sq.rt (fcu)
where the value of factor f depends upon the design
considerations , such as the serviceability and ultimate limit
states of the structural member. These values are specified in
codes of practices for the design of reinforced concrete and
prestressed concrete structures and members .
In prestressed concrete structural element, the BS 8110 classifies
prestressed concrete structure or element depending on the amount
of flexural tensile stresses allowed under service loads as
follows :
Class 1 no flexural tensile stresses.

Class 2 flexural tensile stresses but .no visible cracking .

Class 3 : flexural tensile stresses but with specified crack
widths in the range of 0.1 to 0 . 2 mm.
Considering the environmental conditions, Class 3 elements should
not be used.

7. DURABILITY OF STRUCTURAL CONCRETE

A durable concrete element is one that is designed and constructed

to protect embedded metal from corrosion and to perform
satisfactorily in the working environment for the life-time of the
structure.
One of the main characteristics influencing the durability of
concrete is its permeability to the ingress of water, oxygen,
carbon dioxide and other potentially deleterious substances.
Permeability is governed by the constituents and procedures used
in making the concrete. With normal weight aggregates a suitably
low permeability is achieved by having an adequate cement content,
a sufficiently low free water/ cement ratio, by ensuring complete
compaction of the concrete, and by sufficient hydration of the
cement through sound curing methods.
 OM NOTE NUMBER 004, AUGUST 1990

The factors influencing durability include

[a) the cover to embedded steel
[b J the type of cement
[c) the cement content and water cement ratio of the concrete
[d] the aggregate properties and deleterious contaminants
[e] workmanship, to obt a i n full compaction
[f] efficient curing, and of course
(g) the environment

7.1 corrosion of steel

Corrosion of steel in concrete is one of the major problems wi th
respect to the durability of concrete structures. The enormous
amount of money required for repair measures results in a strong
need to improve durability of new structures in the first instance
as well as guarantee the durability of existing structures after
repair or strengthening .

The protection of the steel in concrete against corrosion depends

upon the alkaline environment provided by an adequate thickness of
good quality concrete cover . It is now generally accepted that
steel in concrete is protected by the passiv ity induced by the
highly alkaline nature of the porewater . The pri mary task of the
concrete cover is to form a physical and chemical barrier against
the penetration of deleterious substances tending to destroy
passivation . The most important substances with respect to
depassivation of reinforcement are carbon dioxide causing
carbonation of the concrete and chlorides .

The steel in concrete is protected agai: s _ corrosion providing the

ph at the steel surface is not reduceu significantly fr:->m its
initial high values of 12 . 5 to 13.5 or the chloride content at the
steel surface does not exceed a ph-dependent critical value. The
above mentioned critical values at the steel surface may be
breached by penetration of substances from the outside namely
penetration of carbon dioxide (initiation by CO2) and penetration
of chloride (initiation by chloride).

7 . 1. 1 Salt contamination The protection provided by the

alkalinity is only effective if a certain chloride content is not
exceeded. This critical chloride content can be attained in two
different ways, ( a) by incorporating too high an amount of
chloride in the original mix - be it via the raw materials or the
additives - or (b) by penetration of chloride ions into the
concrete from the outside environment.
 OM NOTE NUMBER 004, AUGUST 1990

In the case of incorporation of chlorides in the original mix , one

cannot speak of an initiation period for corrosion, because the
reinforcement will be initially in the state of corrosion .
Whether corrosion will subsequently take place at a rate that is
harmful depends upon other factors.

7 . 1. 2 Carbonation The ph of the uncracked concrete may

change by ingress of acids from the environment . These acids are
mainly the CO2 in air and the S03 in water. Of these , CO2 in air
is of major importance.

Initially CO2 will not be able to penetrate deeply into the

concrete because it will be bound within the surface layer by
:basic reaction. The CO2 combining with calcium hydroxide released
by cement hydration process . As a result, ph changes from 13 - 14
to a near neutrality condition. However , as the outermost
portion of the concrete becomes carbonated the carbon dioxide will
ingress further and as soon as the ph at the reinforcement is near
neutrality the passivation of the steel will be lost .
Diffusion rate of carbon dioxide is low in water saturated pores
compared to the diffusion in air , while the diffusion of chlorides
the reverse is the case. Diffusion of Cl ions take place only in
water .
7. 1. 2. 1 Influence of cracks Evidently, carbonation can
penetrate much faster into the interior of concrete via cracks
than it does through uncracked concrete. As regards the pure
process of carbonation, the same basic interrelation as given for
uncracked concrete are valid for carbonation in the region of
cracks as well. In addition, the increasing huJDidity in the
interior of a concrete member as well as the crack itself causes a
lower permeability of concrete.

The water in the crack will evaporate more slowly than the water
at the concrete surface after re-wetting. Therefore, lower values
of the diffusion coefficient must be applied for carbonation
within cracks compared to those relevant for carbonation of
uncracked concrete.
Crack widths - Crack widths can be controlled by adequate
reinforcement and such controlled cracks normally range between
0 . 1mm to 0 . 3mm wide at the surface . The permissible crac k width
in exterior members exposed to particularly aggress i ve environment
is o.1smm.. The amount CO2 diffusing through the crack increases
with increasing crack widths. Consequently, carbonation rate
within the crack increases as well .
 OM NOTE NUMiER 004, AUGUST 1990

Permeability in the crack space - The permeability in the crack

space is dominantly influenced by the type and the amount of
deposits in the crack space. Deposits may originate from the
environment (dirt) as well as from the interior of the concrete
member itself (lime). In the latter case, the deposits may result
from effused and carbonated alkalis (so-called self-healing of
cracks) or from rust products of corroding reinforcing bars. The
density and consequently the permeability of the deposits is
strongly influenced by the environmental conditions (specially
changing humidity), the concrete mix and the concrete cover.
The effectivity of deposits with respect to a decreasing
permeability within the crack face also is highly dependent on
the type of loading. Dynamic loading causes change in crack
widths and consequently the densifying effect of deposits is
reduced, whereas this densifying effect may be of importance in
the case of static loads.

The decreased permeability caused by deposits as well as the

effusion process may result in a deep passivation of concrete
areas where the ph-values depressed by carbonation are increased
as a result of alkali effusion and decreased permeability .

7.1.3 Chlorides in the mix

The presence of chlorides, as contaminants in the original mix can
set up immediate corrosion depending upon its amount in relation
to the cement content in the mix. The severity and extent of
which will depend on chemical and physical interaction with the
hydrated cement matrix .
Chlorides react with calcium aluminates and, to a lesser extent,
calcium alumino ferrites in the cements to form chloroaluminate
and chloroferrite hydrates. Thus some binding of chloride to the
hydrated cement compounds occurs, the predominant reaction being
that of the formation of the chloroaluminate hydrate known as
Friedel's salt.

The stability of this, and other solid chloride binding hydrates

is, however, governed by their chemical equilibrium with chloride
dissolved in the aqueous phase contained in the pore liquid. Thus
to retain stability there will be continuing requirement for a
proportion of chloride to remain in the pore liquid. It is this
solution or "free" chloride which is available to promote
corrosion. The proportion of free chloride will be dependent on
several factors, including the total amount of chloride in the
concrete and the binding capacity of the cement and will be
modified by the source of chloride . Cement with low C3A contents
will be less able to bind chlorides than those with greater
amounts.
 OM ~OTE NUMBER 004, AUGUST 1990

The presence of excessive amount of sulphate in the concrete can

also influence the stability of the Friedel's salts. Research has
shown that when sulphate and chloride are incorporated within the
original concreting materials, the sulphate is likely to react
preferentially with C_3A forming calcium sulphoaluminate hydrates
and inhibiting the formation of the chloroaluminate hydrates .
This inhibition has the effect of increasing the free chloride
concentration in the pore liquid and so enhancing the probability
of propagation of chloride-induced corrosion.

The risk of chloride induced corrosion increases considerably

after carbonation of concrete , because initially bound chlorides
are released after carbonation and thus increase the amount of
free "corrosive" chlorides.
As a rule, all processes involved will be accelerated with
increasing temperature .
The general corrosion is likely to be controlled by the "time of
wetness" ( a term already accepted in atmospheric corrosion
studies) of the concrete. Recent work has shown that relative
humidities below 50 percent are unlikely to be sufficient to
stimulate corrosion of steel in carbonated and chlo ride-free
concrete, whereas approaching 100 percent RH produces high rates
of corrosion. Therefore temperature differential within R.C.
members in hot humid climates where air-conditioners are used may
be a factor inducing early corrosion.

7.2 Planning The most severe environmental conditions are

frequent wetting and drying cycles . Therefore , measures to keep
water away from the concrete surfaces by an adequate selection of
the structural form and structural detailing should be considered .
Another important requirement is to avoid weak points within the
structure that may lead to frequent wetting and drying e . g .
leaking joints, wide single cracks (>>. 0 . 5 mm), horizontal
surfaces which trap water, etc.

Design detailing of exposed thin and slender sections need special

attention from the point of view of protection of reinforcing
steel against corrosion . Horizontal projections, such as chezzas
could be avoided as they have been serious cause for corrosion .

7.3 Crack Widths While a clear influence of crack width on

the time of corrosion exists, for crack widths between 0.15 and
0. 3 mm and concrete covers between 2 and 4 cm, the time of
initiation may be decisively shorter than 2 years under
unfavourable circumstances .
 OM NOTE NUMBER 004, AUGUST 1990

Test result show, that after depassivat ion anodic dissolution

takes place in the region of the cracks, whereas the steel surface
besides the depassivated crack area, that means the steel surface
between the cracks acts as cathode. Because the cathodic process
is the dominating rate determining process, an influence of crack
widths on corrosion rate nearly does not exist.

If the concrete cover is of high quality, the corrosion damage

remains low, even in the region of cracks with widths upto 0.3mm.
In case of very aggressive environmental conditions additional
measures of protection are required in the region of cracks as
well as uncracked areas.

7. 4 cement Type If a sulphate resistant portland cement

with a low C3A content is used, it should be considered that both
the diffusion resistance and the binding capacity for chlorides
will be lower than for ordinary portland cement. As a consequence
chlorides penetrates much faster into this concrete than they do
into OPC-concrete with comparable composition and strength.

7.5 Water-cement Ratio The water/cement ratio is of

decisive influence on the permeability of the concrete and should
be decreased with increasing environmental aggressivity.
Depending on the environmental conditions water-cement ratios
between w / c = O . 5 and w/ c = o. 4 should be chosen for outdoor
conditions .

7.6 cement Content The amount of cement content varies, i n

general, between 250 and 450 kg/m3 of concrete. The binding
capacity of Cl ion will be proportional to the cement content.
Further, higher cement cQntents in the mix improves workability
leading to sufficiently low permeability. High cement content
produce more alkaline mixes.

7.7 Execution

7 . 7.1 concrete cover - The quality of the concrete cover can be

considered to be the most important structural parameter with
respect to reinforcement corrosion, whereas quality means
thickness and permeability. Depending on the environmental
conditions minimum values of the concrete cover between 30 to 75
mm can be considered to be the lower limits to ensure durable
passivation of steel in uncracked concrete.
 OM NOTE NUMBER 004, AUGUST 1990

7.7.2 Workability - In order to avoid badly compacted concrete,

especially in the outer layers, fluid concrete should be used,
especially in the case of closely spaced reinforcement or in the
case of a complicated structural form to be poured.

7. 7. 3 Curing - The potential quality of concrete cover with

respect to permeability can only be achieved if an adequate
moisture curing is guaranteed. The required duration of curing
depends on the concrete composition, the environment during and
immediately after curing and the environment during use . The
required duration of curing increases with:

decreasing velocity of hardening of cement

increasing cement content
decreasing environmental humidity during curing
increasing aggressivity of environment during use .

Depending on all the parameters mentioned, the required duration

of moisture curing may extend beyond 14 days or more. Lax curing
will significantly reduce the life of concrete. Chloride
diffusion concentrations typically doubles in an eight month
period because of difference in curing technique.
Curing should begin immediately after placement of concrete . Fog
spray of water can be dosed over green concrete and covered with
plastic sheets. Care of the young concrete during the first six
hours is very critical to the future service performance .
The curing could be included as a separate item in the schedule of
quantities and paid for so that effective curing is ensured.

7.8 Critical chloride content

The decisive parameter with regard to corrosion of steel in

concrete is the percentage of free-chlorides (corrosive ions) in
the porewater, related to the percentage of inhibitive ions,
especially (OH) ions.
For reinforced concrete, prestressed concrete and heat-cured
concrete containing embedded metal, the limits of chloride
contents as shown in Table 4 should not be exceeded for minimizing
the incipient danger of corrosion .
 DM NOTE NUMBER 004, AUGUST 1990

Table 4 - Maximum Limits of Chloride and Sulphate content as a

Percent•ge by weight of c.e ment in the Mix

------------------------------------------------------------------
Type of concrete Chlorides Sulphates
as Cl as S03
-------------------------------------------~---------------------~
[a] For reinforced concrete
if made with OPC / MSRPC 0 . 30
if made with SRPC 0.06
3.70
[b] Prestressed concrete and 0.10
Heat-cured reinforced concrete
(c] For mass concrete in all cases
if made with OPC / MSRPC 0.60
if made with SRPC 0.12

------------------------------------------------------------ .-----
Note : The OPC and MSRPC cements can also contain chlorides, the·
relevant standard BS 12 allows upto O .1% Cl. Therefore any
chloride .content present in the cement has to be taken into
account while computing total Cl in the mix. In case the cement
contains the maximum limit of 0.1% Cl, then the aggregates, water
and admixtures used for prestressed concrete or heat cured
reinforced concrete should be absolutely free of chlorides

7.9 Additional measures

Extremely harsh aggressive environmental conditions, salt

contaminations in the mix, poor planning and execution has often
contributed to the development of corrosion damage and cannot be
totally ruled out. These aspects have lead to an increased
interest in providing corrosion protection to the reinforcement
additional to that provided by the concrete cover. In particular
efforts have been directed towards developments in four main
areas, the use of pore blockers, and corrosion inhibitors, the use
of metallic and organic coatings, the application of corrosion
resistant alloys for concrete reinforcement and cathodic
protection.
 DM NOTE NUMBER 004, AUGUST 1990

8. ENVIRONMENT

Significant deterioration of reinforced concrete is likely to

occur in marine tidal and splash zones and in aerated sabkha
environments within very short periods. overall, the most
aggressive environments, based upon salt ingress are the sabkha
zones followed by marine splash and marine tidal zones, marine
submerged zones in turn . If saturation effects are considered,
the submerged sabkha and marine location will become potentially
the least aggressive as far as reinforced concrete is concerned
because of oxygen deficiency.

It would appear that airborne salt attack occurs in UAE concretes.

It therefore should not be assumed that external superstructure
is immune to long-term salt ingress; surface sealers should be
consider~d as standard protection in new structures.
Sulphate ingress in the most aggressive sabkha conditions would be
minimal, indeed i t is greater in marine splash and tidal
conditions. It is suggested that conventional OPC concrete is
suitable for permanently submerged situations because of oxygen
deficiency. In sabkha capillary rise locations (typical Dubai
foundations) tanked, air-entrained type (II) or air-entrained OPC
concrete are perhaps best alternatives.
Air-entrained concrete appeared to retard the early diffusion of
chlorid ions . The mechanism responsible is believed to be
associated with the creation of a cellular network of
discontinuous voids which destroy capillary structure and reduced
,bleeding. The continuous capillary passages which assist ingress
of deleterious elements in conventional concrete are thus reduced .
It is suggested that OPC or Type (II) air-entrained concrete with
a water / cement ratio of 0.42 or less, should be used in the
aerated marine environment in conjunction with a surface sealer/
barrier as appropriate. Table numbers 5 and 6, give requirements
for ensuring durability for different exposure conditions.
 DM NOTE NUMBER 004, AUGUST 1990

TABLE 5 - CRITERIA FOR REINFORCED CONCRETE FOR DURABILITY

(Nominal Maximum Size of Aggregate 20mm)

Exposure Conditions Hin. Cement Content Concrete Grade Max. Free W/C Ratio Type of Cement Nin. Cover
kg/m3 <mn>
-------·----------------------------------------------~--------------·--------------------------------------------------
[ 1J Super-structure,
inland with no risk 330 C 25 0.52 OPC, BS 12 30
of windborne salts ASTM TYPE 1

[2] Super· st-ructure in

sabkha area or near 350 C 30 0. 5 CFOPC, BS 12 40
co.ast e1<posed to ASTM TYPE 2
windborne salts

[3] Concrete submerged

in sea water 370 C 35 0.48 CFOPC, BS 12 45
ASTM TYPE 2

[4] Marine structures

splash zone and 370 C 40 0.42 CFOPC, BS 12 60 to 75
inter·t-idal zone ASTM TYPE 2
(aerated)
[5] Substructures in
capillary r·ise zone, 400 C 45 0.42 OPC, CFOPC, BS 12 75 to 100
discharge of waste, ASTM TYPE 1/V
washing down, etc. SRPC BS 4027
(Tanking)

TABLE 6 DURABILITY OF UN-REINFORCED CONCRETE

(Nominal size of aggregate 20mm)

Exposure Conditions Min. Cement Content Lowest Concrete Grade Max. Free W/C Ratio
kg/m3

[11 Marine concrete in splash,

fluctuating water, and 300 C 30 0.50
capillary rise zones

[21 All other constructions 275 C 25 0.55

 ADVISORY NOTE
NUMBER: 005 JULY, 1990

---------------------------~-----
---------------------------------
READY MIXED CONCRETE
---------------------------------
 ADVISORY NOTE
ON NOTE NUMBER 005
READY MIXED CONCRETE JULY 1990

=======- ,= ======================·= ==-========-------------·- ·- - -- - - - - - · - - -

C O N T E N T S
PAGE
1. INTRODUCTION .89
2. SPECIFICATION 90
3. BASIS OF PURCHASE 90
4. SPECIFICATION OF CONCRETE 90
5. MATERIALS 92
6. ORDERING INFORMATION 95
7. WORKABILITY 96
8. PUMPED CONCRETE 96
9. MEASURING MATERIALS - BATCHING 97
10. MIXING CONCRETE 99
1-i. DELIVERY AND DELIVERY TIME 100
12. HOT WEATHER CONCRETING 101
13. BATCH TICKET INFORMATION 102
14. QUALITY CONTROL 102
15. QUALITY ASSURANCE 106

TABLES

1. MAXIMUM LIMITS OF CHLORIDE AND SULPHATE

CONTENT AS A PERCENTAGE BY WEIGHT OF
CEMENT IN THE MIX 92
2. ACCEPTANCE CRITERIA FOR MIXING WATER 93
3. CHEMICAL LIMITATIONS FOR MIXING WATER 93
4. CHEMICAL LIMITATIONS FOR WASH WATER 94
5. BATCHING ACCURACY REQUIREMENTS 98
6. SAMPLING RATES 103

-------- ---- ------------ ------------------------- --------------- ----------

ADVISORY NOTE DUBAi MUNICIPALITY
ON NOTE NUMBER 005,
READY-Ml:XED CONCRETE JULY 1990-

------------------------------------------------------------------
1. INTRODUCTION

The application techniques of concrete production and placement

has become more sophisticated . One of the improvements was the
establishment ready-mix industry where uniform concrete is
produced industrially in a well-controlled manner and delivered
ready for placing . This type of concrete offers numerous
advantageous in comparison with the conventional method of
manufacture . In the past 10 years there has been a tremendous
increase in the use of ready-mixed concrete in the U. A. E . The
industry is well established and is likely to develop further.

Ready-mixed concrete is particularly useful on the congested sites

where little space for the mixing plants and for extensive
aggregate stockpiles is available, but perhaps the greatest single
advantage of re~dy-mixed concrete is that it may be made under
better conditions of control than are normally possible on
construction sites . A great deal of uncertainty and variability
associated with the production of concrete on many a site is
removed .

Nowadays a significant proportion of the concrete placed is ready­

mixed. The concrete supplied can be for all types of work, from
lean concrete in roads to high strength concrete for structures.
On large sites, even though the contractor elects to site batch,
the operations may .be similar to a typical ready-mixed-concrete
plant operation .

The use of ready-mixed concrete demands efficient organisation of

the day-to-day concrete requirements in the works, and it calls
for good coordination between the contractor and supplier at all
stages from ordering to delivery of the concrete . The placing and
compaction remain, of course, the responsibility of the personnel
on the site . Because of the large batches of concrete that have
to be handled, speed in conveying the fresh concrete into place as
quickly as possible when it arrives on site is crucial, time is
very important especially in summer in order to minimize the
adverse effect of the increased slump loss at elevated
temperatures.
 DM NOTE NUMBER 005, JULY 1990

2. SPECIFICATI ON

ASTM C94 and BS 5328 are specifications for the material, freshly­
mixed concrete . They address the separate and joint
responsibilities of the various parties in a typical job - the
client, specifying agency, contractor and ready-mixed concrete
producer. Included are the basic elements of both prescription
and performance specifications . Appropriate test methods are
defined.

The Engineer considering the possibility of using ready-mixed

co~crete should satisfy himself that the organisation of the
plant, the control of the materials , the quality of the output and
the capability of the supplier to meet the construction schedule
satisfy the requirements of the project specifications .

The responsibility for acceptable performance of concrete in place

is divided inevitably between the concrete producer who must
deliver acceptable material, the contractor who must place it, and
the specifier who must structure appropriate specifications and
plans. Since strength test results are weighted heavily in the
acceptance of the material and since strength is not usually
determined until the concrete has been in the structure for 28
days , it is considered prudent to regulate further the procedures
used to proportion, batch, mix and deliver the concrete.

3• BASIS OF PURCHASE

Ready-mixed concrete is concrete manufactured for delivery to a

purchaser in plastic and unhardened state . The basis of purchase
is by volume of freshly mixed concrete as discharged from the
mixer, the unit of measure being cubic meter. It should be
understood that the volume of hardened concrete may be less than
expected due to waste and spillage, over excavation , spreading
forms, some loss of entrained air , or settlement of wet mixes,
none of which are the responsibility of the producer.

4. SPECIFICATION OF CONCRETE

The concrete is to have certain specified minimum properties,

(Refer DH ADVISORY NOTE 004) and that it is to be produced as
economically as possible . The basis for determining the
proportions of the concrete to produce the required quality both
in the fresh and in the hardened state can be either prescribed or
designed.
 OM NOTE NUMBER 005, JULY 1990

4. 1 Prescri:bed. Mix - is a mix for which the purchaser

specifies the proportions of the constituents and is responsible
for ensuring that the proportions prescribed will produce a
concrete with the performance he requires such as the requirements
for the workability, placeability, durability, surface texture and
density, in addition to those for structural design.

Prescribed mixes may be used only for small work, when the 28-day
strength of concrete does not exceed 20 N/mm2 and the cements use
are traditional portlands. owing to the variability of the mix
ingredients, concrete having fixed cement- aggregate proportions,
and a given workability vary widely in strength. No control
testing is necessary, reliance being made on the weight of the
ingredients . However, to ensure that the mix to be prescribed
results in the strength required, reference may be made to the
mixes prescribed in the standard BS 5328 by quantities of dry
ingredients per 100 kg of cement and by slump for grades of
concrete in the range of 7 to 30. Though these mix proportions
are adjustable due to differences in the characteristics of local
aggregate resources, e.g. grading, they do provide some guidance.

4. 2 Design Mix - is a mix for which the purchaser is

responsible for specifying the required performance and producer
responsible for selecting the mix proportions to produce the
desired performance i.e. the concrete mix has to be designed to
meet the performance requirements. It is therefore commonly
referred to as Designed Mix in order that the implication of the
meaning is broad based.
The performance characteristics of concrete in terms of its grade
and durability result in the specification of a strength, minimum
cement content and/ or water cement ratio.
There has been a change away from the prescribed to the
performance specifications and in fact virtually the norm nowadays
in large and important works.

4.3 control of Chlorides and sulphates

The acceptable levels of equivalent acid soluble chlorides and
sulphates as specified for aggregates and water are indicative and
are subject to over-riding limits for the mixes as given in
Table 1 below.
 DM ~OTE NUMBER 005, JULY 1990

Table 1 - Maximum Limits of Chloride a:r:id Sulphate Content as a

Percentage by Weight of cement in the Mix

------------------------------------------------------------------
Type of concrete Chlorides sulphates
as Cl as S03
------------------------------------------------------------------
[a] For reinforced concrete
if made with OPC / MSRPC 0.30
if made with SRPC 0.06
3.70
[b] For mass concrete in all cases
if made with OPC / MSRPC 0 . 60
if made with SRPC 0.12

The ready mixed concrete producer should test the constituents of

the concrete to establish these contents for compliance and
certify that the total chlorides and sulphates in the mixes he
produce are within permissible limits irrespective of whether the
purchaser specifies the control of these deleterious salts in the
concretes he orders.
The permissible levels of chlorides and sulphates quoted in Table
1 should not be considered as mean values for the whole of the
works, but applies to each batch of concrete delivered .

5• MATERIALS

5.1 Cement - Cement should conform to specifications BS 12,

BS 4027, ASTM 150 or DM ADVISORY NOTE NUMBER 002., as specified.
The purchaser should specify the type or types required. Rapid
hardening cement should not be used. Unless otherwise specified,
low alkali cements are always to be used .

Blended cements such as portland cement with ground granulated

blast furnace slag, pulverised fuel ash and similar pozzolonas may
be allowed after the cements and pozzolonas as such are tested
fully by an independent authority for conformance to specified
standards. Fly ash should not be used with SRPC cements.

5. 2 Aggregates should conform to specifications BS 882,

ASTM C33 or OM ADVISORY NOTE NUMBER 001, as specified.
 DH NOTE NUMBER 005, JULY 1990

5.3 water
5. 3 .1 The mixing water should be clear, apparently clean and
free from matter harmful to concrete in its fresh or hardened
state. Potable water can be used. Water of questionable quality
should comply with the physical tests of Table 2 and chemical
limitations listed in Table 3 .

The temperature of water for concrete should not be less than 5

degree celsius nor more 25 degree celsius. Water may be cooled to
not less than 5 degree celsius by the gradual addition of ice but
on mixing, no ice particles should be present in the mix. Ice
should be the product of frozen water which complies with
acceptance criteria of Tables 2 and 3.
5. 3. 2 Washed water from mixer washout operations may be used
provided tests of wash water comply with the criteria limits shown
in Table 4 and when the purchaser approves of its use. Wash water
should be tested at weekly intervals or as specified by the
purchaser.
Table 2 - Acceptance criteria For Mixing Water
Limits ASTM Test:

compressive strength, min.1fs control at 7 days 90 C 109

Setting time, deviation from control, h:min . from 1:00 early

to 1:30 later C 191

Table 3 - Chemical Limitations for Mixing water

Maximum cooceutratioo, Limit, ppm ASTM Test Method

1. Chloride as Cl ,250 D 512

2. Sulphates as S03 350 D 516

3. Alkali carbonates and bicarbonates 500 D 513

4. Total dissolved ions, including, 2000 D 1888

1, 2, 3 above
'
 OM NOTE NUMBER 005, JULY 199.0

Table 4 - Chemical Limitations for wash water

-----------------------------------------------------------------------
Maximum concentration Limits, ppm ASTM Test Method
-----------------------------------------------------------------------
1. Chloride as Cl 250 D 512

2. Sulphate as S03 1500 D 516

3. Alkalis as ( Na20 + 0 . 658 K20) 600 C 114

4. Total solids 50,000 AASHTO T26, D1888

-----------------------------~----------------------------------------
NOTE : The concent.r ation of Cl and 803 in the mixing water, wash
water, aggregates and other sources should not exceed the
allowable limits expressed as percentage of cement c.o ntent of the
concrete mix as specified in Table 1.

5.4 Admixtures - admixtures should conform to appropriate ASTM

or BS specifications. Further , it should be proved beyond doubt
they do not harm the setting strength and durability of concrete .
Chloride and chloride based admixtures should not be used.

In any given instance the required dosages will vary . Therefore ,

a range of dosages should be allowed which will permit obtaining
the desired effect.

Where recycled wash water is used, attention should be given to

effects on the dosage rate and batching sequence of admixtures.

While allowing the use of admixtures, account should• be taken of

their effects on design requirements and that there are
satisfactory data on their stability and assurance of quality
control. Where necessary, records concerning the details and
performance of such admixtures should be maintained.
 DM NOTE NUMBER 005, JULY 1990

6. O~DERING INFORMATION

The purchaser should specify the following:

Designated size or sizes of coarse aggregates.

Workability of concrete and any particular handling
characteristics it may need to have e.g. pumpability, conveying
or skipping.
Recommended air content for air-entrained concrete at the point
of discharge.
Whether the mix proportions are prescribed or to be
designed.

6 .1 When the purchaser prescribes the proportions of the

concrete mix, he should also specify the following:
Dry weight of aggregates (coarse & fine) and cement.
Water-Cement ratio, nominal.
If admixtures are required, the type, name and dosage.
Cement type.

6.2 When the purchaser requires the manufacturer to design the

mix, he should also specify the following:

Required characteristic strength of concrete.

cement type, minimum cement content, kg/m3.
Maximum free water / cement ratio allowed and limitati on on
minimum water/ cement ratio, if any.
- If admixtures are required, the type, name and dosage to be
used.

6.3 The concrete producer, prior to the actual delivery of the

concrete, furnish a statement to the purchaser giving

The sources, specific gravities & water absorption of aggregate

used.
Dry weights of aggregates, cement and water per cubic meter of
concrete that will be used in the manufacture of concrete
ordered.
Density, kg/m3 of compacted freshly mixed concrete.
Particulars of admixtures, if any, used.
In the case of mixes prescribed by the purchaser, the strength
of concrete achieved.
In the case of desig~ed mixed concrete, the manufacturer should
furnish evidence to the purchaser that the materials to be used
and proportions selected will produce concrete of the quality
specified.
 OM NOTE NUMBER 005, JULY 1990

Whatever be the strengths attained, the quantity of cement used

should not be less than the minimum specified and that the
specified maximum water cement ratio is not exceeded.

The ready-mixed concrete supplier should control the mixes that

will meet all the specified requirements. It is implicit that the
mix should be homogeneous and should not segregate within the
tolerance ranges of the specified workability.

7. WORKABILITY

The degree of workability may be assessed at the point of delivery

by slump test, as per BS 1881 Part 102. The following
tolerances apply for the slumps;

Nominal Slumps Tolerance

50mm and less +/- 10mm

50mm. to 100 +/- 20mm
More than 100mm +/- 30mm

Concrete should be available within the permissible range of slump

for a period of 30 minutes. The first and last 1/4 m3 discharged
are exempt from this requirement. If the user is unprepared for
discharge of concrete from the vehicle, the purchaser is
responsible.

8. PUMPED CONCRETE

A significant portion of ready-mixed concrete is nowadays pumped.

In order to be able to be pumped, the mix must satisfy certain
requirements. Broadly speaking, the mix must not be harsh or
sticky, too dry or too wet, i.e. its consistency is critical.
Unsatisfactory concretes cannot be pumped . The mix has to be
cohesive, should not bleed, and be unsegregated. A slump of
between 40 and 100mm, or a compacting factor of approximately 0.90
to 0. 95, or a Vebe time of 3 to 5 seconds is generally
recommended. The coarse aggregate content should be high, but the
grading should be such that there is a low void content. For
practical mixes with maximum aggregate size of 20mm, the optimum
fine aggregate content lies between 40 and 45 percent, and the
material finer than 300 micron should represent 15 to 30 percent
of the weight of fine aggregate. It has been shown that
volumetric cement content has to be at least equal to the void
content of the aggregate but very fine material other than cement
such as finer fractions of sand or a suitable additive, silica
fume or fly ash, can· be included with the l atter.
 DM NOTE NUMBER 005, JULY 1990

9. MEASURING MATERIALS - BATCHING

The various specification requirements for batching systems are

designed to accomplish one or more objectives . The primary
concern is the quality of the product. Important secondary
objectives are to see that the customer also obtains the quantity
of the concrete ordered and the quantities of cement and
admixtures where those are a part of the purchase agreement.
Specification for most scales or weigh batches contain two kinds
of tolerances - scale accuracy and batching accuracy tolerances.
The scale accuracy tolerances are applicable during calibration
and are designed to ensure that accurate equipment is used .
Batching accuracy tolerances are much more liberal and are
intended to govern the operating conditions . The batching
tolerances generally apply to the indication of the primary or
master device. Somewhat more liberal tolerances are permitted for
secondary devices such as slave dials or recorders.
9.1 Measurement of Materia1s
Materials such as cement and aggregates are weighed . Water is
sometimes weighed on a scale but most of the time it is measured
by bulk volume. Liquid admixtures are measured by volume in a
variety of meters and other positive displacement devices and
calibrated containers.

Some specification requires individual batchers for cement,

pozzolonas, and each aggregate size. However, weighing cement and
pozzolona can be permitted if pozzolona is weighed last, but not
with aggregates .. Aggregates may be weighed cumulatively or
individually.

Batched materials should be measured out within the following

tolerances and discharged into the mixer {Table 5).
 DM NOTE NUMBER 005, JULY 1990

Table 5 - Batching Accuracy Requirements

------------------------------------------------------------------
Material Percent
------------------------------------------------------------------
1. Cement
above 30% of scale capacity +/- 1
below 30% of scale capacity -0, +4
2. Aggregates
[a] individual batchers +/- 2
lb] cumulative batchers, % of required cumulative weight
above 30% of scale capacity +/- 1
below 30% of scale capacity +/- 3
3. Water
(a) added by weight or volume +/- 1
[b] total mixing water required in +/- 3
the batch including water in
aggregates, ice, and water batehed
from plant & mixers.

4. Admixtures
by volume or by weight +/- 3

------------------------------------------------------------------
9.2 Batching systems and Controls
The batching systems are generally of three types and are defined
as follows :

A manual control batcher is one that is actuated manually with

the accuracy dependent on the operator's visual observation.

A semi-automatic batcher is one that, when actuated, starts the

weighing operations and stops automatically when the required
weight has been reached . An interlock prevents batcher
discharge until the required material is within tolerances.

An automat ic batcher starts and stops automatically and

includes interlocks to (a) prevent charging until the scale
returns to zero; (b) prevent charging if the discharge gate
is open; (c) prevent discharge if the charging gate is open;
and (d) prevent discharge until the material is within
tolerances.
Batching systems consist of required combinations of these various
types of batches and the interlocks. Virtually all automatic
batching systems include provisions to switch over to manual
control.
 OM NOTE NUMBER 005, JULY 1990

10. MIXING CONCRETE

10.1 Mixing

There are two principal categories of ready-mixed concrete.

In the first, the mixing is done at a central plant and the mixed
concrete is then transported, usually in an agitator truck. In
transit the drum rotating slowly at about 1 or 2 revolution per
minute so as to prevent segregation and undue stiffening of the
mix. When the truck arrives on site, the drum should always be
speeded up to about 10 to 15 revolutions per minute for at least 2
minutes to make sure that the concrete is thoroughly mixed and
uniform before discharge . Such concrete is known as central-mixed
concrete.

In the second category is transit mixed or tr1,1ck-mixed concrete .

Here the mc1terials are batched dry at a central plant but are
mixed in a mixer truck either in transit to the site or
immediately prior to the concrete being discharged. The drum of
the mixer should be ·rotated for 100 revolutions after the water
has been added. As mixer drum usually rotates at about 10 to 15
revolutions per minute at the fast speed the mixing time required
is about 7 to 10 minutes . Due to dry mixing, the .m ixer blades
wear out rapidly. The blades should therefore be inspected
regularly to ensure conformity with original setting.

Transit mi>dng permits a longer haul and is less vulnerable in

case of delay, but the capacity of a truck used as a mixer is only
about three-quarters of the same truck used solely to agitate pre­
mixed dry concrete . Sometimes, the concrete is partially mixed at
a central plant in order to increase the capacity of the agitator
truck. The mixing is completed enroute. Such concrete is known
as shrink-mixed concrete . Truck mixers usually have a capacity of
6m3 but 7.5rn3 truck also exists. In both cases, water is added
only minutes before reaching the point of discharge so that the
initial setting time is not exceeded.

A truck mixer can discharge concrete at about 0.5m3 per minute, so

that a fully loaded 5rn3 truc k discharging continuously takes only
about 10 minutes. Although it may not always be possible to
discharge at thi s rate, it is advantageous for the concrete to be
discharged as quickly as possible especially when concreting
during high ambient temperature conditions .

It should be explained that agitating differs from mixing solely

by speed of rotation of the mixer . It may be noted that the speed
of mixing affects the rate of stiffening while the total number of
revolutions controls the uniformity of mixing. And overriding
limit of 300 revolutions in toto is laid down in ASTM C94
specification. This is to limit grinding of soft aggregates and
other undesirable effects on concrete in hot weather .
 OH NOTE NUMBER 005, JULY 1990

Of the three systems of mixing, central mixing is to be preferred.

10.2 Uniformity of Mixing

In any mixer, it is essential that sufficient interchange of

materials between different parts of the chamber takes place, so
that uniform concrete is produced. The efficiency of the mixer
can be measured by the variability of the mix discharged into a
number of receptacles without interrupting the flow of concrete.
For instance, in Belgium the mix is discharged in eight parts and
these are compared for homogeneity. A rather rigid test of
ASTM standard C94 lays down the samples of concrete should be
taken from about 1/6 and 5/6 points of a batch, and the
differences in the properties of the two samples should not
exceed any of the following:
Density of concrete calculated to an 16 kg/rn3
air-free basis
Air content, volume% of concrete 1 percent

Slump 25mm when the average is

100mm, and 40mm when the
average is 100 to 150mm.
Percentage aggregate 6%
retained on 5mm sieve
Density of air-free mortar 1.6%

compressive strength, 7.5%

average 7-day strength

11. DELIVERY AND DELIVERY TIME

The main problem in the production of ready-mixed concrete is

maintaining the workability of the mix upto the time of placing.
Concrete stiffens with time and handling ready-mixed concrete
often takes quite a long while. In the case of transit mixing,
water need not be added till nearer the commencement of mixing,
but the time during which the cement and moist aggregate are
allowed to remain in contact should be limited to about 90 minutes
although an amendment to BS 5328 allows two hours.
 OM NOTE NUMBER 005, JULY 1990

Unless, however, the initial workability is high, the stiffening

caused by prolonged agitation result in a concrete of very low
workability especially in hot weather, when a high loss of water
by evaporation takes place in addition to the loss of free water
by hydration of cement. For this reason, concrete is sometimes
re-tempered by the addition of water immediately before discharge;
the workability is thus restored but it must be realized that
resultant compressive strength will be affected and therefore
retempering should not be permitted.

However , the argument of slump control versus water/cement ratio

contJ:"ol continues . The solution lies in use of the statistical
approach to water/cement ratio specifications which recognizes
inherent v.ariability and which encourages use of average water /
cement ra.tio well below the intended maximum.'
The producer is responsible for the ordered slump for 30 minutes
after discharge of the concrete at the job site. Use of super­
plasticizer to re-temper ready-mixed concrete on site instead of
adding re-tempering water is recommended, subject to plasticizer
being acceptaple and proven to be harmless to concrete .

12 . HOT WEATHER CONCRETING

The producer should deliver the ready-mixed concrete during hot

weather at concrete temperatures as low as practicable. The
temperature of concrete at the point and the time of delivery
should be maintained at 25 degree celsius in peak summer to ensure
that the temperature of the placed concrete does not exceed 35
degree celsius. To assist in keeping the temperature of concrete
low it may be necessary to :
[1 ] Protect aggregate stockpiles from direct sun by shading .

[2] Use chilled water for mixing. Use of flaked ice to replace
part of the mixing water is rec ommended . Truck mixers
should be equipped with water tanks to supply chilled
mixing water as may be required for truck-mixed concrete.

[3] Paint truck mixer drums white and insulate.

[4] Reduce hauling distance .
 DM NOTE NUMBER 005, JULY 1990

13. BATCH TICKET INFORMATION

The manufacturer of the concrete should furnish to the purchaser

with each batch of concrete before unloading at the site, a
delivery ticket on which is printed, stamped or written,
information concerning said concrete as follows:
(1] Name of ready-mix batch plant . .
(2] Serial number of ticket.
[3] Date.
(4] Truck number.
(5] Name of purchaser.
(6] Specific designation of the job .
[7] Specific class or designation ef the concrete.
(8] Amount of concrete in cubic meters.
(9) Time loaded or of first mixing of cement and aggregate.
[10] Time when water is added to the mix for the first time .
[11] Reading of revolution counter at the first addition of
water.
(12] Type and brand, and amount of cement .
(13] Type and brand, and amount of admixtures.
[14] Information necessary to calculate the total mixing water
added by the producer. Total mixing water includes free
water on the aggregates, water and ice batched at the
plant, and water added by the truck operator from the
mixer tank .
(15] Maximum size of aggregate .
(16] Weights of fine and coarse aggregate .
[17] Ingredients certified as being previously approved.
(18] Certifying that Chlorides and Sulphates are within
specified limits .
(19] Signature or initials of ready-mix representative .
The representative of the · purchaser should ascertain and record
the delivery ticket number for the concrete and the exact location
in the work at which each load represented by strength test is
deposited.

14 . QUALITY CONTROL

The manufacturer should afford all reasonable access for making

necessary checks of the production facilities and for securing
necessary samples to determine if the concrete is being produced
in accordance with the specifications .

The contractor should afford all reasonable access and assistance

for the procurement of samples of fresh concrete at the time of
placement to determine conformance of it to the specification.
 DM NOTE NUMBER 005, JULY 1990

Slump, air content, and temperature test should be made at the

time of placement at the option of the supervisor as often as is
nece.ssary for control checks. In addition, these tests should be
made when specified and always when strength specimens are made.

The purchaser is responsible for deciding and informing the

producer of the regime of sampling and testing which the purchaser
will adopt. However, tests should generally be made with a
frequency of not less than one test for each 10, 50, or 100 metre
cube concrete depending upon the type of structure as shown in
Table 6. Each test should be made from a separate batch. On each
day concrete is delivered, at least one strength test should be
made for each class of concrete . rn any case, the minimum number
of test specimens shall be six, three for 7-day test and three for
28-day test.

The producer should designate and maintain records for the

concretes produced with codes numbers to enable the identification
of class of concrete, name of the job, name of the client, etc ••••

The producer should supply calibration certificates for the

testing machines and scales of the measuring equipments .
Sampling and testing of constituents materials, curing and testing
of concrete, fresh and hardened, shoulq. be carried out in
accordance v1ith BS 1881 unless stated otherwise.

Table 6 - Sampling Rates

rype of structure Sampling to Represent a Volume of m3

1. Critical structures
e.g. masts, cantilevers, columns 10

2. Intermediate structures
e.g. beams, slabs, bridge decks 50

3. Heavy concrete construction

e.g. breakwaters, solid rafts 100
 OM NOTE NUMBER 005, JULY 1990

14.1 Analysis o f Fresh Concrete

In considering the ingredients of a concrete mix, one has to check

whether actual proportions correspond to those specified. In
practice, mistakes, errors, and even deliberate actions can lead
to incorrect proportions. Therefore it is necessary to determine
the composition of the concrete at an early stage; the two values
of greatest interest are the cement content and water / cement
ratio. The standardized test is prescribed in BS 1881 and the
test has to be commenced virtually as soon as the concrete has
been discharged from the mixture because loss of water can occur.

Compliance is assumed if the results of the analysis tests on

fresh concrete show that

- Cement content is not less than 95% of the specified minimum or

more than 110% of the specified maximum .
Free-water/ cement ratio should not be more than 110% of the
specified value.

Compliance of cement content can also be assessed by observation

of the batching or from autographic records, in which case it
should not be less than 95% of the specified minimum or more than
105% of the specified maxi mum.

As regards water / cement ratio, the compliance can also be

assessed using the workability test results provided satisfactory
evidence is available of the relationship between free-water /
cement ratio and workability for the materials used.

14.2 Air-content of concrete

The percentage air-content determined from individual samples
taken at the point of placing the concrete should be with+/- 1 . 5
of required value.

14.3 Temperature of Fresh Concrete

The t emperature of the concrete at the time of delivery should not

be more than the specified maximum plus 2 degree celsius, beyond
which concrete should not be allowed for pouring unless
sufficiently cooled and the initial setting time is not exceeded.
 DM NOTE ijUMBER 005, JULY 1990

14 . 4 Density of Fully Compacted Concrete

The density, kg/m3, of fully compacted concrete should be+/- St

of the value established at the mix design stage .

14.5 strength Testing

For the assessment of strength, the sample should be taken at the
point of discharge, it should be representative of the whole batch
with increments being taken from different parts of the batch .
Two test specimens should be prepared and cured for 28-days under
specified conditions either normal or any other regime agreed to
between the producer and purchaser.
On completion o-f curing, the specimens tested, the average of two
results is taken as the test result.

Additional tests maybe made at other ages to obtain information

for determining form removal time or when structure may be put in
service.
Compliance with the specified characteristics strength is assumed
if the conditions given in both (a) and (b) are met:
(a) the average strength determined from any group of four
consecutive test results exceeds the specified
characteristic strength by

3 N/mm2 for concretes of grade c20 and above,

2 N/mm2 for concretes of grade C7.5 to C15.

(b) the strength determined from any individual test result is

not less than the specified characteristic strength minus .

3 N/mm2 for concretes of grade c20 and above,

2 N/rnm2 for concretes of grade C7 . 5 to C15.

Quantity of concrete represented by strength test results.

The quantity of concrete represented by any group of four

consecutive test results includes the batches from which the first
and last samples were taken together with all intervening batches .
When a test result fails to comply with (b) above, then only the
particular batch from which the sample was taken would be at risk.
 DM NOTE NUMBER 005, JULY 1990

14.6 Non-compliance

The action to be taken in respect of the concrete which is

represented by the test results that failed to meet the
requirements is to be determined by the purchaser. The
consequences vary greatly, This may range from qualified
acceptance to rejection and removal in the most severe cases.
In determining the action to be taken, the purchaser should have
due regard to the technical consequences of the kind and degree of
non-compliance, and to the economic consequences of alternative
remedial measures to ensure the integrity of any work in which the
concrete has been placed.

Before determining the action to be taken, it is necessary to

establish the validity of the test results, the mix proportions
actually used and its effect on durability and the possible
influence of any reduction in concrete quality and on strength.
The purchaser should carry out tests, if need be on hardened
concrete. These may include non-destructive methods, proving load
tests and/ or taking of core samples.
The producer and purchaser confer in this connection and if they
cannot agree, the matter can be arbitrated upon.

15. QUALITY ASSURANCE

Presently, there is no effective supervision / surveillance of

ready-mix concrete plants, operations and ability to supply
consistently the quality of the concrete grades ordered.
Acceptance is generally made taking into account the personal
integrity of the person and that of his company. There is an
urgent need of a scheme to assist and certify the plants,
The Quality Scheme for Ready-Mixed Concrete (QSRMC) operation in
United Kingdo~ has established to provide effective Quality
Assurance Standards for ready-mix concrete. Under this Scheme
technical regulations have been designed which contain two
principal requirements
- The establishment of a quality management system, and

- The achievement of product conformity through the application of

detailed technical procedures viz design, control and production
process.
 OM NOTE NUMBER 005, JULY 1990

The problem of obtaining accurate testing and of deciding what to

do when test result fail to conform to specifications, continue
to create problems- for specifiers, contractors and producers .
Increasingly sophisticated automation and recording devices will
be more reliable and effic ient and reduce batching errors to the
practical minimum. Developments in the specifications, quality
control , accelerated strength testing have great potential for
reducing and quantifying the risks assumed by producers,
contractors and clients alike . With a well conceived scheme /
programme, improved testing and improved quality control of
constituent material , the incidence of defective concrete could be
reduced .

One additional change will be necessary if the system is to

evolve . That is, the prescriptive requirements must be reduced or
eliminated and the concrete produce r must be able to change
materials and proportions rapidly in response to varying
materials, weather, job conditions, and acceptance testing
procedures used for.
 ADVISORY NOTE
NUMBER: 006 OCTOBER, 1990

=--------------------------------
-------------------------------­
PRECAST CONCRETE PAVING BLOCKS
=================================
 ADVISORY NOTE
ON NOTE NUMBER 006
PRECAST CONCRETE PAVING BLOCKS OCTOBER,1990
_____-:::_______________________________ -----------------------------
" -

C O N T E N T S

PAGE
1. INTRODUCTION 113
2. STANDARDS 114
3. CONCEPTS 115
4. MATERIALS AND MANUFACTURE 117
5, REQUIREMENTS 119
6. QUALITY CONTROL 123

====--===========---========-·- - .. .::::::=======--==--- =====----- --=====----===

ADVISORY NOTE DUBAI MUNICIPALITY
ON NOTE NUMBER 00 6
PRECAST CONCRETE PAVING BLOCKS OCTOBER 19.90

-------------------------------------------------------------------
1. INTRODUCTION

Concrete block paving is a product which has enjoyed increa~:dng

acceptance all over the world . It is a pavement surface
particularly suited to the diverse requirements of to-day's
traffic .

The use of concrete blocks for paving came into prominence in

Holland and Germany in the 1950 s. Since then it has grown
extensively, both there and in many other European countries
where the market increased at compound rates. This high
acceptance level is in large measure due to versatility of
concrete block paving, in response to both aesthetic and high load
situations where its traditional features, combined with its
appearance, scale and load supporting ability enable it to
contribute in a beneficial way to the environment. Concrete block
paving is also CO$t-effective; does not require the use of
expensive specia.l ist paving plant, simple and cheap to lay, low in
initial cost and provides a maintenance free surface throughout
the design life of the pavement.
Although good appearance has undoubtedly had a major influence
upon the popularity of concrete paving blocks, their practical
advantages have helped considerably to extend their use and there
has been a growing use of this form of paving in the U.A . E. , in ·
common with other countries. There are now many manufacturer's
producing paving blocks in the country.
Access to services, which are frequently and unavoidably laid
beneath carriage ways , can create a major problem in breaking out
and reinstating the pavement . With concrete blocks, this problem
is minimal and involves very little cost . Once the road surface
has been broken into, the blocks can be lifted and recovered for
re-use . The authority responsible for maintenance need only hold
a very small stock of blocks to replace the few damaged in opening
the trench . Concrete blocks can be trafficked immediately after
reinstatement and making-good is invisible.
Modern housing estate roads are often complex in layout. Curves
are introduced and road widths varied to add interest to the
development, to make the best use of land and to restrict traffic
movement and speed . This complexity adds considerably to the
difficulties of construction and to the cost of traditional
roads, but causes few problems when blocks are used.
 OM NOTE NUMBER 006, OCTOBER 1990

Concrete blocks provide an ideal surfacing for many forms of

pavement where the traffic travels at a low-speed ( 50-60 km/h).
This includes many roads, goods yards, storage areas, dock side
paving, roll-on roll-off and container terminals .

The blocks can also be used as an industrial surface, being highly

resistant to point loads associated with trailer jacks or heavy
duty racking or impacts. They are not readily damaged by high
surface stresses, but form a flexible surfacing which can
accommodate uneven settlement whilst still retaining continuity.
If unacceptable settlements does occur, the blocks can be removed
and re-used after the settlement has been made good. This ability
to re-use the surfacing makes for considerable long term economies

Some road surfaces are softened by oil spillage, but this cannot
happen to blocks although their surface may become stained. This
resistance to oil is probably a major reason for their choice for
car and lorry parks, bus lay-bys, bus stations, and petrol-station
forecourts.

Colour can easily be introduced to produce colour concrete blocks.

Pavers' range of colours make it possible to create a mosaic of
parking space lines and directional signs, and eliminating
painting. These will have an indefinite life which can, however,
be terminated at will by unplugging the coloured blocks and
replacing them with blocks of the surrounding colour.

In areas liable to uneven ground settlement, such as trench

backfills or reclaimed land, blocks have special advantage in that
they can be lifted and majority recovered for re-use.

Since its introduction to the country concrete block paving has

consistently increased its range and volume of applications such
as pedestrianization schemes (residential developments, town
centers, shopping precincts, sports centers, hotel fore courts
etc.) , car parks, or on roads catering for low-speed vehicular
traffic .

This ADVISORY NOTE states the requirements for precast concrete

paving blocks, giving criteria for materials, performance levels,
dimensional deviations and guidance on items that should be
considered while specifying them.

2• STANDARDS

The pre-cast concrete paving blocks are covered by the following

standard specifications.
 DM NOTE NUMBER 006 , OCTOBER 1990

BS 6717 : Part 1 . " Specification for Paving Block" , is a

manufacturing specification . It specifies requirements for the
blocks intended for the construction of low speed roads and
industrial and other paved surfaces subjected to aLl categories Of
static and vehicular loading and pedestrian traffic .

ASTM C 936 . "Standard Specification for. Solid Concrete

Interlocking Paving Units" covers the requirements for the pavers
manufactured for the construction of the paved surfaces .
DIN 18501 • "Concrete Pavement Setts" applies to pavement setts
with or without facing concrete manufactured from mineral
aggregates for the paving of roads , paths and squares.

3• _CONCEPTS

Paving blocks covered by the above specifications are designed to

form a structural element and the surfacing of the pavements ,
having the block to block joints filled so as to develop
frictional interlock.

Concrete paving blocks form a 'flexible' surfacing because some

degree of articulation can occur but the block still remain in
contact . Friction between the vertical sides of the blocks
provides interlock and load transfer to neighbouring units . This
ability to articulate without signific ant joint opening can only
be achieved with small units . Although blocks do have
considerable load-spreading ·ability, without an adequate
foundation they will be dislodged vertically. Block may also be
moved horizontally by forces from vehicle tyres; to prevent this,
blocks are made of special plan shapes or, in the case of
rectangular blocks, are laid in a herringbone pattern .

The blocks most comm.only used for roads are 60 mm and 80 mm. thick
and are small enough, in width and weight , to allow them to be
picked up in one hand. For heavy industrial appLications, 80 mm
/100 mm thick blocks are used and, in some instances, 120 mm . No
scientific reason has been established for using thicker blocks,
but one possibility is that thicker blocks are less liable to
rotate about their horizontal axis in areas where there is a great
deal of slewing or breaking of very heavy loaded wheels.
In all cases, the blocks are laid on a layer of sharp sand and
then vibrated with a steel-faced plate vibrator, which produces an
even running surface and compact the sand, some of which is forced
between the joints, starting the development of the interlock.
The nominal thickness of the laying-course sand, after vibration,
is 50 mm. Detailed advice on laying is covered by BS 6717:Part 3
"Code of Practice for Laying".
 OM NOTE NUMBER 006, OCTOBER 1990

3.1 Shapes

The blocks are made in various shapes . The specifications place

virtually no restriction on the plan shape of a block but seeks to
ensure that the blocks can be picked up with one hand and that,
when laid correctly, they will fit closely together. Convenient
length : Width ratios are 1 1/2 and 2 but, to allow manufacturers
freedom in shape design, the specification lay down only the
limits for overall plan dimensions of blocks.

BS 6717: Part 1 specifies that rectangular blocks shall be 200mm

in length and 100mm in width. The shaped blocks shall be of any
shape fitting within a 295mm square co-ordinating space and shall
have a width not less than 80mm.

ASTM C936 specifies that units shall not be greater than 240mm in
length, or 160mm in width while DIN 18501 limits only the -1 ength
to be not more than 280mm.

To minimize cutting and promote ease of laying, special starter

blocks needed for various paved surface configurations are also
produced by manufacturers of repute associated with the standard
block types .

3.2 Thickness

As per British standard, the preferred thicknesses are 60mm, 65mm,

80mm and 100mm, while German specifications provides, in addition
to these, 120mm and 140mm. The American specification however,
specifies that the thickness shall not be greater 140mm.

The thickness of the paving blocks shall be selected in the light

of the sub-base material, the subgrade soil, the load and the
shape of the blocks,.

3.3 Special Features

The blocks are produced with the following special features and
the purchaser should specify the uni ts having the desired
particular features while ordering.

3. 3 . 1 Chamfer. An edge chamfer around the wearing surface of

blocks is to be preferred as it will subtly emphasises the laid
pattern and reduces trip risk. The standard however, does not
preclude the square edge profiles. British standard specifies
that a chamfer size should not exceed 7mm in width or depth.
 OM NOTE NUMBER 006~ OCTOBER 1990

3.3.2 Colour. The blocks are produced in colours-red, buff ,

charcoal, grey, brown, etc . - so that a wide variety of designs are
possibl e for special effects and demarcation . The blocks are
generally produced in "through " colours and when required the
units can be "surface applied" reflective colour types.
3. 3. 3 surface Finish . The blocks are made with different types
of wearing course or textured surfaces .

4. MATERIALS AND MANUFACTURE

4.1 Materials
4.1 . 1 Cement used in the manufacture of precast concrete paving
}:)lock should comply with the requirements of e i ther OPC (BS 12) or
SRPC (BS 4027) or MSRPC (ASTM Type 2) or DM ADVISORY NOTE NUMBER
002., as specified.

4 . 1.2 Aggregates used should consist of naturally occurring

crushed or uncrushed materials comply with either BS 882 (except
grading requirements in clause 5) or DM ADVISORY NOTE NUMBER 0·01.,
as specified.

4.1 . 2 . 1 coarse Aggregate

The coarse aggregate used should be 10mm nominal size.

4.1 . 2 . 2 Fine Aggregate

Paving blocks manufactured using fine aggregates containing

excessive amounts of acid-soluble material are prone to develop
polish quickly and become slippery . To ensure that paved surface
does not devel op polish but retains a micro-structure to give a
good low-speed skidding resistance when trafficked, limit on the
acid-soluble material in fine aggregates is specified .
Results obtained by using accelerated wear machine on pavement
quality concrete have shown that, when natural siliceous sand
forms all or part of the fine aggregate, adequate resistance to
skidding is retained . In the case of precast concrete paving
blocks it is possible that other fine aggregates will have similar
adequate skidding resistance but, unless evidence of this can be
provided, it is preferred that the fine aggregate used in the
manufacture of the blocks should contain a minimum of 25% natural
siliceous sand.
 OM NOTE NUMBER 006, OCTOBER 1990

Pend i ng a development of a test method for skid resistance of

precast concrete block paving, BS 6717 excludes the use of fine
aggregate containing significant amounts of acid- soluble material, ·
some of which have found to give poor polishing resistance. More
specifically, the standard stipulates that the fine aggregate
shall contain not more than 25% by mass of acid-soluble material.

The percentage of acid-soluble material shall be determine by the

test method described in BS 812 : Part 119

4.1.2.3 Deleterious salt contamination

In particular, deleterious salt contents in aggregates should not

exceed the following limits depending upon the cement type used in
the concrete mix .

Aggregate
salts as% wt. of agg. Fine Coarse

Acid soluble chlorides (Cl) % Max.

when SRPC cement is used 0.03 0.02
when OPC or MSRPC cement is used 0.05 0.04

Acid soluble sulphates (SO3) % Max. 0.30 0.30

4. 1. 3 water shall be clear and free from organic impurities,

having a pH value in the basic range of 7 - 9. The inorganic
impurities should not exceed the following limits:

------------------~---~~----------------------------------------~-
Maximum concentration Limits, ppm

[1] Chloride as Cl 250

[ 2] Sulphates as S03 350
[3] Alkali carbonate and bicarbonates 500
[4] Total dissolved ions, including 1, 2, 3 above 2000
 D.M NOTE NUMBER 006, OCTOBER 1990

4.1.4 Pigments used should comply with BS 1014.

4.1.5 Admixtures used should comply with requirements of BS 5075

: Part 1. However, chloride and chloride based admixtures should
not be used. Preference should be for the use of lignosulphonate
based water reducing agents .

4.1.6 Control of chlorides and sulphates The acceptable levels

of equivalent acid soluble chlorides and sulphates as specified
above for aggregates and water are indicative and subject to the
over-riding limits for the mixes as given below:

-----------------------------------------------------------------~
By weight of cement in the mix
------------------------------------------------------------------
Acid soluble chlorides (Cl) % Max.
If concrete made with OPC / MSRPC 0.40
If concrete made with SRPC 0.12
Acid soluble sulphates ($03} % Max. 3.7

----------------------------------~-------------------------------
4.2 Manufacture
The manufacturing process of blocks is carried at some plants in
the Emirate on the latest automatic machines. Batching of mix
constituents, mixing and moulding operations does not involve any
manual involvement. Accuracy in size and shape of the blocks is
ensured through vibration presses . The block pellets are belt
conveyed to the curing chambers. The curing process involves
steam treatment. Curing time ranges from 8 to 10 hours.
Following the curing process, t .h e blocks are automatically
depalletised and sent to the cuber. The block cubes are then
dispatched to the storage yard.

5• REQUIREMENTS

5.1 cement Content

Concrete used for paving blocks, in orde to ensure durability,
have a higher cement content of not less than 400 kg/m3 of the
compacted concrete.
 OM NOTE NUMBER 006, OCTOBER 1990

5. 2 c .o ndition
Pavement blocks shall be manufactured with a dense structure, free
from cracks. Pores resulting from the manufacturing process are
of no significance where ·serviceability is concerned, provided
that the requirements specified in the following paras 5.3 to 5.7
are met.

In composite paving blocks, the wearing surface layer must be

formed as an integral part of the core concrete of the block and
shall be not less than 5mm thick. These shall comply with
compressive strength requirement (para 5.5) without delamination.

5.3 Dimensional Tolerances

Blocks must be :manufactured to accurate dimensions . The
dimensional tolerances are meant to ensure that blocks can be laid
closely together and allow the development of interlock when the
joints are filled with sand .

The permissible deviation from the stated work size of paving

blocks, measured in accordance with appendix Al of BS 6717 : Part
1, shall be +/- 2mm for length and width and +/- 3mm for
thickness . In addition, normality betwee.n block sides and the
wearing surface; and parallelism of the opposite faces shall be
assessed in accordance with appendix A2 of BS 6717 : Part 1 .

5.4 water Absorption

Water absorption (average of 3 specimens) tested in accordance
with ASTM method C140 "Method of Sampling and Testing Concrete
Masonry Units" shall not be greater than 5% with no individual
result greater than 7%.

5.5 Compressive Strength

At the time of delivery to the work site, or at the latest when
they are 28-days old, the compressive strengths as required by
different specifications are given below

Test sample Conditioning Strength not less than

Standard size of specimens Average .Individual
(N/mm2) (N/mm2)

BS 6717 16 Nos . ( 1) Wet ( 2) 49 40

ASTM C936 3 Nos . Dry 55 50

DIN 18501 5 Nos. Dry 60 50

 OM NOTE NUMBER 006, OCTOBER 1990

(1) BS 6717 , however states that , if the average crushing strength

of the first four blocks tested is not less than 54 N/mm2 and if
none of these four blocks has a crushing strength of less than 40
N/mm2, the consignment shall be considered to comply with this
standard.

( 2) The wet specimen indicate a lower strength compared to its

strength in dry condition. The loss of strength due to wetting of
a specimen is caused by dilation of the cement gel by adsorbed
water : the forces of cohesion of the solid particles are then
decreased .

The DU:bai Municipality requires that average strength of 10 paving

blocks sampled in accordance with c l ause 6 . 4 of this NOTE and
tested as described in appendix. B of BS 6717 : Part 1 shall not be
less than 49 N/mm2 and with no block less than 40 N/mm2 .

5.6 Tensile strength

The consensus of the task group responsible for f armulation of
ASTM C936 is that compressive strength does not truly express a
significant property of paving- block . Rather, flexural property
evaluated by means of a tensile splitting test will be . more
meaningful. Test data in this respect is being developed and
evaluated to arrive at a specification value .

5.7 Performance
Field performance of pav ed surfaces in few cases has not been very
satisfactory . The surfaces showing s i gns of erosion. The causes
could be inadequate strength, poor resistance to attacks from
sulphate and chloride bearing sub-soil water at places where the
water table is too close to surface, and / or stagnant surface
water where the paved surfaces are not laid to required falls and
gradients to shed the water. to drain away.

Choice of suitable cement type, selection of suitable aggregates,

proper design of concrete mixes, application of adequate vibro­
compaction effort during manufacture of blocks and adoption of
sound practices for the construction of paved surfaces would
definitely ensure satisfactory service performance. As an
additional measure , use of silicate or similar type of additives
could be used integrally with the mix to reduce the permeability
of cement matrix of the block to further enhance the service
performance.
 OM NOTE NUMBER 006, OCTOBER 1990

5.7.1 Test for Performance against Salt Attack

The blocks complying with the requirement specified in paras

numbers 5. 2 to 5. 6 above are meant to ensure their satisfactory
in-service performance . However, there is no specific standard
test method for the direct assessment of overall service
performance of block units and block paved surfaces exposed to
aggressive actions of salt-laden surface conditions. There is a
need to evolve an accelerated test method for this purpose.
Perhaps, DIN 52206 "Testing Roofing Slates, Acid Resistance Test",
ASTM 03774 "Aggregate Durability Index" and ASTM C88
"Standard Test Method for Soundness of Aggregates" could provide
guidance in the development of such method.

5.7.2 Test for Abrasion Resistance

Abrasion resistance is one of the service performance requirements

in ASTM specification. Neither BS nor DIN standards specify any
requirement for abrasion resistance of paving blocks, while ASTM
C936 1 Clause 4.4 does. This clause requires that when tested in
accordance with ASTM C418, "Test Method for Abrasion Resistance
of Concrete by Sand Blasting", specimen shall not have a greater
volume loss than 15 cm3 per 50 cm2 and average thickness loss
shall not exceed 3mm.
This test method covers the laboratory evaluation of the relative
resistance of concrete surface to abrasion. This procedure
simulates the action of water borne abrasives and abrasives under
traffic on concrete surfaces. As there is not much of water
borne abrasive action in the prevalent service conditions of the
Emirate, this test method is not quite applicable. Other test
procedures are available in ASTM standards for measuring abrasive
resistance of concrete surfaces.
They are outlined in:
ASTM C779 "Test Method for Abrasion Resistance of
Horizontal Concrete Surface s"
and
ASTM C944 "Test Methods for Abrasion Resistance of
Concrete or Mortar surfaces by Rotating - Cutter Method".

The C944 closely represent the prevalent service conditions and

hence recommended as an alternative to C418 for evaluating
relative wear resistance of paving blocks .
 DM NOTE NUMBER 006, OCTOBER 1990

6• QUALITY CONTROL

6.1 sources

Individual paving units shall be obtained from approved source(s)

or manufacturer(s) but no section of the paving shall be
constructed with a mixture of units from differing sources.

6.2 Visual Inspection

All units shall be hard, sound, square, clean with sharp we.1 1
defined arises and free of cracks or other defects that would
interfere with the proper placing of the unit or impair the
strength and service performance of the paved surfaces. Minor
chipping resulting from customary methods of handling in shipment
and delivery, shall not be deemed grounds for rejection.
The purchaser or his authorized representative shall be permitted
access to the place where paving blocks are manufactured, for the
purpose of examining and sampling the materials and the finished
blocks from the lots ready for delivery.

6.3 compliance
Compliance with the requirements specified shall be verified by
inspection, comprising internal control and third party
inspection.

6.3 . 1 Internal control

The manufacturer shall opera:te a quality control scheme which
shall be available for inspection by prospective purchaser and
inspecting agency . Type, minimum scope and frequency of internal
control shall be as follows :

[a] Once per day of production and for each manufacturing

machine, the block dimensions and squareness shall be
checked for four units.

[b] Twice per week of production and for each manufacturing

machine, but at least once per 1000 Nos. of blocks, the
compressive strength shall be checked for four blocks
deriving from the production of different days.
Deviations from the scope and frequency of testing may
exceptionally be permitted by the inspection agency and are also
permissible in cases where the inspection, especially of the
records of internal control, has not given rise to any complaints
and are adequate for the works in question.
 DM NOTE NUMBER 006, OCTOBER 1990

6.3.2 Third Party Inspection

Third party mentioned herein shall be the Dubai Municipality
Laboratory . The inspection shall involve testing of the
following :
[a] Dimensions
[b] Compressive strength
[c] Water absorption
[d] Abrasion resistance
[e] Cement content of the mix
[f] Constituent materials of concrete

6.3.3 Certificate of compliance

The manufacturer shall provide the purchaser with a certificate of
compliance with the specification. This certificate shall state
that the manufacturer has made arrangements for his products to be
sampled and tested at regular intervals.
6.4 sampling
A representative sample of paving blocks required for test
purposes shall be selected to the mutual satisfaction of
manufacturer, and purchaser. The sample shall be taken either
immediately before deli very, or as soon after delivery as
convenient to all parties.
Two specimens shall be drawn at random from each group of 1000
blocks for every designated 5000 block section or part thereof in
a consignment. All samples shall be clearly marked at the time of
sampling in such a way that the designated section or part t:tiereof
and the consignment represented by the sample, are clearly
defined .
6.4.1 Number of Specimens

The nuber of specimens required for each test shall be as

follows:
[a] For routine testing
For dimensional checks and compressive strength determination: 10
[b] For optional testing, when specified
Water absorption determination 3
Abrasion resistance test : 3

Test for cement content determination from the broken fragments of

blocks tested for compression .
 OM NOTE NUMB-ER 006, .OCTOBER 1990

6.4.2 Identification

[ a] Mark on blocks Line mark ( s) not exceeding 3 mm

projection and 5 mm wide on the side faces of units and
groove ( s) matching to the projection ( s) on the opposite
side face. Number of line marks, their position and
spacing shall be according to those assigned by Dubai
Mu nicipality to each of the manufacturer.

[b] The metallic strap tying each consignment unit / cube

(e.g. package of blocks) to be embossed / clipped to
furnish the following information

Manufqcturer's Logo

Lot Number

Production Number

Date of Production

D.M. Certification Mark

[c ] Certificate of Compliance as per 6.3.3

 ADVISORY NOTE
NUMBER: 007 AUGUST, 1990

---------------------------------
CONCRETE MASONRY BLOCKS
---------- --·--- -- ----- ----- ------
---------------------------------
 ADV:ISORY NOTE
ON NOTE NUMBER 007
CONCRETE MASONRY BLOCKS AUGUST 1990

C ON T E N T S
PAGE

1. INTRODUCTION 131
2. STANDARD 131
3. MATERIALS AND MANUFACTURE 132
4. CONCRETE BLOCKS 134
5. PHYSICAL REQUIREMENTS 136
6. QUALITY CONTROL 138

-------- - ----- ----·- -------- --------------------- ---- -- --- -------------

.
ADVISORY NOTE DUBAI MUNICIPALITY
ON NOTE NUMBER 007
CONCRETE MASONRY BLOCKS AUGUST 1990
------------------------------------------------------------------
1. INTRODUCTION

It is essential that the choice of form of construction and design

decisions are made with the actual exposure conditions in mind.
Because th.e corrosion of reinforcement is the main cause of rapid
deterioration of the concrete and loss of structural integrity,
there is a strong case for using block work or plain concrete
wherever this is an acceptable alternative to reinforced concrete .
Unreinforced masonry or unreinforced concrete containing no crack­
control reinforcement has many applications and they can be more
durable in aggressive exposure con.ditions than concrete which is
reinforc~d only to limit crack-widths .
Masonry is an assemblage of structural units, either laid in-situ
or constructed in prefabricated panels, in which the structural
units are bonded or solidly put together with mortar or grout.
Structural units comprise calcium silicate (sandlime) bricks
(BS 187) ; clay bricks and blocks (BS 3921); stone masonry
(BS 5390) ; precast concrete masonry units (BS 6073) and
reconstructed stone masonry units (BS 6457).

This ADVISORY NOTE states the requirements for precast concrete

masonry blocks, giving criteria for materials, performance levels,
dimensional deviations and guidance on items that should be
considered while specifying them.

2. STANDARD

The BS 6073 : Parts 1 & 2 specifies precast concrete bricks and

blocks designed both for load bearing an~ non-load bearing masonry
and used primarily to build external and internal walls as
specified in BS 5628 : Parts 1, 2 and 3, Code of Practice for Use
of Masonry.

For the purpose of distinguishing between a brick, a block and a

panel, the following definitions apply:

A .brick is a unit not exceeding 337. 5mm in length, 225mm in

thickness or 112 . 5mm in height .

A .block is a unit exceeding in length or height, the dimensions

stated for a brick but no work size dimension to exceed 650 mm .

A panel is a unit in which the height exceeds the length or six

times the thickness, and is outside the scope of this standard .
 OM NOTE NUMBER 007, AUGUST 1990

The specification covers masonry units made using lightweight

aggregate concrete, autoclaved aerated concrete and normal weight
concrete. But in this NOTE, the block units made with concrete
using natural aggregates only are considered.

3. MATERIALS AND MANUFACTURE

3,1 Materials

3.1.1 Cement used in the manufacture of concrete masonry block

should comply with the requirements of either OPC (BS 12), (ASTM
Type I) or SRPC (BS 4027), (ASTM Type V) or MSRPC (ASTM Type II)
or DK ADVISORY NOTE NUMBER 002., as specified.
The cement content in the concrete mix used for the manufacture of
blocks should not be less than 200 kg/m3 of concrete.

3 .1. 2 Aggregates used should consist of naturally occurring

crushed or unorushed materials complying with either BS 882
(except grading requirements in clause 5) or DM ADVISORY NO'l'B
NVHBER 001., as specified. The coarse aggregate used should be
10mm nominal size for standard blocks. In particular, deleterious
salt contents in aggregates should not exceed the following limits
depending upon the cement type used in the concrete mix.

Aggregate
Sal~• as l w~. of agg . Fine Coarse

Acid soluble chlorides (Cl) % Max.

when SRPC cement is used 0.03 0.02
when OPC or MSRPC cement ie ueed o.os 0.04

Acid soluble sulphates ( S03) \ Max. 0.30 o. 30

 OM NOTE NUMBER 007, AUGUST 1990

3. 1. 3 Water shall l:>e clear and free from organic impurities,

having a pH value in the basic range of 7 - 9 . The inorganic
impurities should not exceed the following- limits:

Maximum concentration Limits, ppm

--------------------------------------------------------------- .--
[l] Chloride as Cl 250
(2) sulphates as S03 350
( 3) Alkali carbonate and bicarbonates 500
[4) Total dissolved ions 7 including 1, 2, 3 above 2000

3 . 1. 4 Pigments used should comply with BS 1014 .

3. 1. 5 Admi~tures used should comply with requirements of BS 5075

: Part 1~ However, chloride and chloride based admixtures should
not be used. Preference should be for the use of lignosulphonate
based water reducing agents.
3.1.6 Control of chlorides and sulphates: The acceptable levels
of equivalent acid soluble chlorides and sulphates as specified
above for aggregates and water are indicative and subject to the
over-riding limits for the mixes as given below:
By weight of cement in the mix

Acid solub l e chlorides (Cl) % Max.

If concrete made with OPC / MSRPC 0.40
If concrete made with SRPC 0 . 12

Acid soluble sulphates (S03) % Max. 3.7

3.2 Manufacture

The manufacturing of blocks is carried at various plants in the

Emirate using the latest automatic machines. Batching of mix
constituents, mixing and moulding operations do not involve any
manual involvement. Accuracy in size and shape of the blocks is
ensured through vibrations involving hydraulic pressure with a
high speed of 360 rpm. The block pellets are belt conveyed to
the curing chambers . The curing process involves steam treatment .
curing time ranges from 8 to 10 hours. Following the curing
process, th~ blocks are automatically depalletised and sent to the
cuber . The block cubes are then dispatched to the storage yard.
 OM NOTE NUMBER 007, AUGUST 1990

In some plants, the blocks are normally produced by semi-manual

operations In such cases, the blocks should be made in approved
block making machines. The materials for all blocks shall be
correctly measured / batched and mixed in approved mechanical
mixers and shall be gauged with sufficient water to enable the
materials to bind together under pressure . Water / cement ratio
shall be strictly governed to produce stiff mix of zero slump.
The concrete mix is then placed in the block making machines in
layers and machine vibrated and simultaneously applying pressure .
Immediately after moulding, the blocks shall be placed on clean,
level, non-absorbent pallets. The blocks shall be protected from
the direct sun rays in an approved manner. Blocks shall be cured
by being kept thoroughly wet by means of water, sprinklers or
other approved means for a specified period but in all cases not
less than 10 days. After which they can be stacked in honeycomb
fashion. Solid stacking should not be permitted. Each batch of
blocks shall be marked in a distinguishing manner.

4. CONCRETE BLOCKS

The concrete block has become increasingly popular in the Gulf,

primarily because of its inherent advantages as a building
material. It not only provides strength, economy and resistance
to fire, but its insulation qualities make it ideal for hot
climates.

4.1 Types of Blocks

solid Block: A block having no formed holes or cavities.

Hollow Block : A block which has one or more formed holes or
cavities which pass through the block .

Cellular Block: A block which has one or more formed holes or

cavities which do not wholly pass through the block.
The thickness of the closed face should not be less than 20mm.

special Types : These include quoin or closure units , split

fluted block, textured face block, fair faced block, screening
block, purpose-made shaped units for arches, etc.

4.2 Shape

The shape of a block is that of a body defined by rectangles.

Their end faces may be plain and provided with grooves or be
grooved and tongued.
 OM NOTE NUMBER 007, AUGUST 1990

Though blocks with plain end faces are specified and in fact some
block manufacturing plants in the Emirate do produce such blocks,
but from the performance point of view , blocks with profiled /
grooved end faces are to be preferred. Typical profiled/ grooved
end face details as specified in BS 6073 : Part 2 or DIN-18151:
Lightweight concrete hollow blocks or DIN 18152 Lightweight
concrete solid bricks and blocks could be adopted .
Grooves and tongues provided on end faces should ensure proper
keying of the joint faces, with the depth of fit of the tongue in
the groove being not less than 10mm.

The cavities in the hollow and cellular blocks should be evenly

distributed and must have voids ranging between 25 to 50 percent
with a minimum external shell thickness of 35mm or 1. 75 times the
nominal maximum size of aggregate, whichever is greater.

4.3 Dimensions and Tolerances

standard dimensions or work size of a block are the manufacturer's
designated dimensions. To obtain the nominal size of masonry
block, add the nominal mortar joint width, which is normally 10mm,
to the work size length and height of the block, while the
thickness remains unchanged.

No overall dimensions (length, height or thickness) should differ

by more than 3mm at any point from the standard dimensions.
When rneasur ing the length of grooved and tongued blocks, the
tongue shall be ignored.

Tolerances for special shapes of uni ts for which special

tolerances are necessary, the purchaser should agree on the shape,
tolerance and appropriate methods of measurements with the
manufacturer. Likewise, end face groove patterns, dimensions, and
associated limit deviations should also be agreed upon .
BS 6073 : Part 2 specifies a range of work sizes of blocks. The
lengths range from 390mm to 590mm with appropriate heights and
thicknesses from 60mm to 250mm. For the blocks made using normal
weight aggregate concrete, however, the weight of an individual
unit from the handling consideration point of view restrict the
choice of work sizes. A 390mm dimension for the length could be
quite suitable. Locally both hollow and solid blocks are
manufactured with the following dimensions:
 DM NOTE HUMBER 007, AUGUST 1990

------------------------------------------------------
Length (mm) Height(mm) Thickness(mm)
-----------------------~~--------~----------------~---
390 190 190
390 190 140
390 190 90
400 200 200

Strictly, some of the above dimensions are non-standard. A full­

size modular block's standard dimensions should be 390mm in
length, 190mm in height, and 200mm in thickness

Load bearing block sizes are to have thickness not less than
200mm.

5. PHYSICAL REQUIREMENTS

At the time of delivery to the work site the blocks shall conform
to the following physical requirements:

5.1 strength

Masonry blocks of thickness 7 5mm or greater are tested for

compressive strength and those with thickness less than 75mm are
tested for transverse strength.

5.1.1 compressive strength

Ten block specimens, as sampled in accordance with clause 6.4
shall be tested in compression as specified in BS 6073 : Part 1,
Appendix 'B' .
Compressive strength of a specimen is obtained by dividing the
maximum load carried by the specimen during the test by the gross­
cross-sectional area of the unit. The gross area of a unit is the
total area of a section perpendicular to the direction of the
load, including areas within cells and within re-entrant spaces
unless these spaces are to be occupied in the masonry by portions
of adjacent masonry.

D.M. Specification requires that concrete blocks shall have an

average compressive strength of 12. 5 N/mrn2 with a minimum
individual strength of not less than 10 N/mm2 for load bearing
blocks; and an average strength more than 7.5 N/nun2 with a minimum
individual strength not less than 6 N/mm2 for non-loading blocks.
 DM NOTE NUMBER 007, AUGUST 1990

The BS 6073 : Part 2, however requires that for a specified

strength, say, G, and the average of the ten results, Xav shall
satisfy the following two conditions

[a] xav greater than or equal to G

and

[b] xav greater than or equal to (0.9 G + 0.62 S)

where S is the standard deviation of the sample .

It can be shown that the conditions stipulated in the DM

Specifications, in other words, requires a standard deviation of
2 or less for load bearing blocks case and 1. 21 or less for non­
load bearing blocks .
The British Standard permits a secon sample of ten units to be
tested in case the first set of results does not satisfy both the
conditions. A similar option should be provided when the test
results are assessed on the basis of DM Specification as well.

TEST SPECIMENS - BS 6073 specifies a sample of ten specimens to

be tested while ASTM C14 O {Standard Methods of Sampl.ing and
Testing of Concrete Masonry Units) specifies three units and DIN
18152, six units for initial testing and three numbers for routine
testing. Further, air-dry samples are subjected to load according
to ASTM & DIN specifications while BS 6073 require the test
specimen shall be test loaded in soaked-wet condition. The wet
specimen indicate a lower strength compared to its strength in dry
condition. The loss of strength due to wetting of a compression
test specimen is caused by the dilation of the cement gel by
adsorbed water: the forces of cohesion of the solid particles are
then decreased.

5.1.2 Transverse Strength

For determination of transverse strength, blocks are tested in

accordance with appendix 'C I of BS 6073 Part 1. The average
transverse strength of five blocks shall be not less than o. 65
N/mm2 .

5.2 Drying Shrinkage

Drying shrinkage is defined as the change in linear dimension of
the test specimen due to drying from a saturated condition to an
equilibrium weight and length under specified accelerated drying
conditions .
 OM NOTE NUMBER 007, AUGUST 1990

The average drying shrinkage of a sample of masonry units tested

in accordance with appendix 'D' of BS 6073 Part 1 should not
exceed 0 . 05 %.

5.2 Water Absrption

Water absorption (average of 3 units} tested in accordance with

ASTM method C140 shall not exceed 15% of its dry weight .

5.3 Apparent Density

The apparent density, is the mass of the block dried to constant

mass at 105 degree centigrade divided by the unit volume (product
of length, width and height}! The dry mass is found by drying
whole units or fragments. The results shall be expressed in
kg/m3 as the mean of three results. The apparent density is
determined in .accordance with a method given in Appendix •c•
BS 6073 : Part 2.

5.4 Optional Requirements

The purchaser shall also specify any other required properties,

such as net area, colour and texture .

The net area of hollow block is required for assessing the

characteristic compressive strength of hollow concrete blocks
filled with in-situ concrete. A method for determining net area
is given in Appendix 'C' BS 60733 : Part 2 .

6. QUALITY CONTROL

The strength of masonry unit is the main significant factor in the

determination of the characteristic strength of masonry walls.
Safety factors used in the application of the design procedures of
load bearing masonry walls is related to the quality control
exercised . The value adopted should be commensurate with the
degree of control exercised during the manufacture of the block
units, and the ability of the supplier to meet the requirements
for compressive strength of the units. Two levels of controls are
recognized:

First, the normal category where the strength meet the

requirements of BS 6073 : Part 2
 OM NOTE NUMBER 007, AUGUST 1990

Second, the special category where the supplier agrees to

supply the units to a specified "acceptance limit for strength 11
with a probability of not more than 2. 5% of being below the
acceptance limit, and operates a quality control scheme to enable
the acceptance limit is consistently being met in practice .

6.1 sources

Individual masonry units shall be obtained from approved source(s)

or manufacturer(s) but no section of the work shall be constructed
with a mixture of units from differing sources .

6.2 Visual Inspection

All units shall be hard, sound, square, clean with sharp well
defined arises and free of cracks or other defects that would
interfere with the proper placing of the unit or impair the
strength or permanence of the construction . Minor chipping
resulting from customary methods of handling in shipment and
delivery, shall not be deemed grounds for rejection . For load
bearing walls cracked blocks s-h all not be permitted.
Where units are to be used in exposed wall construction, the face
or faces that are to be exposed shall be free of chips, cracks , or
other imperfections, except that if not more than 5% of a shipment
contains small chips not larger than 20mm, this shall not be
deemed grounds for rejection. Further, the manufacture shall
supply batches of units to ensure that no patchiness results from
allowable manufacturing or natural vari ations in colour .

The purchaser or his authorized representative shall be accorded

proper facilities to inspect and sample the units at the place of
manufacture from the lots ready for delivery.

6.3 compliance
Compliance with the requirements specified shall be verified by
inspection, comprising internal c ontrol and third party
inspection.

6.3.1 Internal control

The manufacturer shall operate a quality control scheme which
shall be available for inspection by prospective purchaser and
inspecting agency . Type , minimum scope and frequency of internal
control shall be as follows :
 OM NOTE NUMBER 007, AUGUST 1990

(a) Once per day of production and for each manufacturing

machine, the block height shall be checked for three
units.

[b] Once per day of production and for each manufacturing

machine, dimension and apparent density shall be checked
for one unit.

[c) once per week of production and for each type of solid or
pollow block and manufacturing machine, but at least once
per 1000 m3 of processed concrete, the compressive
strength shall be checked for three units deriving from
the production of different days.
Deviations from the scope and frequency of testing may
exceptionally be permitted by the inspection agency and are also
permissible in cases where the inspection, especially of the
records of internal control, has not given rise to any complaints
and are adequate for the works in question.

6.3.2 Third Party Inspection

Third party mentioned herein shall be the Dubai Municipality
Laboratory. The inspection shall involve testing of the
following:

(a] Dimensions
[b] Compressive strength
[c] Drying shrinkage
[d] Water absorption
[e) Constituent materials of concrete
6.3.3 Certificate of Compliance
The manufacturer shall provide the purchaser with a certificate of
compliance with the specification. This certificate shall state
that the manufacturer has made arrangements for his products to be
sampled and tested at regular intervals.

6. 4 sampling
A representative sample of masonry units required for test
purposes shall be selected to the mutual satisfaction of
manufacturer, and purchaser. The sample sha 11 be taken either
immediately before deli very, or as soon after delivery as
convenient to all parties.
 OM NOTE NUMBER 007, AUGUST 1990

The specimens shall be drawn at random from every designated

section or part thereof in a consignment. All samples shall be
clearly marked at the time of sampling in such a way that the
designated section or part thereof and the consignment represented
by the sample, are clearly defined.

Number of Specimens

The number of specimens required for each test shall be as

follows :

For dimensional checks and compressive strength determination : 10

Drying shrinkage determination 4

Water absorption determination 3

Apparent density determination : 3

For the strength, drying shrinkage, absorption and apparent

density 20 units shall be selected from each lot of 10,000 units
or fraction thereof and 49 units from each lot of more than 10,000
or less than 100,000 units. For lots of more than 100,000 units,
20 units shall be selected from each of 50,000 units or fraction
thereof contained in the lot. Additional specimens may be taken
at the discretion of the purchaser .

6.4 . 2 Identification

(a] Mark on Blocks : Quality control mark, as approved by

Dubai Municipality, shall be provided in the form of
"frog" on top face of each block.
[b] The metallic strap tying each consignment unit (e . g .
package of blocks) to be embossed/ clipped to furnish the
following information:
Manufacturer's Logo
Strength Class

Lot Number

Production Number

Date of Production

D.M. Certification Mark

[c] Certificate of compliance as per clause 6.3.3