Specification - Tunnel Shotcrete Lining

Cv

Thiess John Holland Joint Venture Airport Link | Northern Busway | EWAG GL - Supplementary Specification - Tunnel Shotcrete Lining GLTSP102

Document ref BC-PBA-GLTSP102SPC-0001-1-03 26 May 2010 DCN: 00047

IFA / AFC

Thiess John Holland Joint Venture Airport Link | Northern Busway | EWAG GL - Supplementary Specification - Tunnel Shotcrete Lining GLTSP102

May 2010

Parsons Brinckerhoff Arup Joint Venture ABN 88 642 968 608 Parsons Brinckerhoff Australia Pty Ltd ABN 80 078 004 798 Arup Pty Ltd ABN 18 000 966 165 Copyright 2008 Thiess Pty Ltd, John Holland Pty Ltd, Parsons Brinckerhoff Australia Pty Ltd, Arup Pty Ltd Parsons Brinckerhoff Arup Joint Venture Level 6 515 St Paul's Terrace, Fortitude Valley QLD 4006, PO Box 3546 South Brisbane BC QLD 4101 Tel +61 7 3309 7500 Fax +61 7 3309 7890

This report takes into account the particular instructions and requirements of our client. It is not intended for and should not be relied upon by any third party and no responsibility is undertaken to any third party

Job number A125840

PB2108209A

Document Verification Page 1 of 1

Airport Link | Northern Busway | EWAG

Job title

Job number

PB2108209A A125840 Document title

GL - Supplementary Specification - Tunnel - Shotcrete Lining GLTSP102

Document ref

BC-PBA-GLTSP102-SPC-0001-1-03

Revision

Date

AFC Issue 25/02/09

26 May 2010

Filename

BC-PBA-AGTSP100-SPC-0002-0-01.doc

Description

AFC Issue

Name

File reference

Prepared by

Checked by

Approved by

Andreas Amon

Robert Bertuzzi

Eddie Woods

Signature

Review

16/02/10

Filename

BC-PBA-GLTSP102-SPC-0001-1-01.doc

Description

Issued for Review, DCN: 00047, Refer to Table 2

Name

Prepared by

Checked by

Approved by

Eddie Woods

Richard Page

Eddie Woods

Signature

Review

29/03/10

Filename

BC-PBA-GLTSP102-SPC-0001-1-02.doc

Description

Issued for External Review, DCN: 00047, Refer to Table 2

Name

Prepared by

Checked by

Approved by

Eddie Woods

Richard Page

Eddie Woods

Signature

IFA / AFC

26/05/10

Filename

BC-PBA-GLTSP102-SPC-0001-1-03.doc

Description

Issued for IFA / AFC, DCN: 00047, Refer to Table 2

Name

Prepared by

Checked by

Approved by

Eddie Woods

Richard Page

Eddie Woods

Signature

Issue Document Verification with Document

C:\APL-PBAJV\KIERAN.COOK\DMS47695\BC-PBA-GLTSP102-SPC-0001-1-03.DOC BC-PBA-GLTSP102-SPC-0001-1-03 26 May 2010

9

Parsons Brinckerhoff Arup Joint Venture IFA / AFC 26 May 2010

Thiess John Holland Joint Venture

Airport Link | Northern Busway | EWAG GL - Supplementary Specification - Tunnel - Shotcrete Lining GLTSP102

Contents 1 

2 

3 

4 

5 

6 

Page 1 

General 1.1 

Scope

1 

1.2 

Definition of Terms

2 

1.3 

Standards and Related Specifications

3 

1.4 

Discrepancy Between Drawings and Specification

5 

1.5 

Changes to previous revisions

5 

1.6 

Records Maintained by the Contractor

8 

Quality System Requirements

9 

2.1 

General

9 

2.2 

Hold Points, Witness Points and Milestones

9 

2.3 

Work Method Statements

10 

2.4 

Testing Frequency

10 

2.5 

QDMR Registered Suppliers and Products

10 

Shotcrete Materials

11 

3.1 

General

11 

3.2 

Shotcrete Types

11 

3.3 

Water

11 

3.4 

Cement

11 

3.5 

Supplementary Cementitious Materials

12 

3.6 

Aggregates

12 

3.7 

Alkali-Aggregate Reaction (AAR)

14 

3.8 

Admixtures

14 

3.9 

Fibres

16 

3.10 

Soluble Salts (permanent shotcrete only)

17 

Shotcrete Requirements

17 

4.1 

Construction Method Statements

17 

4.2 

Mix

18 

4.3 

Acceptance Testing and Field Trials

18 

4.4 

Sprayed Concrete Trials

19 

4.5 

Submission Details

21 

4.6 

Performance

21 

Surface Preparation for Shotcrete Application

22 

5.1 

Preparation of Rock Surfaces

22 

5.2 

Preparation of Shotcrete / Concrete Surfaces

23 

5.3 

Preparation for Installation of Waterproof Membrane

23 

Application of Shotcrete and Curing

C:\APL-PBAJV\KIERAN.COOK\DMS47695\BC-PBA-GLTSP102-SPC-0001-1-03.DOC BC-PBA-GLTSP102-SPC-0001-1-03 26 May 2010

24  Parsons Brinckerhoff Arup Joint Venture IFA / AFC 26 May 2010

Thiess John Holland Joint Venture

7 

8 

9 

Airport Link | Northern Busway | EWAG GL - Supplementary Specification - Tunnel - Shotcrete Lining GLTSP102

6.1 

Equipment

24 

6.2 

Proficiency of Nozzlemen

25 

6.3 

Production and Transport

25 

6.4 

Application

26 

6.5 

Thickness and Profile Control

27 

6.6 

Curing

28 

Shotcrete Testing

28 

7.1 

Production Tests

28 

7.2 

Compressive Strength Test

30 

7.3 

Flexural Toughness Test

31 

7.4 

Dry Density, Boiled Absorption and Voids Volume

31 

7.5 

Fibre Content

31 

7.6 

Slump

32 

7.7 

Test of Steel Fibre

32 

Repair of Shotcrete

32 

8.1 

General

32 

8.2 

Core Hole Repair

32 

Remedial Works to Non-Conforming Shotcrete

32 

9.1 

General

32 

9.2 

Compressive Strength Failures

33 

Tables Table 1 – Definition of Terms  Table 2 – Changes made to previously issued revisions  Table 3 – Hold Points  Table 4 – Witness Points  Table 5 – Milestones  Table 6 – Work Method Statements  Table 7 – Items Requiring Use of QDMR Registered Suppliers and Products  Table 8 – Aggregate Grading for Shotcrete  Table 9 – Maximum Dosages of Accelerator  Table 10 – Maximum Values of Acid-Soluble Chloride-Ion Content in Shotcrete  Table 11 – Particular Mix Requirements  Table 12 – Testing Methods – Field Trials  Table 13 – Minimum Performance Requirements for Shotcrete  Table 14 – Test Methods – Production Testing for Temporary Shotcrete Lining  Table 15 – Test Methods – Production Testing for Permanent Shotcrete Lining 

Appendices Appendix A  Verification Records  Appendix B  Response to Comments 

C:\APL-PBAJV\KIERAN.COOK\DMS47695\BC-PBA-GLTSP102-SPC-0001-1-03.DOC BC-PBA-GLTSP102-SPC-0001-1-03 26 May 2010

Parsons Brinckerhoff Arup Joint Venture IFA / AFC 26 May 2010

Thiess John Holland Joint Venture

1

Airport Link | Northern Busway | EWAG GL - Supplementary Specification - Tunnel - Shotcrete Lining GLTSP102

General This technical specification has been provided by Parsons Brinckerhoff Arup Joint Venture on behalf of Thiess John Holland Joint Venture for use in execution of the Design and Construct Contract with the Airport Link, Northern Busway and ARU project (the Project). 1.1

Scope

This specification supersedes Shotcrete Lining (reference AGTSP100-0002). This Specification applies to the manufacture, supply and application of shotcrete for the temporary and permanent (pump sumps and substations) shotcrete lining of the Airport Link and Northern Busway tunnels. In addition, this document specifies the performance based requirements for shotcrete and details the testing requirements to ensure that the shotcrete applied on site is consistent with these performance requirements. For this Project, shotcrete is concrete with or without admixtures pneumatically applied to a prepared rock surface, in and around steel sets, or in and around lattice girders. The scope of this Specification comprises: •

steel or synthetic fibre reinforced shotcrete (SFRS),

•

steel mesh reinforced shotcrete

•

and plain or unreinforced shotcrete (URS)

•

plain shotcrete with polypropylene fibres to provide fire protection

•

aggregates for use in permanent shotcrete requiring fire resistance

The specification covers both temporary works shotcrete and permanent shotcrete. The specification complies with the Mined Tunnels Design Manual and will be reviewed and updated as necessary during execution of the Works. The types of shotcrete for underground works are as follows: •

SFRS applied as temporary (initial) and permanent (pump sumps and substations) ground support

•

URS applied as a smoothing layer prior to installation of the tunnel waterproofing membrane or providing an initial layer in combination with mesh reinforcement prior to application of permanent lining or as a finishing layer for permanent ground support (pump sumps and substations).

This Specification shall be read in conjunction with the Temporary and Permanent Works Design Drawings and other relevant Specifications. The thickness dimensions shown on the Drawings are minimum thicknesses. Shotcrete thicknesses shall be such as to provide a minimum cover, as shown on the Drawings, over all steel components and fixtures including rockbolt heads, steel sets, lattice girders and reinforcing mesh. The General Specification (reference BC-PBA-GLRSP000-SPC-0001) provides general information relating to all other specifications. The General Specification must be used with this Specification. Users of this Specification and related specifications and documents are required to ensure, that they are referring the current version. The durability of shotcrete manufactured in accordance with this specification has been assessed in the Durability Report (reference PBA-BC-AGDTR100-RPT-0001). This specification is to be read in conjunction with the related specifications outlined in Clause 1.3.

C:\APL-PBAJV\KIERAN.COOK\DMS47695\BC-PBA-GLTSP102-SPC-0001-103.DOC BC-PBA-GLTSP102-SPC-0001-1-03 26 May 2010

Page 1

Parsons Brinckerhoff Arup Joint Venture IFA / AFC 26 May 2010

Thiess John Holland Joint Venture

1.2

Airport Link | Northern Busway | EWAG GL - Supplementary Specification - Tunnel - Shotcrete Lining GLTSP102

Definition of Terms

Definitions applicable to many specifications, including this Specification, shall include those found in the General Specification (reference BC-PBA-GLRSP000-SPC-0001). While the definitions found in the General Specification take precedence, the following definitions, when not found in the General Specification, apply particularly to this Specification: Table 1 – Definition of Terms Term

Definition

Relative Strength for Silica Fume

The relative strength for silica fume is the ratio (in percent) of the compressive strength of standard mortar bars, prepared with 90% cement plus 10% silica fume by mass, to the compressive strength of standard mortar bars made from cement only.

Admixtures

Materials added to base concrete such as accelerators and hydration control mixtures. (Note that silica fume, plasticisers and retarders may be included in Base Concrete if proposed to be used in the Temporary and Permanent Works shotcrete).

Cement

An active hydraulic binder formed by grinding clinker and conforming to AS 3972. Cement and cementitious content exclude the mass of silica fume.

Characteristic Cylinder strength at 28 days

The value of the standard cylinder strength at 28 days below which 5% of the population of all possible strength measurements are expected to fall. (Characteristic cylinder strengths are quoted in the Specification for the purpose of the development of mix design only).

Curing

The control of temperature and moisture in the concrete until the concrete has developed required properties.

Flash Coat

Sprayed concrete applied as a thin layer protecting, priming or finishing the surface of the tunnel. A flash coat shall be at least 20mm thick.

In Situ Cylinder Strength

The notional strength of shotcrete at a single location, considered as the strength of a cylinder of shotcrete as it exists in the structure. In situ cylinder strengths are given in the Specification for the purpose of compliance requirements.

Lattice Girder

A lightweight, three dimensional steel or fibreglass frame made to act as a unit by connecting all components with lacing bars; used in conjunction with shotcrete for shotcrete lining reinforcement.

Layer

A discrete thickness of sprayed concrete built up from a number of passes of the nozzle which is allowed to set.

Nozzle

Attachment at end of delivery hose from which shotcrete is projected.

Overspray

Material projected outside the intended receiving surface.

Rebound

Shotcrete which having passed through a spraying nozzle does not adhere to the surface to which shotcrete is being applied.

SFRS

Steel fibre reinforced shotcrete

Silica Fume Concrete

Concrete manufactured by combining cement complying with AS 3972 with silica fume. The Contractor shall ensure that sufficient lime is available for reaction with the silica fume, particularly when sulphate resistant cement or pulverised fuel-ash is used.

Sloughing

Subsidence of fresh shotcrete.

Shotcrete

A mixture of cement, aggregate, and water projected at high velocity from a

C:\APL-PBAJV\KIERAN.COOK\DMS47695\BC-PBA-GLTSP102-SPC-0001-103.DOC BC-PBA-GLTSP102-SPC-0001-1-03 26 May 2010

Page 2

Parsons Brinckerhoff Arup Joint Venture IFA / AFC 26 May 2010

Thiess John Holland Joint Venture

Airport Link | Northern Busway | EWAG GL - Supplementary Specification - Tunnel - Shotcrete Lining GLTSP102

Term

Definition nozzle into place to produce a dense, homogeneous mass, applied directly to the ground surface in one or more layers to form the lining of a sprayed concrete support structure.

Shotcrete Type S1

Steel fibre reinforced shotcrete (SFRS) which is applied as initial or primary ground support and is designed to carry temporary loads only.

Shotcrete Type S2

Steel mesh reinforced shotcrete (SMRS) which is applied as initial or primary ground support and is designed to carry temporary loads only.

Shotcrete Type S3

Un-reinforced shotcrete (URS) which is applied as initial or primary ground support and is designed to carry temporary loads only.

Shotcrete Type S4

Un-reinforced shotcrete (URS) which is applied as backfill shotcrete, smoothing shotcrete and/or as a protective layer to shotcrete Type S1, P1 or bare rock, and is designed to carry temporary loads only.

Shotcrete Type P1

SFRS which is applied as permanent ground support and is designed to carry permanent loads.

Shotcrete Type P2

SMRS which is applied as permanent ground support and is designed to carry permanent loads.

Shotcrete Type P3

Plane shotcrete used as a smoothing layer and to provide fire protection

Shotcrete Mix Terms

Base Mix: Concrete designed, tested and supplied independent from the shotcreting process, equipment and personnel. Shotcrete Mix: The base mix after it is applied to the Works, or to test panels.

Sprayed Concrete Support Systems Structure

A structure built underground in accordance with this specification.

Standard Cylinder strength

The measured compressive strength of a cylinder made, cured and tested in accordance with AS 1012.8 and AS 1012.9 for cast samples and in accordance with AS 1012.14 for cored samples.

URS

Unreinforced Shotcrete

Waterproofing Supervisor

As defined in the Waterproofing and Drainage Specification (reference BCPBA-GLTSP107 SPC-0001).

Wet-mix Process

The process of producing shotcrete in which cement and aggregate are weigh batched and mixed with water at or near the shotcreting location or in mixer trucks prior to being pumped through a pipeline to a nozzle where compressed air, and admixtures if necessary, are injected and the mix projected into place without interruption.

1.3

Standards and Related Specifications

1.3.1 General Specification The General Specification (reference BC-PBA-GLRSP000-SPC-0001) contains information required for an understanding of any and all of the specifications applicable to the Project. The General Specification shall be read prior to use of any of the other specifications, including this Specification. Standards and Related Specifications 1.3.2 This specification is to be read in conjunction with the following:

PBAJV SS C:\APL-PBAJV\KIERAN.COOK\DMS47695\BC-PBA-GLTSP102-SPC-0001-103.DOC BC-PBA-GLTSP102-SPC-0001-1-03 26 May 2010

Page 3

Parsons Brinckerhoff Arup Joint Venture IFA / AFC 26 May 2010

Thiess John Holland Joint Venture

Airport Link | Northern Busway | EWAG GL - Supplementary Specification - Tunnel - Shotcrete Lining GLTSP102

BC-PBA-GLTSP101-SPC-0001 Global – Supplementary Specification – Tunnel - Rock Reinforcement BC-PBA-GLTSP102-SPC-0001 Global – Supplementary Specification – Tunnel - Mined Tunnel Excavation and Implementation BC-PBA-GLTSP106-SPC-0001 Global – Supplementary Specification – Tunnel – Cast in Place Concrete BC-PBA-GLRSP009-SPC-0001 Global – Supplementary Specification – Road – Projectwide Instrumentation and Monitoring BC-PBA-GLTSP107-SPC-0001. Global - Supplementary Specification – Waterproofing and Drainage BC-PBA-AGDTR100-RPT-0001 – Durability Technical Report PSTS PSTS01

Introduction to Technical Standards

PSTS03

Drainage, Retaining Structures and Protective Treatments

PSTS50

Specific Quality System Requirements

PSTS70

Concrete

PSTS71

Reinforcing Steel

Australian Standards AS 1012

Methods of Testing Concrete

AS 1141

Methods for Sampling and Testing Aggregates

AS 1379

Specification and Supply of Concrete

AS 1478.1

Chemical Admixtures for Concrete

AS 2350

Methods of Testing Portland and Blended Cements

AS 2758.1

Aggregates and Rock for Engineering Purposes – Concrete Aggregates

AS 3582.1

Supplementary cementitious materials for use with Portland and blended cement – Fly Ash

AS 3582.2

Supplementary cementitious materials for use with Portland and blended cement – Slag – Ground Granulated Iron Blast Furnace

AS 3582.3

Supplementary cementitious materials for use with Portland and blended cement – Silica Fume

AS 3583.6

Methods of test for supplementary cementitious materials for use with portland cement

AS 3972

Portland and Blended Cements

AS/NZS 4671

Steel Reinforcing Materials

AS/NZS ISO 9001 Quality Management Systems – Requirements ASTM Standards ASTM A820

Standard Specification for Steel Fibres for Fibre-Reinforced Concrete

ASTM C1260

Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar-Bar Method)

ASTM C1550

Standard Test Method for Flexural Toughness of Fibre Reinforced Concrete (Using Centrally Loaded Round Panel)

C:\APL-PBAJV\KIERAN.COOK\DMS47695\BC-PBA-GLTSP102-SPC-0001-103.DOC BC-PBA-GLTSP102-SPC-0001-1-03 26 May 2010

Page 4

Parsons Brinckerhoff Arup Joint Venture IFA / AFC 26 May 2010

Thiess John Holland Joint Venture

Airport Link | Northern Busway | EWAG GL - Supplementary Specification - Tunnel - Shotcrete Lining GLTSP102

ASTM C311

Standard Test Methods for Sampling and Testing Fly Ash or Natural Pozzolans for Use in Portland-Cement Concrete

ASTM C94

Standard Specification for Ready-Mixed Concrete

British Standards BS EN 1367-2

Tests for Thermal and Weathering Properties of Aggregates

BS EN 14488-4

Testing sprayed concrete. Bond strength of cores by direct tension

BS EN 14488-7

Testing sprayed concrete. Fibre content of fibre reinforced concrete

BS EN 14889-1

Fibres for concrete - Part 1: Steel fibres - Definitions, specification and conformity

BS EN 14889-2

Fibres for concrete - Part 2: Polymer fibres - Definitions, specification and conformity

Other Standards ACI 506R-05

Guide to Shotcrete

Specification for Tunnelling, British Tunnelling Society and the Institution of Civil Engineers ITA-shotcrete guidelines, Sprayed concrete for final linings: ITA working group report, AITES / ITA, 2001 Concrete Institute of Australia, Recommended Practice – Shotcreting in Australia 1.4

Discrepancy Between Drawings and Specification

Where a discrepancy exists between the Design Drawings and this Specification the Contractor shall seek clarification from the Construction Certifier. Drawing notes will take precedence over the Specification. 1.5

Changes to previous revisions

The following table details all the changes made to this specification since previously issued revisions. Table 2 – Changes made to previously issued revisions Revision

Clause

Change Description

Description

1-01

General

Modification

Paragraphs and lists numbered for ease of referencing

DCN: 00047

Section 1 – Sections reorganised inline with the new specification template. 1.1

Modification

Minor text changes clarifying scope

1.1

Modification

Addition of last 2 bullet points to first set of bullet th points, First sentence of 5 paragraph added, and additional text added to the last bullet point in second set of bullet points.

1.2

Modification

Activity Index for Silica Fume has been amended to Relative Strength, SFRS definition added, Shotcrete Type P3 definition added and URS definition added.

1.3

Addition

Addition of reference AS 3583.6

1.5

Addition

Section added in Table 2 to specify all changes in

C:\APL-PBAJV\KIERAN.COOK\DMS47695\BC-PBA-GLTSP102-SPC-0001-103.DOC BC-PBA-GLTSP102-SPC-0001-1-03 26 May 2010

Page 5

Parsons Brinckerhoff Arup Joint Venture IFA / AFC 26 May 2010

Thiess John Holland Joint Venture

Airport Link | Northern Busway | EWAG GL - Supplementary Specification - Tunnel - Shotcrete Lining GLTSP102

the report. 3.2

Modification

Addition of the final bullet point added

3.5.2 a) I.

Deletion

Text deleted – (undensified)

3.5.2

Modification

I,vi changed from Silica activity index to relative strength and reference added.

3.6 v.

Addition

Text added – “For aggregates comprising volcanic breccia, mudstone, shale, sandstone, weathered or altered rocks” Bullet Points added

3.6

Modification

Table 8 revised. S3 put in column one for % passing and S4 replaces S3 for % passing.

3.8.2 e)

Addition

Text added – “The Contractor shall test selected types of accelerators for the range of ±2% in 5.0%, 8.0% dosages or the manufacturer’s recommended dosage to ensure the short and long term strength is not impaired and meets the specified requirements”

3.10

Addition

Text added – (permanent shotcrete only)

4.1

Addition

Section 4.1 Inserted

4.2

Modification

Witness point added Section moved from Section 4.1 to 4.2

4.3 vi.

Addition

Text added – (for permanent shotcrete only)

4.4. ( b)

Modification

Text modified and added – “The target slump(s) shall be determined by trial mixes with and without superplasticisers provided the pre production and production tests show that the sprayed concrete achieves the short and long term strengths specified in Table 13 for field tests and production tests (cores), for sprayed concrete the target slump shall be;

Addition

Without superplasticiser: 80 to 120mm With superplasticiser: 80 to 150mm”

4.4.( i)

Addition

Text added – (a spare specimen shall be taken but not tested)

4.4 (n)

Addition

Text added – “The Contractor shall provide 1,7,28 & 90 day strength verses time curves for cores taken directly from the tunnel lining together with early strength results (less than 1 day) for beam end test verses needle penetrometer tests”

4.6

Modification

Table 13 updated – Field trials and Production Tests (Cylinder) updated Dry density 2150 to 2400Kg/m³ - “for permanent shotcrete only “added to Boiled Absorption and Apparent Volume

C:\APL-PBAJV\KIERAN.COOK\DMS47695\BC-PBA-GLTSP102-SPC-0001-103.DOC BC-PBA-GLTSP102-SPC-0001-1-03 26 May 2010

Page 6

Parsons Brinckerhoff Arup Joint Venture IFA / AFC 26 May 2010

Thiess John Holland Joint Venture

Airport Link | Northern Busway | EWAG GL - Supplementary Specification - Tunnel - Shotcrete Lining GLTSP102

Note (1) added clarifying purpose of maximum strength Addition of “Fire Performance of P3 shotcrete” row 5.3

Addition

(a) text added in first paragraph Clause 5.3.1 Smoothing Shotcrete section added

6.3 f)

Addition

Text added – “however, using a drop pipe to transfer the concrete from the surface underground into an agitator truck is acceptable provided the material does not become overly segregated and remixing produces a homogenous sprayable mix.”

7.1 (Table 14)

Modification

Requirement for 1 day tests deleted (as covered by beam end tests) Compressive strength test changed to a cylinder sample Deletion of Boiled Absorption and Voids Volume

7.1 (Table 15)

Modification

Requirement for 1 day test deleted as covered by Early age compressive strength test Compressive strength test changed to a cylinder sample Boiled absorption test required for permanent shotcrete only Flexural strength test method added.

1-02

1.1

Addition

Addition of text – “The durability of shotcrete…..”

1.2

Modification

Definition of Silica Fume Concrete has been modified. Wording used now has been modified from comment response for clarity.

1.2

Addition

Addition of Waterproofing Supervisor definition

1.3

Addition

Addition of references to Waterproofing and Drainage specification and Durability Report.

3.6

Modification

Table 8 updated – P3 added into column

3.8.2

Modification

Addition of text – “But shall not exceed”

3.8.4

Modification

Part C changed to include P3

3.9

Addition/Modification

Structure changed around to include new headings. 3.9.1 General, 3.9.2 Steel Fibres etc.

DCN: 00047

C:\APL-PBAJV\KIERAN.COOK\DMS47695\BC-PBA-GLTSP102-SPC-0001-103.DOC BC-PBA-GLTSP102-SPC-0001-1-03 26 May 2010

Page 7

Parsons Brinckerhoff Arup Joint Venture IFA / AFC 26 May 2010

Thiess John Holland Joint Venture

1.6

Airport Link | Northern Busway | EWAG GL - Supplementary Specification - Tunnel - Shotcrete Lining GLTSP102

4.2

Modification

Addition of column to Table 11 of P3

Table 11

Modification

No change to content but Table has been reformatted for clarity.

4.4 b

Modification

“Determined” has been replaced with “confirmed”

5.3

Addition

Addition of text – “as required by the Waterproofing….”

5.3.1

Deletion

Deletion of 5.3.1 Part b part iii.

5.3.1

Modification

Text modified to say “manufacturer’s”

6.1

Addition

Addition of P3 to 1st paragraph

General

Modification

Where items have been shown for the approval of the Designer, this should have referred to the Construction Certifier. This general error has been corrected throughout the document.

General

Modification

Formatting and grammatical errors have been amended for the IFA / AFC issue.

Records Maintained by the Contractor

a) General guidelines for records are provided in the General Specification (reference BCPBA-GLRSP000-SPC-0001). b) Records of work methods, listed in Table 6 related to this specification are required to be submitted by the Contractor to the Construction Certifier in accordance with the quality system requirements of the Contract. c) This Specification requires the Contractor to prepare and maintain, as a minimum, the following documents in accordance with the Contractors Project Quality Plan and make them available for audit purposes: i.

Proposals to adopt alternative materials and equipment

ii.

All information necessary to produce as-built drawings and records

iii. Details of cement for shotcrete, including suppliers details and information to demonstrate compliance with AS 3972 iv. Details of fly ash, slag and silica fume for shotcrete v.

Details of aggregates and aggregate sources for shotcrete, including testing and properties of the aggregates

vi. Manufacturer’s test certificates and product analysis certificates for the fibres to be used for the fibre reinforced shotcrete vii. Test results for the water used in the mixing and curing of the shotcrete viii. Concrete Supplier’s batch card showing details of the mix design for each type of shotcrete ix. Details of all admixtures for shotcrete, including manufacturer’s product data, and the equipment and method of controlling the addition of admixtures to the shotcrete x.

Records of the type of equipment used for batching, mixing, transport and application of shotcrete, including location of the batching plant and method of delivery to site

C:\APL-PBAJV\KIERAN.COOK\DMS47695\BC-PBA-GLTSP102-SPC-0001-103.DOC BC-PBA-GLTSP102-SPC-0001-1-03 26 May 2010

Page 8

Parsons Brinckerhoff Arup Joint Venture IFA / AFC 26 May 2010

Thiess John Holland Joint Venture

Airport Link | Northern Busway | EWAG GL - Supplementary Specification - Tunnel - Shotcrete Lining GLTSP102

xi. Results of all acceptance testing and field trials, and results of production testing of the shotcrete xii. The mix design for each type of shotcrete shall be approved by the Construction Certifier. xiii. Records of inspection and written approval of the Temporary and Permanent Works shall be provided in accordance with this Specification.

2

Quality System Requirements 2.1

General

a) Specific quality system requirements are detailed within PSTS50. Construction activities shall be carried out in accordance with the provisions of the Contractor’s Quality System which shall comply with the requirements of AS/NZS ISO 9001. 2.2

Hold Points, Witness Points and Milestones

a) The Hold and Witness Points particular to this Specification are listed in Table 3, Table 4 and Table 5 below. Refer General Specification (reference BC-PBA-GLRSP000-SPC0001) for Hold Point, Witness Point and Milestone definitions and requirements. b) The Contractor shall not proceed beyond a Hold Point until the Hold Point has been released by the person nominated in Table 3. The Contractor shall notify the relevant person when a Hold Point will be reached so that they can review and/or witness any work process, record or test being undertaken by the Contractor and thus expedite the release of that Hold Point. Table 3 – Hold Points Specification Clause

Hold Point Details

For Release By

All relevant Hold Points outlined in the Specifications and Project Deed including the hold points referred to in the QDMR Project Specific Technical Standards (PSTS) as described in Annexure 10 Part 1

IV

Hold Points as the Contractor deems necessary to meet its obligations under the Deed.

Contractor

4.3

Approval of shotcrete mix designs and mix trials (pre-construction tests) including the proposed curing regime

Construction Certifier

6.2

Certification of nozzlemen

Contractor

8

Repair of shotcrete

Construction Certifier

9

Remedial works to non-conforming shotcrete

Construction Certifier

c) The Contractor shall provide the person nominated in Table 4 reasonable notice (minimum 24 hours or as otherwise specified) of all Witness Points so that inspection may be made of the following: Table 4 – Witness Points Specification Clause

Witness Point Details

For Release By

Witness Points as the Independent Verifier deems necessary to meet its obligations under the Deed.

IV

Witness points as the Contractor deems

Contractor

C:\APL-PBAJV\KIERAN.COOK\DMS47695\BC-PBA-GLTSP102-SPC-0001-103.DOC BC-PBA-GLTSP102-SPC-0001-1-03 26 May 2010

Page 9

Parsons Brinckerhoff Arup Joint Venture IFA / AFC 26 May 2010

Thiess John Holland Joint Venture

Airport Link | Northern Busway | EWAG GL - Supplementary Specification - Tunnel - Shotcrete Lining GLTSP102

Specification Clause

Witness Point Details

For Release By

necessary to meet its obligations under the Deed. 4.1/4.3 5

6.5

Trial Mixes / Field Trials

Construction Certifier

Surface preparation complete (rock, concrete or waterproofing)

Construction Certifier

Final surface within tolerance

Construction Certifier

d) The Contractor shall submit at the time nominated in Table 5, documentary evidence of Milestones to the Construction Certifier for approval of materials and workmanship as specified throughout the Specification. Table 5 – Milestones Specification Clause

2.3

Milestone Details

Timing

4.1

Construction Method Statement

30 days prior to commencement of work

4.3

Submit proposed shotcrete mix designs

30 days prior to commencement of work

4.3

Submit results of field trials

30 days prior to commencement of work

Work Method Statements

Work Method Statements which are required to be submitted by the Contractor to the Construction Certifier in accordance with the quality system requirements of the Contract are listed below in Table 6. Table 6 – Work Method Statements Specification Clause 4.1

2.4

Work Method Statements Construction Method Statement for Tunnel Shotcrete Placement

Testing Frequency

The minimum testing frequency for work covered by this Specification is specified in Clause 7. 2.5

QDMR Registered Suppliers and Products

The use of QDMR registered suppliers and products for the construction of the project works are required for the items listed in Table 7. Table 7 – Items Requiring Use of QDMR Registered Suppliers and Products Specification Clause 3.4

Category of Work Cement Supply

3.5.1

Fly Ash

3.5.2

Silica Fume

3.8

Admixtures

C:\APL-PBAJV\KIERAN.COOK\DMS47695\BC-PBA-GLTSP102-SPC-0001-103.DOC BC-PBA-GLTSP102-SPC-0001-1-03 26 May 2010

Page 10

Parsons Brinckerhoff Arup Joint Venture IFA / AFC 26 May 2010

Thiess John Holland Joint Venture

3

Airport Link | Northern Busway | EWAG GL - Supplementary Specification - Tunnel - Shotcrete Lining GLTSP102

Shotcrete Materials 3.1

General

Materials for shotcrete as a minimum must conform to the requirements of this Clause of the Specification. 3.2

Shotcrete Types

The following shotcrete mixes are specified for this project: a) Shotcrete Type S1: Steel fibre reinforced shotcrete for temporary support of excavations. The characteristic cylinder strength of Shotcrete Type S1 at 28 days is 40 MPa. b) Shotcrete Type S2: Steel mesh reinforced shotcrete for temporary support of excavations. The characteristic cylinder strength of Shotcrete Type S2 at 28 days is 40 MPa. c) Shotcrete Type S3: Unreinforced shotcrete for temporary support of excavations. The characteristic cylinder strength of Shotcrete Type S3 at 28 days is 40 MPa. d) Shotcrete Type S4: Un-reinforced shotcrete for infilling voids and smoothing of surfaces. The characteristic cylinder strength of Shotcrete Type S4 at 28 days is 25 MPa. e) Shotcrete Type P1: Steel fibre reinforced shotcrete for permanent support of excavations. The characteristic cylinder strength of Shotcrete Type P1 at 28 days is 40 MPa. f)

Shotcrete Type P2: Steel mesh reinforced shotcrete for permanent support of excavations. The characteristic cylinder strength of Shotcrete Type P2 at 28 days is 40 MPa.

g) Shotcrete Type P3: Plain Shotcrete shall have monofilament polypropylene fibres in accordance with Section 3.9. The characteristic cylinder strength of Shotcrete Type P3 at 28 days is 40 MPa. 3.3

Water

a) Water incorporated into shotcrete shall be potable, free from contaminants harmful to concrete or reinforcement and have electrical conductivity not exceeding 1000 microsiemens/metre. b) Water to be used in the manufacture of shotcrete for the Temporary and Permanent Works shall be of an acceptable quality as defined in Clause 2.4 of AS 1379. c) Water used for curing, testing water tightness or for other purposes where it may come in contact with shotcrete, shall be potable, clean and free from oil and suspended matter, and shall otherwise comply with the requirements of Clause 2.4 of AS 1379. 3.4

Cement

a) Cement shall be Type GB or GP in accordance with AS 3972. b) All blended cement shall contain not more than 15% Fly Ash. The final blend shall be nominated by the Supplier or selected during field trials. c) Cement older than three months from the date of dispatch from the manufacturer's holding silos shall not be used for the Temporary and Permanent Works. d) All mixes shall contain a minimum mass of Portland cement equal to 55% of the total mass of cementitious material. e) Test certificates for the cement showing suppliers’ details and demonstrating compliance with AS 3972 used shall be maintained for audit purposes. The test C:\APL-PBAJV\KIERAN.COOK\DMS47695\BC-PBA-GLTSP102-SPC-0001-103.DOC BC-PBA-GLTSP102-SPC-0001-1-03 26 May 2010

Page 11

Parsons Brinckerhoff Arup Joint Venture IFA / AFC 26 May 2010

Thiess John Holland Joint Venture

Airport Link | Northern Busway | EWAG GL - Supplementary Specification - Tunnel - Shotcrete Lining GLTSP102

certificates shall cover the period from at least 12 months prior to commencement of the project. Testing of cement properties in accordance with AS 3972 shall be carried out at least monthly. f)

Cementitious products shall be supplied only by a QDMR Registered Cement Supplier.

3.5

Supplementary Cementitious Materials

3.5.1 Fly Ash a) Supplementary cementitious materials Fly Ash and Slag shall comply with AS 3582 Parts 1 and 2 respectively and shall be a QDMR registered fly ash or slag, with the following modifications: i.

The amount of fly ash retained when wet sieved on a 45 micron sieve shall not exceed 15% by weight.

ii.

Loss on ignition to be not more than 4% by weight.

iii. Specific gravity shall not vary by more than 5%. The uniformity of specific gravity shall be determined in accordance with Section 17 of ASTM C311. 3.5.2 Microsilica (Silica Fume) a) Supplementary cementitious material Silica Fume shall comply with AS 3582 Part 3. Silica fume is a latent hydraulic binder which shall comply with the following requirements: I.

Silica Fume/Dry Powder i.

Bulk density not exceeding 650kg/m3

ii.

Silica content shall be not less than 85%

iii. Carbon content of silica fume shall be less than 5% iv. Particle size shall be between 0.1 and 0.2 microns v. Fineness: specific surface area shall not be less than 15,000m2/kg vi. Relative Strength >95% after 28 days. Testing shall be in accordance with AS3583.6 vii. Moisture content