Cvl-301.05 Inspect Concrete Post-pour

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PARTICIPANT MODULE CVL 301.05NSN SAUDI ARAMCO SAP BET ID 40009511 INSPECT CONCRETE P OST - POUR WARNING : The training materials contained in this manual are the property of the Saudi Arabian Oil Company (Saudi Aramco) and are intended for the exclusive use of Saudi Aramco employees enrolled in advanced inspection training workshops. Any material contained in this manual which is not already in the public domain, may not be copied, reproduced, sold, given or disclosed to third parties or otherwise used, in whole or in part, for purposes other than for use in Saudi Aramco’s Professional Engineering Development Unit courses without the prior written permission of the Chief Engineer of Saudi Aramco.

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concrete

Transcript of Cvl-301.05 Inspect Concrete Post-pour

Page 1: Cvl-301.05 Inspect Concrete Post-pour

PARTICIPANT MODULE CVL 301.05NSN

SAUDI ARAMCO

SAP BET ID 400 0 9 5 1 1

INSPECT CONCRETE P OST -POUR

WARNING : The training materials contained in this manual are the property of the Saudi Arabian Oil Company (Saudi Aramco) and are intended for the exclusive use of Saudi Aramco employees enrolled in advanced inspection training workshops. Any material contained in this manual which is not already in the public domain, may not be copied, reproduced, sold, given or disclosed to third parties or otherwise used, in whole or in part, for purposes other than for use in Saudi Aramco’s Professional Engineering Development Unit courses without the prior written permission of the Chief Engineer of Saudi Aramco.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT REVISION

D ATE REVISION D ESCRIPTION P AGE( S ) AFFECTED

03/02/02 RE-SCANNED FIGURES ALL

CONVERTED MODULE FROM MAC-FORMAT TO PC-FORMAT

ALL

INCORPORATED MARK-UPS BY A. W. CORNISH ,SR. CIVIL INSTRUCTOR, T&DG/AU/ID, AFTER 1 ST REVIEW

ALL

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CVL 301.05 (SAP ID 40009511) PARTICIPANT TABLE OF CONTENTS

MODULE COMPONENT P AGE

OBJECTIVES 1

Terminal Objective ..............................................1

Enabling Objectives ............................................1

INTRODUCTION 2

Purpose 2

Scope 2

INSPECTING THE CONCRETE FINISHING 3

INSPECTING THE CONCRETE FINISHING (CONT'D) 5

Finish Tolerances .................................................5

INSPECTING THE CONCRETE FINISHING (CONT'D) 6

Finish Tolerances (Cont'd) ...............................6

INSPECTING THE CONCRETE FINISHING (CONT'D) 7

Types of Surfaces ................................................7

INSPECTING THE CONCRETE FINISHING (CONT'D) 8

Types of Surfaces (Cont 'd) ..............................8

Tools Used for Leveling and Finishing .........8

INSPECTING THE CONCRETE FINISHING (CONT'D) 9

Leveling Concre t e ...............................................9

INSPECTING THE CONCRETE FINISHING (CONT'D) 10

Leveling Concre t e (Cont 'd) ...........................10

INSPECTING THE CONCRETE FINISHING (CONT'D) 11

Leveling Concre t e (Cont 'd) ...........................11

INSPECTING THE CONCRETE FINISHING (CONT'D) 12

Leveling Concre t e (Cont 'd) ...........................12

INSPECTING THE CONCRETE FINISHING (CONT'D) 13

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Leveling Concre t e (Cont 'd) ...........................13

INSPECTING THE CONCRETE FINISHING (CONT'D) 14

Tools Used for Finishing Concre t e ..............14

INSPECTING THE CONCRETE FINISHING (CONT'D) 15

Techniques of Finishing Concre t e ..............15

INSPECTING THE CONCRETE FINISHING (CONT'D) 16

Techniques of Finishing Concre t e (Cont'd)......................................................16

INSPECTING THE CONCRETE FINISHING (CONT'D) 17

Techniques of Finishing Concre t e (Cont'd)......................................................17

INSPECTING THE CONCRETE FINISHING (CONT'D) 18

Techniques of Finishing Concre t e (Cont'd)......................................................18

INSPECTING THE CONCRETE FINISHING (CONT'D) 19

Techniques of Finishing Concre t e (Cont'd)......................................................19

INSPECTING THE CONCRETE FINISHING (CONT'D) 20

Techniques of Finishing Concre t e (Cont'd)......................................................20

INSPECTING THE CONCRETE FINISHING (CONT'D) 21

Techniques of Finishing Concre t e (Cont'd)......................................................21

INSPECTING THE CONCRETE FINISHING (CONT'D) 22

Techniques of Finishing Concre t e (Cont'd)......................................................22

INSPECTING THE CONCRETE FINISHING (CONT'D) 24

Techniques of Finishing Concre t e (Cont'd)......................................................24

INSPECTING THE CONCRETE FINISHING (CONT'D) 25

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Techniques of Finishing Concre t e (Cont'd)......................................................25

INSPECTING THE CONCRETE CURING 26

Description and Purpose of Curing ............26

INSPECTING THE CONCRETE CURING (CONT'D) 27

Description and Purpose of Curing (Cont 'd)......................................................27

INSPECTING THE CONCRETE CURING (CONT'D) 28

Effects of Weather on Curing .......................28

INSPECTING THE CONCRETE CURING (CONT'D) 29

Effects of Weather on Curing (Cont 'd) .....29

INSPECTING THE CONCRETE CURING (CONT'D) 30

Effects of Weather on Curing (Cont 'd) .....30

INSPECTING THE CONCRETE CURING (CONT'D) 31

Curing Methods ..................................................31

INSPECTING THE CONCRETE CURING (CONT'D) 32

Curing Materials ................................................32

INSPECTING THE CONCRETE CURING (CONT'D) 33

Curing Materials (Cont'd) ...............................33

INSPECTING THE CONCRETE CURING (CONT'D) 34

Curing Materials (Cont'd) ...............................34

INSPECTING THE CONCRETE CURING (CONT'D) 35

Curing Materials (Cont'd) ...............................35

INSPECTING THE CONCRETE CURING (CONT'D) 36

Curing Specific Structur es .............................36

INSPECTING THE CONCRETE CURING (CONT'D) 38

Curing Exterior Walls, Columns and Bridge Piers .............................................38

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Curing Interior Concre t e Surfaces ..............38

INSPECTING THE CONCRETE CURING (CONT'D) 39

Inspection Points ...............................................39

PERFORMING TEST FOR HARDENED CONCRETE 40

Sampling Harden e d Concre t e ......................40

PERFORMING TEST FOR HARDENED CONCRETE (CONT'D) 42

Sampling Harden e d Concre t e (Cont 'd) ....42

PERFORMING TEST FOR HARDENED CONCRETE (CONT'D) 43

Sampling Harden e d Concre t e (Cont 'd) ....43

PERFORMING TEST FOR HARDENED CONCRETE (CONT'D) 45

Sampling Harden e d Concre t e (Cont 'd) ....45

DOCUMENTING INSPECTION RESULTS 46

Field Notes 46

Site Logbook 46

DOCUMENTING INSPECTION RESULTS (CONT'D) 47

Site Logbook (Cont 'd) ......................................47

Projects Inspection Report (Saudi Aramco Form 8213- ENG).....................47

DOCUMENTING INSPECTION RESULTS (CONT'D) 48

Projects Inspection Report (Saudi Aramco Form 8213- ENG) (Cont'd) .. .48

DOCUMENTING INSPECTION RESULTS (CONT'D) 49

Projects Inspection Report (Saudi Aramco Form 8213- ENG) (Cont'd) .. .49

Labora tory Testing Forms .............................49

DOCUMENTING INSPECTION RESULTS (CONT'D) 50

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Laboratory Testing Forms (Cont'd) ............50

EXERCISE 1. INSPECTING THE CONCRETE FINISHING

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EXERCISE 1. INSPECTING THE CONCRETE FINISHING (CONT'D) 53

EXERCISE 1. INSPECTING THE CONCRETE FINISHING (CONT'D) 54

EXERCISE 1. INSPECTING THE CONCRETE FINISHING (CONT'D) 56

EXERCISE 1. INSPECTING THE CONCRETE FINISHING (CONT'D) 58

EXERCISE 2. INSPECTING THE CONCRETE CURING 60

EXERCISE 2. INSPECTING THE CONCRETE CURING (CONT'D) 62

EXERCISE 2. INSPECTING THE CONCRETE CURING (CONT'D) 63

EXERCISE 3. PERFORM TESTS FOR HARDENED CONCRETE 64

EXERCISE 3. PERFORM TESTS FOR HARDENED CONCRETE (CONT'D) 65

EXERCISE 3. PERFORM TESTS FOR HARDENED CONCRETE (CONT'D) 66

EXERCISE 4. DOCUMENT INSPECTION RESULTS 67

EXERCISE 4. DOCUMENT INSPECTION RESULTS (CONT'D) 68

Exercise 4A. Make Field Notes in Field Notebook ...................................68

Exercise 4B. Complet e the Proper Docume n t of the Inspection Findings ......................................68

Exercise 4C. Complet e Saudi Aramco Form 8563 ............................................68

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Exercise 4D. Complet e a Labora tory Reques t Form ..........................68

WORK AID 1. HOW TO INSPECT THE CONCRETE FINISHING 69

WORK AID 2. HOW TO INSPECT THE CONCRETE CURING 71

WORK AID 3. HOW TO PERFORM TEST ON HARDENED CONCRETE 73

Sampling Harden e d Concre t e ......................73

WORK AID 3. HOW TO PERFORM TEST ON HARDENED CONCRETE (CONT'D) 75

Sampling Harden e d Concre t e (Cont 'd) ....75

Onsite Tests for Hardene d Concre t e .........75

WORK AID 3. HOW TO PERFORM TEST ON HARDENED CONCRETE (CONT'D) 77

Onsite Tests for Hardene d Concre t e (Cont 'd) ......................................77

WORK AID 4. HOW TO DOCUMENT THE INSPECTION RESULTS 79

WORK AID 4. HOW TO DOCUMENT THE INSPECTION RESULTS (CONT'D) 80

Work Aid 4A. Make Field Notes in a Field Logbook .....................................80

WORK AID 4. HOW TO DOCUMENT THE INSPECTION RESULTS (CONT'D) 82

Work Aid 4A. Make Field Notes in a Field Logbook (Cont 'd) ....................82

WORK AID 4. HOW TO DOCUMENT THE INSPECTION RESULTS (CONT'D) 83

Work Aid 4A. How to Write Field Notes (Cont 'd) ......................................83

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WORK AID 4. HOW TO DOCUMENT THE INSPECTION RESULTS (CONT'D) 84

Work Aid 4B. Make Entries in the Site Logbook .....................................84

WORK AID 4. HOW TO DOCUMENT THE INSPECTION RESULTS (CONT'D) 85

Work Aid 4B. Make Entries in the Site Logbook (Cont 'd) ....................85

WORK AID 4. HOW TO DOCUMENT THE INSPECTION RESULTS (CONT'D) 86

Work Aid 4C. How to Complet e a Projects Inspection Report (PIR) ........86

WORK AID 4. HOW TO DOCUMENT THE INSPECTION RESULTS (CONT'D) 88

Work Aid 4C. How to Complet e a Projects Inspection Report (PIR) (Cont 'd) ......................................88

WORK AID 4. HOW TO DOCUMENT THE INSPECTION RESULTS (CONT'D) 89

Work Aid 4C. How to Complet e a Projects Inspection Report (PIR) (Cont 'd) ......................................89

GLOSSARY 90

GLOSSARY (CONT'D) 92

GLOSSARY (CONT'D) 94

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CVL 301.05 (SAP ID 40009511) PARTICIPANT OBJECTIVES

OBJECTIVES

Terminal Objec t iv e

Upon completion of this module, the participan t will be able to inspect concre t e postpour , in accordanc e with applicable standards .

Enablin g Objec t iv e s

In order to accomplish the terminal objective, the participan t will be able to accomplish the following:

◊ Inspect the concre t e finishing,

◊ Inspect the concre t e curing,

◊ Perform test on harden e d concre t e .

◊ Docume n t the inspection results .

Note: This training material has been developed using the latest available versions of applicable Saudi Aramco and industry standards. However, these documents are regularly updated. Therefore, it is the responsibility of the inspector to ensure that he is conducting his inspections according to the latest versions of these documents.

Note: Italicized words are found in the glossary.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INTRODUCTION

Purpo s e

The purpos e of concre t e post pour is to provide Saudi Aramco with the means of assuring quality construction. You must perform post pour inspections to verify that the vendor has met all Saudi Aramco requirem e n t s .

You are responsible for inspecting and verifying all details concerning concre t e postpour procedur e s . You will learn how to inspect the finishing and the curling of concre t e and the tes ts required for harden e d concre t e .

You will perform the inspections according to Saudi Aramco Engineering Standards , using methods deter mined by the American Concre t e Institute (ACI), the American Society for Testing and Materials (ASTM) and the Uniform Building Code (UBC) Standards . After each inspection you will docume n t your findings using specific Saudi Aramco forms.

You must know all Saudi Aramco requirem e n t s and procedure s for inspecting concre t e post pour. You will conduct all tes t procedur e s exactly as stated In the Saudi Aramco Engineering Standards and other industry stand ards for harden e d concre t e .

It is the purpos e of this module to give you the knowledg e and skills to do all these things.

Scop e

This module does not cover the actual place m e n t of the concre t e . It star ts at the finishing process after the concre t e has been poured. It does not cover the installa tion of the formwork or any placem e n t of embed d e d objects , other than those used to perform in -place streng th test on the concre t e once it is harden e d . Those subjects are covered in module CVL-301.03, Inspect Concre t e Prepour. This module does not cover testing of the plas tic concre t e . That subject is covered in module CVL-200.02. The testing covered in this module only pertains to harden e d concre t e .

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE FINISHING

Finishing is the work performe d after the concre t e is placed and before it hardens . This work gives the concre t e its textur e and appea r a nc e . Finishing serves two purpos es ; it enhanc es the appea r a nc e and provides the required type of surface specified in the plans. You deter mine the quality of the concre t e surface by examining the condition and the appea r a nc e of the finished product.

Finishing begins immedia t ely after the workers place the concre t e . It is usually required on all concre t e surfaces that are visible. Examples of concre t e surfaces that require finishing include sidewalks, floors and finished walls (interior and exterior). The specific type of finish is a result of how the workers place the forms and what methods the workers use to finish the surface. You must verify that the workmen finish the concre t e surface to toleranc es and texture s according to Saudi Aramco stand ards and the American Concre t e Institute specifications .

The construction plans and Scope of Work will usually specify the procedure s and mate rials need ed to achieve the desired finish. Following are some of the specifications usually found for finishing in the plans:

◊ The plans will require only a uniform, rough finish when the building specifications require subsequ e n t toppings of concre t e , mortar , asphal t , flooring roofing or other similar building materials .

◊ For inset tile and linoleum, the plans usually require relatively level and smooth finishes and the workers must repair any cracks.

◊ For sidewalks and other outdoor concre t e surfaces used by pedes t rians , the plans, for safety reasons , usually requires a smooth or non- skid finish.

The main considera tion is to use the minimu m amount of surface manipula tion to get the desired finish.

Following are the things you must know about inspecting concre t e finishes:

◊ Finish tolerance s

◊ Types of surfaces

◊ Tools used for finishing

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

◊ Inspection points

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE FINISHING (CONT'D)

Finish Toleranc e s

Tolerance is a term specifying the degree or depth of the finish. The two factors you use to calculat e toleranc e:

1. Flatne ss, which is a statis tical analysis of elevation differences you deter min e by meas uring a straight line at 12 inches (304.8 mm) intervals.

2. Levelnes s is a factor you deter min e by taking consecu tive meas ur e m e n t s of eleva tion differences at 10 feet (3.048 m) intervals along a straight line.

If using hand meas ure m e n t procedure s , concre t e floors and slabs must finish to a levelness tolerance of 3/16 inch for every 10 feet (4.76 mm for every 3.048 m).

You may use a profilom e t er to verify that the finish mee t s the specifications and tolerances as noted on the design drawing and as specified in ACI 117, Standard Specifications for Tolerances for Concre t e Construction and Materials and the ACI 301, Specifications for Structur al Concre t e (Use ASTM E 1155 for procedure s for meas uring and calculating the factors).

When placed upon the surface in the required manne r , the profilomet e r will give an index numb er . A spring- loaded plunger with a fine tip on it accomplishes this. The tip meas ure s the differences and displays them on a scale. Figure 1 is a table showing the American Concre t e Institute (ACI) tolerances for floor finishes , according to levelness and flatness factors. These numb er s are the minimu m requirem e n t s . Slabs and floors that have levelness and flatness that do not mee t thes e requirem e n t s are unsatisfac tory.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE FINISHING (CONT'D)

Finish Toleranc e s (Cont'd)

Figure 1. Table of recom m e n d e d floor finish toleranc e s as specified in ACI 117

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE FINISHING (CONT'D)

Type s of Surfac e s

You classify concre t e finished surfaces as either unform e d or formed . Unform e d finish requires only a small amount of finish to make them accept a ble . Unformed finish is usually specified in areas where appea r a nc e is not importan t .

Formed finishes describe the degre e of labor required for final finishing. Formed surfaces require more labor and effort than unforme d . Formed finishing usually adds appe ar a nc e or serviceability to the concre t e .

Following are types of formed finishes:

◊ Matching- sample finish

◊ As-cast finish

◊ Rubbed finished

Matchin g - sam pl e Finish

Matching- sample finish requires that the contrac tor produce a sample showing the actual finished surface. The sample must meas ure at leas t 100 ft 2 (9.29 m 2) a designa t e d location. You must verify that the sample match es the specifications before the workers can proceed with that specified finish for that area. Different areas or different finish require m e n t s require another sample.

As- cas t Finish

The as- cast finish has two sub- types:

1. Rough- form finish which requires tie holes and defects to be patche d, fins exceeding 1/4 inch (6.35 mm) in height mus t be chipped or rubbed off and to preserve the textur e left by the forms.

2. Smooth- form finish requires the workers to fill all tie holes, patch any defects , remove of any fins, and give the surface a final rubbed finish.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE FINISHING (CONT'D)

Type s of Surfac e s (Cont'd)

Rubb e d Finish e d

Following are the types of rubbed finishes:

◊ The smooth- rubbed finish, requires the workers to remove the forms as early as can be permit t ed , followed by immedia t e patching of holes and defects . The concre t e surface is then rubbed with a carborundu m brick or other abrasive, after wetting until a uniform color and textur e is achieved. The grout used in this process is the grout produced by the rubbing.

◊ Grout- cleaned finish requires that the workers first clean and prepare the surface. Next, the workers apply a coating of grout, consisting of 1- part Portland cemen t and 1 ½- parts of fine sand. The workers scrub the grout into all the voids and all the excess grout is then remove d. When the grout star ts to turn white, the workers rub the surface . The surface is kept damp for 72 hours. The grout mixture may require an addition of white cemen t to make the colors uniform.

◊ Cork- floated finish requires the forms to be removed as soon as possible, followed by any necess a ry patching. Finish is then done with a cork- covered float

Tools Use d for Levelin g and Finishin g

There are numerous tools the workers use to level and finish concre t e . Each tool serves a particular purpos e . When you inspect finish work, you must know these tools and their specific purpos e .

Following are the most commonly used tools for leveling work:

◊ Screed, leveling (see Figure 2)

◊ Mechanical screed (Mechanical vibrating strike- off machine) (not shown)

◊ Hand screed (see Figure 3)

◊ Bull float (see Figure 4)

◊ Hand- float (Darby)

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE FINISHING (CONT'D)

Levelin g Concre t e

Leveling is the work required to level the concre t e after it is placed and vibrated to consolida t e it. This work levels the concre t e and ensure s that the large aggreg a t e are compac t e d into the mixture. When the concre t e is placed, the workers immedia t ely go to work leveling the concre t e . During this time, you must ensure that the ambien t conditions and the temp er a t u r e are properly maintained .

Following are the methods that can be used to prefinish or level the concre t e :

◊ Screeding (striking off)

◊ Tamping

◊ Bull floating

To prefinish (rough finish) and to level horizontal concre t e surfaces , workers use a leveling screed . Figure 2 shows two workmen using a leveling screed . A leveling screed is a very long, straight length of 2 ” x 4 ” (50 mm x 100 mm) aluminu m box section (or other similar material), used as a straight edge . The workers slide the straight edge back and forth in a sawing motion over the surface of the forms containing the fresh concre t e . This motion flattens the ceme n t and brings natural mortar and water to the surface which assists in the finishing and curing process . The screed is moved in one direction in this sawing motion until the workmen reach the end of the forms or until the poured section is done. The workmen always try to keep some cemen t mix in front of the screed to fill in the low spots. As the work progress e s , the workers will use a shovel to add cemen t to low spots or remove it from high spots.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE FINISHING (CONT'D)

Levelin g Concre t e (Cont'd)

Figure 2. Workers using a leveling scree d to rough finish concre t e

Sometime s a vibrator is mount ed on the straight edge , which helps to consolida t e it and level it. If the slab is to have a crown, the straight edge will have a curve in the middle section on the bottom side. Sometime s the slab will require drainag e to only one side, such as to the lawn side of a patio next to a building. It would not be desirable to have the water drain toward the building. In this case, a long 2 x 4 piece of mate rial may be placed upon the side opposite the direction of the required drainag e . This will smooth the concre t e and give a slight incline to the outside edge toward the lawn.

The screeding should be finished as soon as possible but before the bleed water appe ar s on the surface . When the workers finish this phas e , the concre t e is approxima t e ly level, but it Is not smooth or finished.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE FINISHING (CONT'D)

Levelin g Concre t e (Cont'd)

Hand Scre e d

After the workmen have rough- leveled the concre t e , they use the blade of the hand screed to lightly tap on the surface of the concre t e . This gently compres s e s and pushes the coarse aggreg a t e below the surface and forces the fine aggreg a t e , the water and the ceme n t to the surface . This process levels the concre t e and smooth es the surface. Figure 3 shows a worker using a hand screed .

Figure 3. A worker using a hand screed

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE FINISHING (CONT'D)

Levelin g Concre t e (Cont'd)

Bull Float and Darby

The workman uses the bull float or the Darby after he uses the hand or mechanical screed . These are used to further smooth out the rough surface of the concre t e . The Darby is a handh eld float with a shorter handle than the bull float. The Darby is some tim e s used when the workers can walk on the concre t e . The Darby produces a surface that is closer to the tolerance s than the bull float. If the workers can not walk on the mixture, the bull float with a long handle is used as shown in Figure 4. The long handle allows the workman to level large areas of the concre t e uniformly without having to step on the surface . The bull float made of aluminu m is the last of the tools used by the workmen before setting begins.

There is a manda to ry waiting period betwee n the time the floating is done and the final finish work star ts . This waiting period is absolutely necess a ry to permit the bleed water to leave the surface of the concre t e .

Caution: It is a basic rule in finishing concrete that you never use any finishing tool on the fresh concrete while the bleed water is present on the surface.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE FINISHING (CONT'D)

Levelin g Concre t e (Cont'd)

Bull Float and Darby (Cont'd)

Figure 4. A worker using a bull float

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE FINISHING (CONT'D)

Tools Use d for Finishin g Concre t e

Following are the most common tools used in finishing the concre t e (see Figure 5):

◊ Corner trowel (edger)

◊ Grooving trowel or groover

◊ Hand trowel (steel trowel)

◊ Finishing broom

◊ Mechanical trowel

Figure 5. Hand tool and equipm e n t used for finishing concre t e

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE FINISHING (CONT'D)

Techniqu e s of Finishin g Concre t e

The five basic stages for concre t e slab finish work are:

1. Edging

2. Grooving

3. Floating

4. Troweling

5. Brooming

All of these techniques may be used on a project, but sometime s they are not required. All five will usually be used of flat exterior surfaces where heavy foot traffic is expec t e d , such as, sidewalks, outdoor patios, and pavilions.

Edgin g

In some construction, the edging is star t ed right after the waiting period. In others, it is done after the float. At some point there will be a manda to ry waiting period until the free water is gone.

Not all slabs require edging. If edging is required, it is the first finishing technique applied in the series of final finish opera tions .

The corner trowel (edger) is a fine detail trowel used in finishing. Figure 6 shows the use of this tool. The workman uses the corner trowel or edging trowel to place a uniform, rounded edge on concre t e floors and slabs. This gives the edges of the concre t e more streng th and reduces chipping of this area. The workman places the corner trowel betwee n the suppor ting form and the fresh concre t e slab to square the edges or corners of the concre t e surface. The corner or edging trowel is used after the bull float and normally, after the manda to ry waiting period.

It may be necess a ry to add small amoun ts of concre t e or mortar to small areas that are jagged from large aggreg a t e holes. Do not allow the workmen to work the edges so much that they leave a deep impression on the top surface of the slab. These impressions are extre m ely hard to remove once they are made. Do not allow the workmen to add dry ceme n t mix to the surface to soak up bleed water.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE FINISHING (CONT'D)

Techniqu e s of Finishin g Concre t e (Cont'd)

Edgin g (Cont'd)

Figure 6. Use of a corner trowel (edger)

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE FINISHING (CONT'D)

Techniqu e s of Finishin g Concre t e (Cont'd)

Groovin g

The grooving trowel is used to make finished grooves in the concre t e , such as the joints in concre t e sidewalks and patio slabs. This can be done at the same time as the edging or it can be done after the edging is comple t ed . The grooving trowel gives a stronger finished joint in the groove. These grooves relieve the pressure on the slab. If the cemen t cracks, it will usually crack along these grooves , which does not grea tly affect the streng th or appea r a nc e of the work The groover trowel is like a steel hand trowel with a grooved blade on the bottom called a bit The normal bit size for most slab construction is 3/4” (19.05 mm) or 1 ” (25.4 mm) deep. Figure 7 shows a groover being used on a concre t e slab.

Figure 7. Use a grooving trowel to make grooves in slabs and sidewalks

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE FINISHING (CONT'D)

Techniqu e s of Finishin g Concre t e (Cont'd)

Floatin g

After edging and grooving, the workman uses the hand float to begin the third stage of smoothing the surface of the concre t e . This floating procedure is done after the concre t e initially sets . This is not to be confused with using a bull float to level the concre t e . Bull floating is done while the cemen t is still fluid. Figure 8 shows the use of a hand float.

The purpos e of floating the concre t e is to smooth out rough spots left by the leveling process and to embe d large aggreg a t e undern e a t h the surface of the concre t e . This procedure slightly consolida t e s and tightens the surface. When properly done, the floating leaves the surface dense and smooth and ready for the steel troweling.

Hand floats are used for the floating procedur e . They come in a variety of sizes and shapes and are made from different mate rials. The all-wood hand float is the most used one. Special floats are also available for special surfaces . These surfaces will depend on the final covering of the slab or floor. If the concre t e is to be white concre t e , be sure the workmen use plastic or stainless steel to preven t stains on the finished surface.

The time to star t the floating depends on many factors, such as, temp er a t u r e , wind, humidity, slump of the concre t e and the type of subgrad e . The time may be two hours after leveling is comple t ed or it may be as long as eight hours. The factors you must depend on when deter mining when to star t the floating are:

◊ The water sheen or shine must have disapp e a r e d from the concre t e surface .

◊ The mix must be stiff enough that when you stand on the concre t e surface , you will leave only a slight footprint, not more than 1/4” (6.35 mm) deep.

The footprints will be smooth e d away during the floating procedur e .

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE FINISHING (CONT'D)

Techniqu e s of Finishin g Concre t e (Cont'd)

Floatin g (Cont'd)

Figure 8. A worker using a hand float

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE FINISHING (CONT'D)

Techniqu e s of Finishin g Concre t e (Cont'd)

Trow elin g

The hand trowel or steel trowel is used in the final stages of the finishing. This produces a hard and dens e surface . Figure 9 shows the use of this tool.

The hand trowel is usually made of metal and is sometime s called a steel trowel, although they can be made of other materials . There are special trowels for special purpos es . Some have special rounded ends for work on rounded surfaces .

The workman uses the hand trowel over small areas of concre t e during the final stage of surface finishing. He uses the trowel before the final set of the concre t e . The hand trowel gives the concre t e surface a very smooth finish. This finish is called a hand- troweled finish .

The first troweling is done as soon as the surface is floated . The blade is kept as flat agains t the surface as possible. If the blade is not held flat agains t the surface, it will vibrate (chat t e r) and produce a rough, wavy effect in the surface. Ensure that the troweled surface is smooth and free of defec ts . Additional troweling can improve the smoothing. Each additional troweling is done after a short time lapse to increas e the set of the concre t e . A smaller trowel is necess a ry on each additional troweling so the worker can apply grea t e r pressure on the concre t e surface .

The successive troweling are done with the blade at a slight angle to the surface. This allows the back side of the blade to exert pressure and smooth the surface.

The final troweling (burnishing) is called a hard trowel and is also done with the blade at the proper angle. You will know this is done correc tly by the ringing sound the trowel makes as it passes over the surface .

The use of power tools some tim e s replaces the troweling procedur e . This is discuss ed later.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE FINISHING (CONT'D)

Techniqu e s of Finishin g Concre t e (Cont'd)

Trow elin g (Cont'd)

Figure 9. A workman using a hand trowel

Sometime s bubbles and blisters will appe ar in the concre t e surface during troweling. This may happe n when the partially harden e d slab is sprayed with water and then sprinkled with dry cemen t . This is caused by the water get ting trappe d in the aggreg a t e voids under the cemen t topping. This procedur e of cemen t topping should never be allowed.

Any of the finishing opera tions done while water is still on the surface may cause scaling . Excessive early troweling may result in crazing .

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE FINISHING (CONT'D)

Techniqu e s of Finishin g Concre t e (Cont'd)

Broomin g

The concre t e surface from troweling is hard, dens e and very smooth , but it is also slippery, especially when it become s wet after curing. To provide a nonslip finish, the workman uses the finishing broom. Any degre e of roughn es s can be obtained, depending on the type of brush or broom used and the time at which the brushing is done.

Figure 10 shows a workman pulling the broom over the surface of the concre t e . The broom bristles comb the concre t e surface and leave an abrasive finish. You call this abrasive finish a broom finish .

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Figure 10. A workman using a finishing broom

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE FINISHING (CONT'D)

Techniqu e s of Finishin g Concre t e (Cont'd)

Mech a nic a l Finish er

Most concre t e slabs and floors require a broom finish or a hand-troweled finish. Sometime s the construction plans specify a mecha nical finish. The workman uses a mecha nical finisher to provide a smooth, uniform finish. The mechanical finisher, also called a power float , has an engine that rotat e s four blades . Some mecha nical finishers have three rotary engines . The rota ting blades smooth the concre t e surface until the required finish is obtained. Figure 11 shows a single rotary mecha nical finisher.

Bubbles may appea r from star ting power troweling too early or by troweling with the front of the trowel angled too high. This causes troweling with only the back side of the blade. This causes the surface to seal too early and traps air under the surface . This can be avoided by troweling when the right time is indicated and by opera ting the power trowel with the blades at the proper , flat angle.

Figure 11. A workman using a mech a nical finisher

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INSPECTING THE CONCRETE FINISHING (CONT'D)

Techniqu e s of Finishin g Concre t e (Cont'd)

Verifica t io n

During concre t e finishing, you must verify that the workmen follow following procedure s :

◊ Every precau tion is taken to preven t finishing faults. You must verify that the concre t e is properly leveled and ready to finish.

◊ The timing and the removal of forms, after initial set ting is correc t. Do not allow tempor ary forms and props to be remove d to quickly.

◊ No finishing opera tion is performe d while free water is still presen t on the surface.

◊ The amount of finishing necess a ry is kept to a minimu m to produce the required surface .

◊ Do not overwork the fresh concre t e during finishing or begin troweling too soon after placem e n t . Troweling should begin after all free water is gone and after the initial rest period.

◊ The finish mee ts the specifications and toleranc es according to Saudi Aramco and industry specifications .

Refer to Work Aid 1 for steps on how to verify concre t e finishing.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE CURING

Descrip t i o n and Purpo s e of Curing

Curing is the process involving monitoring fresh concre t e to assure sufficient levels of water during hydra tion. Curing promot e s hydration , which is the chemical process of the reaction of cemen t and water. This process star ts when the two product s are placed togeth e r and continues in a steadily decrea sing rate for month or even years . If there is not enough water , hydra tion of the cemen t will stop and there will be no further gain in streng th and durability of the concre t e . There is a sufficient amoun t of water in the right mixture of concre t e for the hydra tion. It is your job to ensure that it is retained during the curing process . This is done by not allowing the water in the concre t e to evapora t e , but to be consum e d by the hydra tion process . You ensure reten tion by one of the following curing methods :

◊ The application of water directly or through some mate rial in contac t with the surface that holds a reservoir of water .

◊ The use of a seal material, such as polyethylen e or curing compound , to preven t or retard the escape of moisture from the concre t e .

Alterna t e wetting and drying will do more dama g e than no curing at all.

Curing makes good, durable concre t e . If concre t e is not properly cured it has low streng th , poor durability and other deficiencies that affect the usefulness and beau ty of the ceme n t structure .

Your job during the curing process is to ensure that sufficient water is provided. In some mann er so as to continue this process for at leas t 7 days, as specified in SAES- Q-001, Paragraph 10.3, which states , “Water curing shall be continuous until the compres sive streng th has reached 70% of the specified streng th , but not less than 7 days after place m e n t .” Concre t e increas e s in streng th almost indefinitely if it is kept moist, but dry concre t e quickly reaches its curing limit as shown in Figure 12. Notice that after about six months , the curing of the dry concre t e stops and at one year the dry concre t e is only about half as strong as it would have been if wet.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE CURING (CONT 'D)

Descrip t i o n and Purpo s e of Curing (Cont'd)

Figure 12. Graph comp arison of curing wet and dry concre t e

You must verify that all types of concre t e are cured in the specified way. Improper or non- uniform curing procedure s will cause following defects :

◊ The formation of voids and honeyco m bing resulting in the lowering of streng th of concre t e .

◊ A variation in the color of the surface of the concre t e .

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INSPECTING THE CONCRETE CURING (CONT 'D)

Effec t s of Weath er on Curing

All the various aspec t s of weather have an effect of the curing process . But, most importan t are heat , cold and vapor. Figure 13 shows the effects of heat and cold.

Hot Weat h e r

High temp er a t u r e s during hot weather advers ely affect the curing of

concre t e . A concre t e temp er a t u r e of 80 ºF (26.6 ºC) or above during and immedia t ely after placing will result in lower streng th compar e d with

concre t e mixed and placed at 40ºF to 80

ºF (4.44

ºC to 26.6

ºC). Figure

13A shows how high temp er a t u r e affects the streng th of concre t e . Notice that concre t e made and cured at a high temp er a t u r e has high early streng th up to four or five days, but beyond that time, the streng th is not as good as concre t e made and cured at a temp er a t u r e

of 73 ºF (22.7 ºC).

More moisture is required as the temp er a t u r e rises. At 70ºF (21.1

ºC),

0.016 lbs of water are required per pound of air to maintain a 100%

humidity rate. For the same situa tion, with a temp er a t u r e of 140 ºF

(60ºC) it requires 0.15 lbs of water and at 180

ºF (82.2

ºC), it requires

0.66 lb of water.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE CURING (CONT 'D)

Effec t s of Weath er on Curing (Cont'd)

Cold Weath e r

Figure 13B shows that concre t e made and cured at low temp er a t u r e s

does not develop streng th like concre t e cured at 73 ºF (22.7 ºC). Cold weath er requires heating to keep the concre t e warm. Heating the concre t e makes it difficult to maintain sufficient moisture . It is usually recom m e n d e d not to remove the forms in cold weath er during curing. Curing compounds are used becaus e water for curing cannot be used in cold weath er . Observe following precau tions for curing concre t e in cold weath er:

◊ Provide insulation and heat e d enclosure s , as necess a ry.

◊ Heat enclosure with stea m and blowers instead of stoves .

◊ If heat e r s are used, vent them outside the enclosure and raise them above surface level.

◊ Leave forms in place as long as possible.

◊ Maintain the proper temp er a t u r e as specified.

◊ Avoid overhe a t ing the concre t e .

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INSPECTING THE CONCRETE CURING (CONT 'D)

Effec t s of Weath er on Curing (Cont'd)

Cold Weath e r (Cont'd)

Figure 13. Effects of temp er a t u r e on curing of concre t e

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INSPECTING THE CONCRETE CURING (CONT 'D)

Curing Metho d s

Curing methods can be grouped into two general categories :

1. those that supply additional moisture to the concre t e , and,

2. those that preven t loss of moisture from the surface by sealing

Curing of the concre t e is probably the most violated portion of the concre t e construction process . Any commo n method of curing will give the type of concre t e required, if the method is properly applied.

Supplyin g Addition a l Moistur e

In this category of curing are such methods as sprinkling, ponding and wet covers of various kinds. The problem arises in the difficulty of keeping the concre t e continuously wet. Frequen tly, workers sprinkle water one time a day and go on to their other jobs. This once a day sprinkling will not provide the amoun t of water required. In situa tions such as this, the water curing does not work as well as it should. In fact, sometime s intermit t e n t watering is worse than no watering at all, depending on the temp er a t u r e . Water sprinklers, soaker hoses and other means of keeping the entire surface wet are the best methods . Pieces of burlap loosely draped over the concre t e , whether wet or dry, do little for the curing process . Alternating wet and dry are worse than no wetting at all.

Another way to supply additional moisture is to use a moisten e d material such as burlap blanke t s and mats of cotton or other material. Even thes e however should be kept constan tly moist by a sprinkling method.

Prev e n t i n g Loss of Moistur e

This method can be classified as sealing, either with a plastic material or a compound . The function of this method is to seal the water that is already in the concre t e so it will not escape , thus making it available for curing. This method does not supply any additional water, but it does supply moisture that would have been lost without the seal.

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INSPECTING THE CONCRETE CURING (CONT 'D)

Curing Material s

Following are the materials that are use for curing:

◊ Water

◊ Wet coverings

◊ Immersible shee t mate rial

◊ Sealing compounds

Water

The water used for curing concre t e must be sweet water (1000 ppm TDS). Concre t e mixing water is also suitable for curing water. An adequ a t e sweet water supply must be available to the workers at all times during the curing process . If you have any doubts about the supply of water for curing, send a sample to the labora tory for tes ting. Refer to the section on docume n ting the inspection results and Work Aid 4 for information about comple ting this form and the results you will obtain from the labora tory.

Wet Coverin g s

Burlap, cotton mats and other moisture retaining fabrics are commonly used in curing, particularly on surfaces that are not flat and which are difficult to keep wet. Burlap sacks used for storage container s must be thoroughly cleane d of all material so that it will not cause harm to the fresh concre t e . Some burlap is resistan t to rot and fire. New burlap should be washed to remove the material which they are trea t e d with called sizing . Washing will remove the sizing which is a waterproof coating and will make the burlap more absorben t . Curing mats may be made from cotton or similar mate rials. The outside cover is usually waterproof to aid in retaining the moisture. Therefore , these mats must be water ed and then placed upon the structure . Watering the outside cover will do no good. Sometime s a small water tube is placed inside these covers to provide a steady flow of water. The mats are usually quilted to absorb more water. They becom e quite heavy when satura t e d so they must be properly secured so that they will not slip off the surface.

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INSPECTING THE CONCRETE CURING (CONT 'D)

Curing Material s (Cont'd)

Imperm e a b l e She e t Material

Slabs and pave m e n t s are frequen tly cured by covering with an imperm e a bl e shee ting of some type. ASTM C 1 71 specifies three types of material:

◊ Waterproof paper , either regular or white. Ensure that it is in two layers with padding betwe e n . Ensure that it is factory trea t e d to provide high wet streng th .

◊ Polyethylen e film, clear or white, of at leas t 6 mils (0.15 mm) thickness . The clear film should be transparen t and the white film should be opaque .

◊ White burlap- polyethylen e shee t

Check the mate rial to ensure that it is strong tough and resilient. It mus t be strong and thick enough to withstand the heat and the wind that is presen t during summ e r in Saudi Arabia. It should withstand normal use without puncture or tearing. Any holes will allow the water to evapora t e and not be usable during the curing process .

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INSPECTING THE CONCRETE CURING (CONT 'D)

Curing Material s (Cont'd)

Sealin g Comp o u n d s

Sealing compound s are used to seal the surface of new concre t e after it has been finished. It preven t s the loss of moisture from the concre t e , thereby retaining it for the hydra tion process . This material is known by various name s such as sealing compound , curing compound and membr a n e- forming compoun d. It is a paint- like liquid that, when spraye d on concre t e , forms a water tigh t membr a n e on the surface. This holds the free water in the concre t e mixture while it cures. ASTM C 309 gives the specifications for these types of compound s :

◊ Type 1 - Clear or translucen t without dye

◊ Type 1-D - Clear or translucen t with fugitive dye

◊ Type 2 - White pigmen t e d

These compound s are placed in a liquid for delivery through the spray. This liquid is called the vehicle . Following are the restrictions on the types of vehicles that can be used with the various types:

◊ If the compound is classified as Type A, there are no restrictions on the vehicle.

◊ If the compound is classified as Type B, all vehicle solids are limited to all resin material.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

INSPECTING THE CONCRETE CURING (CONT 'D)

Curing Material s (Cont'd)

Sealin g Comp o u n d s (Cont'd)

Ensure thes e things about the compoun ds :

◊ If dye is used, it is distinctly visible for at leas t four hours and fades comple t ely in not more than one week

◊ It is a consistency suitable for spraying

◊ It is nontoxic

◊ It adhere to vertical and horizontal surfaces when properly applied

◊ Clear compound s should not darken the natural color of the concre t e

◊ The workmen do not apply the curing compoun d until the concre t e has initially harden e d

The ready- mixed compound s must be vigorously stirred after receipt and before spraying. Although they are ready- mixed, the compound and the vehicle will separa t e when stored . Usually the drums in which the compound is shipped have agita tors . To ensure proper mixing be sure the agita tor is opera t e d before and during spraying.

Water- emulsion, resin- based compoun ds are being widely used now in areas where solvent- releas e mate rials are prohibited . These water-emulsion, resin- based compoun ds satisfy the requirem e n t s of ASTM Type 1, Class B and ASTM Type 2, Class B.

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INSPECTING THE CONCRETE CURING (CONT 'D)

Curing Spe c i f i c Structur e s

Different concre t e structure s are cured in differen t mann er s mainly becaus e of their shape and intende d purpos e .

Curing Exterior Flat Concre t e Surfac e s

To monitor the curing of large flat areas , such as pave m e n t s , roofs, bridge decks and exterior floors, you must verify that the workers maintain the best temp er a t u r e and moisture levels. The first step is to preven t rapid drying of the concre t e surface . The workers must use a lightweight film, such as polyethylen e film, to protec t the concre t e . This will produce a fine fog that will retain the moisture . The workers must properly seal the polyethylen e film along the edges to preven t the wind from blowing under the plastic cover. This method usually doesn’t require much labor or an extensive water supply.

Flat slabs can be cured simply and properly by building a small ear th dike around them and flooding it with water. This method called ponding is especially suitable for small slabs on grade . If ponding is to be use on suspend e d slabs, the shoring and formwork will require construction to withstand this extra load. On footings and below grade walls, a moist- ear th backfill can be used for curing as soon as the concre t e has harden e d to withstand the earth pressure . Additional props may be required in this case, which should be engineer e d into the plans. The disadvan t a g e s of using ear th backfill are that it may contain chemicals harmful to the concre t e and it may stain the concre t e . Therefore, this method should only be used in areas where appea r a nc e is not a primary considera tion. As soon as the backfill is remove d, the walls and footings should be cleaned with a cleaner that mee t s Saudi Aramco specifications for concre t e cleaning.

On uniform surfaces such as the tops of walls or girders , wet burlap mats should be used as soon as the concre t e has harden e d sufficiently. This is particularly importan t at construction joints, which cannot be cured with sealing compoun d.

The workers may also use sand, provided they use a steady strea m of water to keep the surface wet. This method is not always feasible or possible here in Saudi Arabia, becaus e the sand has so much of the compound s chloride and sulfate . These compounds are detrimen t a l to

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new concre t e . Clean sand is expensive to make in country or ship from abroad.

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INSPECTING THE CONCRETE CURING (CONT 'D)

Curing Exterior Walls , Column s and Bridg e Piers

The procedure for curing vertical exterior surfaces is similar to curing horizontal surfaces with one excep tion. After removal of the forms, the workers will use a liquid membr a n e -forming compound sprayed, rolled or brushed on the fresh concre t e . This spraye d- on compound will retain the necess a ry moisture in the same way a layer of polyethylen e placed over a horizontal concre t e surface .

A method for curing pier abutm e n t s is to have workers place shee t s of polyethylen e or burlap over and around the vertical surfaces and apply a steady trickle of water betwee n the concre t e and the airtight polyethylen e cover. The sprayed water will cure the concre t e satisfactorily but will not give much protec tion agains t the solar heat . This is only practical where there is an abund a nc e of fresh mineral-free water . The water mus t not contain any sulfides or iron. These minerals will perma n e n t ly stain the concre t e .

Curing Interior Concre t e Surfac e s

Workers can proceed with curing inside enclosed buildings using any of the following: methods :

◊ Liquid membr a n e- forming compound

◊ Impervious shee t material, such as paper or plas tic

◊ A fine spray from a hose, if the room is closed to maintain high humidity

◊ Use of absorbe n t covers, such as burlap, cotton mats , washed sand or sawdus t

If workmen will be moving about on the concre t e during the curing periods, use wet washed sand or sawdus t instead of the membr a n e curing method to protec t the concre t e from abrasion. However , the workers must keep the sand or sawdus t wet and keep it deep enough to protec t the surface until the curing is comple t e .

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INSPECTING THE CONCRETE CURING (CONT 'D)

Insp e c t i o n Point s

During concre t e curing, you must verify that the workmen follow following procedure s :

◊ Maintain the optimu m temp er a t u r e range for the concre t e immedia t ely after placing.

◊ Maintain a strea m of water over the mixture at all times. The supply of water for hydra tion is always of primary importanc e . Alterna t e wetting and drying will do more damag e than non-curing at all.

◊ Do not apply any curing compound until the concre t e has initially harden e d .

◊ Tightly secure the polyethylen e to preven t the wind from blowing under the plastic cover.

◊ If workmen will be moving about on the concre t e during the curing periods , you must verify they use wet sand or sawdus t instead of the membr a n e curing method to protec t the concre t e from abrasion.

Refer to Work Aid for procedur e s on inspecting concre t e curing.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

P ERFORMING TEST FOR HARDENED CONCRETE

There are several ASTM standards for sampling harden e d concre t e and tes ting concre t e for streng th , percen t of air, specific gravity and ceme n t conten t . These tes ts are usually performe d by the labora tory on harden e d concre t e and are only performe d in case there are ques tions or resulting problems. You may be required to collect and prepare the samples for thes e tes ts , so the empha sis will be on sampling for thes e tests and on- site hardnes s testing

Samplin g Harden e d Concre t e

Core Sam plin g

One of the most common way of sampling harden e d concre t e is to extrac t core samples from the structur e using a diamond drill. The diame t e r of the core depends on the following:

◊ The thickness of the concre t e memb e r being sampled

◊ Maximum size of the aggreg a t e (MSA) in the concre t e . The diame t e r of the core must be at leas t twice the size of the nominal MSA; three times the size is even bet t er

◊ The presenc e of embed d e d Items that might be dama g e d by drilling

Check the drill to ensure that it Is In good opera ting condition and that it is well anchored . Any loosenes s in the machine or loose bearings may cause the bit to wobble which may damag e the core.

ASTM C 42 covers the removal of cores and sawed beams from harden e d concre t e . Samples should be repres e n t a t ive of the concre t e placed. Avoid any obvious defects or discontinuities. If you can identify the area by the batch numb er , you should take the core near the center of the area where the batch was placed. The ratio of the length to the diame t e r of the core should be about 2:1, however shorter ones may be required to avoid dama g e to embed d e d items. Any core with a length of less than 95% of its diame t e r should not be used for compres s ive streng th tes ting.

Cores may be taken for purpos es other than streng th tes t Core samples are used to check the depths of honeyco m b, surface deteriora tion, thickness of slab or to examine construction joints.

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Honeyco m b s occur where the areas around the aggreg a t e do not fill with cemen t during the pour. This is usually a result of poor consolida tion techniques . The result is a rough surface with cavities up to several inches deep. Honeyco mb s may extend complet ely through the memb er and make it structur ally unsound. This condition is more common in vertical surfaces than in horizontal surfaces .

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

P ERFORMING TEST FOR HARDENED CONCRETE (CONT 'D)

Samplin g Harden e d Concre t e (Cont'd)

Core Sam plin g (Cont'd)

The location of the cores for these purpos es will depend on the surface appea r a nc e of the concre t e and the best approach to the affected area .

Most coring and cutting machines use water for lubricating and cooling. Samples taken in thes e ways will not be sufficient for moisture tests .

Broke n Concre t e Sam pl e s

Samples of concre t e broken from the structur e are sometime s sent to the labora tory for analysis or tes ting. The sample should be taken so that it is repres e n t a t ive of the portion of the concre t e requiring testing. Select several pieces , if possible or a single piece, if necess a ry. The total should be about 300 mm of samples for concre t e with 20 mm (or more) MSA.

Mark each sampling with sufficient informa tion to identify the location from which it was taken. Include the batch numb er for that area, if available. Place each sampling (area) in a differen t sample bag or box, Samples should be well padded and protec t e d from breakag e . If moisture conten t is importan t , place the sample in a moisture proof plastic bag.

Regardles s of any other tests , there should be tests for specific gravity and density of the concre t e . Some of the sample for these tests must be boiled prior to tes ting. These boiled samples must not be use for streng th testing.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

P ERFORMING TEST FOR HARDENED CONCRETE (CONT 'D)

Samplin g Harden e d Concre t e (Cont'd)

Onsit e Test s for Hard e n e d Concre t e

Testing of harden e d concre t e on- site usually consists of two categories of tests; in-place streng th tes ting and nondes t ruc tive streng th testing

In- plac e Stren g t h Testin g

This tes t is usually accomplished by a device inserted into the concre t e in some mann er and then remove d. The amount of energy required to remove the device is recorded. This data is used to deter mine the in-place streng th of the harden e d concre t e .

Following are the two methods of doing this test:

1. An insert is embe d d e d into the fresh concre t e when it is poured. Once the concre t e has harden e d , this inser t is pulled out of the harden e d concre t e and the results are deter min ed and recorded . This method is covered in ASTM C 900

2. In this method, a hole is drilled into the harden e d concre t e and a special device is inser ted into the hole. This inser t is then remove d and the results deter mined and recorded.

In both methods , the force required to pull out the inser ted device is a meas ur e of the streng th of the harden e d concre t e .

Nond e s t r u c t i v e Stren g t h Tes tin g

Impact devices are used to deter min e the streng th of harden e d concre t e . There are two instrum e n t s used for this purpos e; the Swiss ham m e r (also called the Schmidt ham m e r) , used for what is commonly called hamm e r testing and the Windsor probe used for testing at grea t e r depths of the concre t e . The Swiss hamm e r uses a spring actua t e d plunger that strikes the concre t e and meas ure s the rebound of the tip (ham m e r) . This tool is commonly called the rebound ham m e r . For Information on the rebound ham m e r , refer to module, CVL 200.02, Concre t e Testing.

The Windsor probe is similar to the Swiss hamm e r in both use and results . The main difference is that this tool is activa t ed by a cartridge filled with gun powder, similar to the cartridge- driven fastening tools, such as the Ramse t fastening tool. The powder- filled cartridge

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explodes actua ting a probe that strikes the concre t e surface. The rebounding force is an indication of the streng th of the harden e d concre t e .

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

P ERFORMING TEST FOR HARDENED CONCRETE (CONT 'D)

Samplin g Harden e d Concre t e (Cont'd)

Onsit e Test s for Hard e n e d Concre t e (Cont'd)

Nond e s t r u c t i v e Stren g t h Tes tin g (Cont ’d)

Warning: If the Windsor probe is used, ensure that it is used safely in accordance with the manufacturer’s instructions. It uses a powder- filled cartridge (like a blank cartridge used in a gun). It is very powerful and can be deadly at close range. Do not point it at yourself or anyone else while it is in use.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

DOCUMENTING INSPECTION RESULTS

The Inspection results will be docume n t e d on the project Inspection forms as specified in Saudi Aramco Engineering Procedure , SAEP-1150.

Field Not e s

Write you findings in your field notes to record data and Informa tion about your inspection. These notes are personal observa tions about an inspection. Record all of your observa tions , findings, conclusions and recom m e n d a t ions about the inspection. You will use thes e notes later when you make logbook entries , comple t e the required forms or write your reports .

Site Logbo o k

Use the inspection Logbook maintained on site to communica t e with the construction agency. Logbook entries are the most common form of communica tion with the agency. SAEP-1150, Paragraph 9.4, explains the inspection logbook. Figure 14 illustra t e s a comple t e d page from a logbook. The pages in the logbook are numb er e d for referenc e purpos es .

Use the site logbook to record any initial findings during the prepara t ion for the inspection and any findings in the finishing, curing and testing procedur e s . The discrep ancies in the finishing inspection may require corrective action before the curing can begin. Refer to module on “Write Inspection Reports (Generic)," for more informa tion and work aids on how to comple t e these forms. When a discrepa ncy/ies is satisfactorily comple t ed , you must always legibly sign the logbook entry in the far right- hand column across from the original entry. Notice, in the figure, that one item has been complet ed and signed off. The other item has still not been accomplished or cleared.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

DOCUMENTING INSPECTION RESULTS (CONT 'D)

Site Logbo o k (Cont'd)

Figure 14. Example of inspection logbook

Projec t s Insp e c t i o n Report (Saudi Aramc o Form 82 1 3 - ENG)

By the time you get to the point of testing the harden e d concre t e , the site logbook may not be available. Also, on small jobs, there may not be a site logbook. In either case, use the Projects Inspection Report to call atten tion to a problem. Saudi Aramco Inspection Procedure , SAEP-1150, explains the Projects Inspection Report. Supporting docume n t a t ion for the report , such as, sketches , are also made a part of the report Figure 15 shows a comple t ed Projects Inspection Report.

Note: Refer to SAEP-1150 for other uses.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

DOCUMENTING INSPECTION RESULTS (CONT 'D)

Projec t s Insp e c t i o n Report (Saudi Aramc o Form 82 1 3 - ENG) (Cont'd)

Figure 15. Complet e d Project s Inspection Report , SAF 8213- ENG

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

DOCUMENTING INSPECTION RESULTS (CONT 'D)

Projec t s Insp e c t i o n Report (Saudi Aramc o Form 82 1 3 - ENG) (Cont'd)

Always identify second and succeeding pages . Use another original form for the subsequ e n t pages . Enter this minimu m of informa tion on subsequ e n t pages of the report:

◊ Bl/JO numb er

◊ Report number

◊ Project title

◊ Plant number and/or equipme n t numb er

◊ Date of the inspection

Identify the subsequ e n t pages by numb ering them with the next consecu tive numb er and also the total numb er of pages . For example, for a 5-page report , you numb er subsequ e n t pages as Page 2 of 5, 3 of 5, 4 of 5 and 5 of 5.

Laborat ory Testin g Forms

When specimen s and core samples are sent to the labora tory for the jobsite, you may use the labora tory form, SAF 8563 to include your portion of the required informa tion. The labora tory will return the forms with the results of the cylinder tes ts indicated in the bottom portion of the form.

You are required only to provide the informa tion about the specime ns on this form. Use Work Aid 4C to assist you in comple ting this form.

Water quality test may be required for the curing water. If you have any doubts as to the quality of the water, send a sample to the labora tory for tes ting. When submit ting the sample of water for testing, use the labora tory reques t form. Follow the instructions in Work Aid 4D to comple t e the form. The results will be returne d on the form as shown in Addendu m 2.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT INFORMATION

DOCUMENTING INSPECTION RESULTS (CONT 'D)

Laborat ory Testin g Forms (Cont'd)

ARAMCO 2600 (2/59)

SPECIMEN NUMBER

REMARKS

SPECIMEN NO. DATE SAMPLED

DESIGN W/C RATIO

LOCATION IN STRUCTURE

COARSE AGGREGATE

FINE AGGREGATE CEMENT WATER

ACTUAL SLUMP

TEST DATA AIR TEMP

MIX TEMP

AIR UNIT WT kg/cu m

DATE CAST

DATE TESTED

MIX DESIGN DATA

ADMIXTURE

OTHER

DESIGN STRENGTH & MIX CODE

FIELD TEST REPORT OF PORTLAND CEMENT CONCRETE SAUDI ARAMCO 8563 REPORT NO.

TYPE OF SPECIMEN (CHECK ONE) ( ) CYLINDER 150 x 300 mm

( X ) CYLINDER 6" x 12"

PROJECT NAME

CONTRACTOR

SOURCE SOURCE SOURCE SOURCE SOURCE SOURCE

7

14

28

28

DATE & TIME SPECIMEN RECEIVED AT LABORATORY

COPY TO: LAB. ENGINEER

INSPECTION DEPARTMENT PROJECTS INSPECTION DIVISION

CIVIL TESTING GROUP TIME SAMPLED DATE SAMPLED

LOCATION OF JOB SITE

TICKET & LOAD NO. TEST REPRESENT cu m

kg/cu m

L

Litre (%)

kg/cu m kg/cu m kg/cu m

DESIGN SLUMP TOTAL FREE mm

DESIGN AIR CONTENT %

WATER ADDED BY CONTRACTOR / SUPPLIER

%

AVERAGE STRENGTH, N/sq mm

REMARKS UNIT WT., kgs/cu m

STRENGTH, N/sq mm

BREAKING LOAD, kN

WATER ADDED AT SITE L

BEFORE OR AFTER TESTING

PLANT LOCATION/SUPPLIER SPECIMEN NO. JOB NUMBER

AGE DAYS

( ) OTHER

mm °C °C

Figure 16. SAF 8563, Field Test Report of Portland Cement Concret e

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CVL 301.05 (SAP ID 40009511) PARTICIPANT EXERCISES

EXERCISE 1. INSPECTING THE CONCRETE FINISHING

Multipl e Choic e:

Circle the letter indicating the best answer.

1. What is the primary purpos e of finishing concre t e?

A. Assists in curing

B. Helps get rid of the bleed water

C. Makes the concre t e harder

D. Gives the required surface

2. When does the finishing of concre t e star t?

A. After the concre t e is placed

B. Before bleed water is gone

C. Before the forms are removed

D. When the concre t e star ts to harden

3. When do the plans require only a rough, uniform finish?

A. When the concre t e is used for heavy foot traffic.

B. When the concre t e is used in industrial.

C. When the concre t e will have a topping.

D. When the concre t e will be tiled.

4. When would the plan call for a non- skid finish of the concre t e?

A. When the concre t e is used for heavy foot traffic.

B. When the concre t e is used in industrial.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT EXERCISES

C. When the concre t e will have a topping.

D. When the concre t e will be tiled.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT EXERCISES

EXERCISE 1. INSPECTING THE CONCRETE FINISHING (CONT 'D)

Multipl e Choic e:

Circle the letter indicating the best answer.

5. To what tolerance s must workers finish floors and slabs?

A. 1/16" for every 5'

B. 3/16" for every 10'

C. 1/16" for every 10'

D. 3/16" for every 20'

6. Which of the following flatness and level numb er s indicate the most flat and level floor profile?

A. 50, 13

B. 20, 20

C. 15, 30

D. 50, 30

7. Which of the following types of finish is not one of the three major types of formed finish?

A. Cork float finish

B. Matched sample finish

C. As-cast finish

D. Rubbed finish

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CVL 301.05 (SAP ID 40009511) PARTICIPANT EXERCISES

EXERCISE 1. INSPECTING THE CONCRETE FINISHING (CONT 'D)

Multipl e Choic e:

Circle the letter indicating the best answer.

8. Which of the following tools is not used during the leveling portion of the finish work?

A. Screed

B. Bull float

C. Steel trowel

D. Darby

9. When using the trowel on the first troweling, how is the troweling done?

A. While the bleed water is till presen t and the trowel is held at an angle to the concre t e .

B. As soon as the surface is floated and the trowel is held flat agains t the surface .

C. After the concre t e has harden e d and the blade is held flat as possible agains t the surface .

D. As soon as the surface is floated and the trowel is held at an angle to the surface.

10. After the first troweling, successive troweling are done in which of the following ways?

A. A slight angle of the blade to the surface with a larger blade each time.

B. The blade is flat to the surface using a smaller blade each time.

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C. The blade is at an angle to the surface with a similar blade each time.

D. The blade is flat to the surface with a smaller blade each time.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT EXERCISES

EXERCISE 1. INSPECTING THE CONCRETE FINISHING (CONT 'D)

The following situations pertain to the finishing of concret e . Inspection findings are given. Write your conclusions (what is wrong) and recom m e n d a tions (actions taken). If the procedure is correct, write "This is the correct procedure," in "Conclusions" and "No action is required" in "Recom m e n d a tions ."

11. Findin g s : Workers are removing formwork as soon as the workers finish the concre t e .

Conclu s i o n s :

Reco m m e n d a t i o n s :

12. Findin g s : Workers are finishing the surface with bleed water presen t .

Conclu s i o n s :

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CVL 301.05 (SAP ID 40009511) PARTICIPANT EXERCISES

Reco m m e n d a t i o n s :

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CVL 301.05 (SAP ID 40009511) PARTICIPANT EXERCISES

EXERCISE 1. INSPECTING THE CONCRETE FINISHING (CONT 'D)

The following situations pertain to the finishing of concret e . Inspection findings are given. Write your conclusions (what is wrong) and recom m e n d a tions (actions taken). If the procedure is correct, write "This is the correct procedure," in "Conclusions" and "No action is required" in "Recom m e n d a tions ."

13. Findin g s : Workers are finishing the concre t e after it has harden e d .

Conclu s i o n s :

Reco m m e n d a t i o n s :

14. Findin g s : You suspec t that water used in the curing process is conta mina t e d .

Conclu s i o n s :

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CVL 301.05 (SAP ID 40009511) PARTICIPANT EXERCISES

Reco m m e n d a t i o n s :

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CVL 301.05 (SAP ID 40009511) PARTICIPANT EXERCISES

EXERCISE 2. INSPECTING THE CONCRETE CURING

Multipl e Choic e:

Circle the letter indicating the best answer.

1. What is the primary purpos e of curing concre t e?

A. Giving it a good appe ar a nc e .

B. Helps get rid of the bleed water

C. Makes the concre t e harder

D. Gives the concre t e good streng th and durability

2. What is the primary concern in curing concre t e?

A. The proper curing time

B. The proper streng th of the concre t e

C. Sufficient water for hydra tion

D. Sufficient set ting time

3. Which of the following is not a good curing method?

A. Alterna t e wetting and drying

B. Direct application of water

C. Ponding

D. Sealing

4. What is the minimu m requirem e n t for curing dura tion?

A. 70% of specified streng th

B. 80% of specified streng th

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CVL 301.05 (SAP ID 40009511) PARTICIPANT EXERCISES

C. 90% of specified streng th

D. Not less than 7 days

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CVL 301.05 (SAP ID 40009511) PARTICIPANT EXERCISES

EXERCISE 2. INSPECTING THE CONCRETE CURING (CONT 'D)

Multipl e Choic e:

Circle the letter indicating the best answer.

5. In comparing properly wetted concre t e to dry- cured concre t e , what would be the streng th difference after one year?

A. The dry- cured concre t e is 20% stronger than the wet.

B. The wet is 50% stronger that the dry- cured concre t e .

C. The wet is 2x as strong as the dry- cured concre t e .

D. There is little difference after one year.

6. Which of the following would be the nest temp er a t u r e for curing concre t e?

A. 30 ºC

B. 90ºC

C. 35 ºC

D. 25ºC

7. Which of the following is correct concerning the curing temp er a t u r e and the amoun t of water required per pound of air to maintain 100% humidity?

A. At 30 ºF, 0.016 pounds of water is required

B. At 140ºF, 0.25 pounds of water is required

C. At 60 ºC, 0.22 pounds of water is required

D. At 180ºF, 1 pound of water is required

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CVL 301.05 (SAP ID 40009511) PARTICIPANT EXERCISES

EXERCISE 2. INSPECTING THE CONCRETE CURING (CONT 'D)

Multipl e Choic e:

Circle the letter indicating the best answer.

8. When is it safe for the workers to apply a curing compound?

A. When the bleed water is gone

B. Before finishing

C. When concre t e has initially harden e d

D. After forms are remove d

9. Which of the following type of curing compound has dye?

A. Type 1

B. Type 1-D

C. Type 2

D. Type 2-B

10. What must workers do if it is necess a ry to walk on new concre t e while it is curing?

A. Spray it with curing compoun d

B. Sprinkle washed sand on the surface

C. Use planking to walk on

D. Cover with plastic and walk on the plastic

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CVL 301.05 (SAP ID 40009511) PARTICIPANT EXERCISES

EXERCISE 3. P ERFORM TESTS FOR HARDENED CONCRETE

Multipl e Choic e:

Circle the letter indicating the best answer.

1. What is the relationship to the diame t e r of the core sample and the size of the MSA?

A. There is no relationship.

B. The diame t e r of the core sample should be the size of the MSA.

C. The diame t e r of the core sample should twice the size of the MSA.

D. The diame t e r of the core sample should ten times the size of the MSA.

2. What ASTM would you refer to for information about concre t e core samples for tes ting?

A. ASTM C 171

B. ASTM C 900

C. ASTM D 516

D. ASTM C 42

3. What should be the ratio of the length of the core to the diame t e r?

A. 1:2

B. 2:1

C. 1:1

D. 2:3

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CVL 301.05 (SAP ID 40009511) PARTICIPANT EXERCISES

EXERCISE 3. P ERFORM TESTS FOR HARDENED CONCRETE (CONT 'D)

Multipl e Choic e:

Circle the letter indicating the best answer.

4. What is the required total cubic meas ur e m e n t of a broken concre t e sample for MSA of one or more inches?

A. 1 cu ft

B. 1 cu yd

C. 1 cu m

D. 100 cu cm

5. What ASTM coves embe d d e d inserts used for streng th testing harden e d concre t e?

A. ASTM C 171

B. ASTM C 309

C. ASTM C 683

D. ASTM C 900

6. What activa t e s the Swiss ham m e r?

A. A spring

B. A plunger

C. A cartridge

D. An air gun

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CVL 301.05 (SAP ID 40009511) PARTICIPANT EXERCISES

EXERCISE 3. P ERFORM TESTS FOR HARDENED CONCRETE (CONT 'D)

Multipl e Choic e:

Circle the letter indicating the best answer.

7. What activa t e s the Windsor probe?

A. A spring

B. A plunger

C. A cartridge

D. An air gun

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CVL 301.05 (SAP ID 40009511) PARTICIPANT EXERCISES

EXERCISE 4. DOCUMENT INSPECTION RESULTS

For this exercise, refer to problem s 11, 12, 13 and 14 in Exercise 1. As specified in this exercise, use those findings to comple t e the required forms. Use the data below to fill out the headings .

◊ Use today' s date

◊ Use your own name

◊ Use your organiza tion and phone number

◊ There is no Job File located in the main office

◊ The addres s for the Projects Inspection Section is Box 5290, Abqaiq. The FAX numb er is 572- 1094

◊ The addres s e e (To) is the Project Engineer . His address is P.O. Box 12, Abqaiq

◊ The BI/JO No. is 9201/21001

◊ The Report No. is SAPIS/123/92

◊ The Project Title is the Abqaiq Dining Hall Addition

◊ The Job Location is Abqaiq Dining Hall Patio

◊ Your Supervisor is Mr. Cain. His telephon e no. is 874- 1122.

◊ You took 5 core samples on the concre t e 14 days from the time you did your first notebook entry on finishing concre t e .

◊ You took 3 samples of broken concre t e for additional tes ts .

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CVL 301.05 (SAP ID 40009511) PARTICIPANT EXERCISES

EXERCISE 4. DOCUMENT INSPECTION RESULTS (CONT 'D)

Exerci s e 4A. Make Field Not e s in Field Not e b o o k

For each of the entries in proble m s 11, 12, 13 and 14, make a field notebook entry.

Exerci s e 4B. Compl e t e the Prop er Docu m e n t of the Insp e c t i o n Findin g s

Using the information in the data section and the require m e n t s given in Exercise 4A, make the proper entries and fill out the proper inspection docu m e n t according to the data given.

Exerci s e 4C. Compl e t e Saudi Aramco Form 856 3

For the core samples and broken concret e specim e n s you took, comple t e a Saudi Aramco form 8563.

Exerci s e 4D. Compl e t e a Laborat ory Requ e s t Form

For the water samples you took in proble m 14, comple t e a Laboratory Reques t Form. State specifically what the water is to be tested for. Include any chemical compound s or materials that might be detrim e n tal to concret e curing as specified in the information section of this module.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT WORK AIDS

WORK AID 1. HOW TO INSPECT THE CONCRETE FINISHING

Use this checklist as a me m or y aid to help you inspect the finishing of concret e . A checklist is only an aid. For specific instructions , procedures and specifications , always consult the applicable standard(s).

Place a check mark () or () by items as you check the m. Mark items N/A, if they do not apply. Consider unsatisfac tory all items you did not check, which are not marked N/A. List these items in your inspection report, including recom m e n d a t ions , corrective action and applicable standards .

Verify that the bleed water is gone from the concre t e surface before

finishing work begins so that crazing will not occur in the harden e d

concre t e .

Verify that the workers do not perform excessive early troweling

which may result in crazing.

Verify that the workers do not spread dry cemen t on concre t e that

is too wet to trowel.

Verify that the workers do not sprinkle water on concre t e that has

becom e too dry for proper finishing.

Verify that the workers do not perform any finish opera tion, such as

screeding, floating or troweling while bleed water is on the surface.

Verify that the workers do not trowel concre t e that has harden e d .

(Troweling of a surface that has harden e d will result indiscolora tion.)

Verify that the workers remove the forms only when the timing is

correc t. (Prema tu r e removal of forms will result in tearing and

spalling of the exterior surface of the construction.)

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Verify that bleed water is only removed through evapora tion.

(Fans may be used to assist in some cases .)

Verify that workers keep to a minimu m the amoun t of finishing

necess a ry to produce the required surface.

Verify that the workers do not over manipula t e the fresh concre t e

during finishing.

Using a surveyor ' s instrum e n t , verify that the finish mee ts the

specifications and tolerances as noted on the design drawing and

industry standards .

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WORK AID 2. HOW TO INSPECT THE CONCRETE CURING

Use this checklist as a me m or y aid to help you inspect the finishing of concret e . A checklist is only an aid. For specific instructions , procedures and specifications , always consult the applicable standard(s).

Place a check mark () or () by items as you check the m. Mark items N/A, if they do not apply. Consider unsatisfac tory all items you did not check, which are not marked N/A. List these items in your inspection report, including recom m e n d a t ions , corrective action and applicable standards .

Verify that the workers maintain a sufficient supply of water to the

concre t e at all times. Do not allow continuous wetting and drying.

Verify that the workers maintain the optimu m temp er a t u r e range for

the concre t e immedia t ely after placing and during finishing.

Verify that the workers keep the concre t e at a modera t etemp er a t u r e during curing to assure its streng th .

When used, verify that the workers do not apply any curing

compound until the concre t e has initially harden e d .

When used, verify that the workers tightly secure the polyethylen e

shee ting to preven t the wind from blowing under the plastic cover.

If workmen will be moving about on the concre t e during the curing

periods, verify that they use wet washed sand or sawdus t to protec t

the concre t e from abrasion. In this case, do not allow the use of

curing compoun d.

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Verify that the workers use every effort to keep the concre t e wet

and within a temp er a t u r e of 50 ºF to 80 ºF

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WORK AID 3. HOW TO P ERFORM TEST ON HARDENED CONCRETE

Use this checklist as a me m or y aid to help you inspect the finishing of concret e . A checklist is only an aid. For specific instructions , procedures and specifications , always consult the applicable standard(s).

Place a check mark () or () by items as you check the m. Mark items N/A, if they do not apply. Consider unsatisfac tory all items you did not check, which are not marked N/A. List these items in your inspection report, including recom m e n d a t ions , corrective action and applicable standards .

Samplin g Harden e d Concre t e

Core Sam plin g

Review ASTM C 42 prior to taking samples .

Check the core drill to ensure it is in good working condition.

Ensure that samples taken are repres e n t a t ive of the portion of the

harden e d concre t e to be tested .

Ensure that the diame t e r of the core is at leas t twice the size of the

averag e MSA in the concre t e .

Avoid drilling through embed d e d items, if possible.

If possible, identify the batch numb er where the samples are taken

and take the sample in the middle portion of that pour.

If at all possible, ensure that the length- to- diame t e r ratio is at leas t

2:1.

Ensure that cores with a length of less than 95% of the diame t e r

are not used for compres sive streng th test .

Check the surface appea r a nc e and the best approach route for

core samples for purpos es other than streng th tes t .

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Do not use core samples for moisture test when the samples are

taken with drills that use water for cooling and lubrication.

Do not allow cores that are used for test requiring boiling to be

used for streng th test .

Docume n t the collection of core samples in the proper forms and

complet e the proper forms for the labora tory. Be sure to make entry

in the logbook of inspection report form.

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WORK AID 3. HOW TO P ERFORM TEST ON HARDENED CONCRETE (CONT 'D)

Use this checklist as a me m or y aid to help you inspect the finishing of concret e . A checklist is only an aid. For specific instructions , procedures and specifications , always consult the applicable standard(s).

Place a check mark () or () by items as you check the m. Mark items N/A, if they do not apply. Consider unsatisfac tory all items you did not check, which are not marked N/A. List these items in your inspection report, including recom m e n d a t ions , corrective action and applicable standards .

Samplin g Harden e d Concre t e (Cont'd)

Broke n Concre t e Sam pl e s

Ensure that the broken concre t e samples are repres e n t a t ive of the

area requiring testing.

For MSA of 1" size or more, ensure that total sample meas ur e s

1 cubic foot.

Label and identify each sample with the proper information.

Place each sample in a differen t bag or box with padding.

If moisture conten t is to be tested , place the samples in amoisture proof plastic bag.

Docume n t the collection of broken concre t e samples in the proper

forms and complet e the proper forms for the labora tory. Be sure to

make entry in the logbook or inspection report form.

Onsit e Test s for Harde n e d Concre t e

In- plac e Stren g t h Testin g

Review ASTM C 900 before conducting in-place streng th testing.

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When use for streng th tes ts , ensure that embed d e d inser ts are

properly placed in the concre t e when poured.

When used for streng th tests , ensure that drilled inser ts are

inser ted into the proper size hole.

Determine and record the results of the tests on the proper forms.

Make the proper entries in the logbook or inspection report form.

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WORK AID 3. HOW TO P ERFORM TEST ON HARDENED CONCRETE (CONT 'D)

Use this checklist as a me m or y aid to help you inspect the finishing of concret e . A checklist is only an aid. For specific instructions , procedures and specifications , always consult the applicable standard(s).

Place a check mark () or () by items as you check the m. Mark items N/A, if they do not apply. Consider unsatisfac tory all items you did not check, which are not marked N/A. List these items in your inspection report, including recom m e n d a t ions , corrective action and applicable standards .

Onsit e Test s for Harde n e d Concre t e (Cont'd)

Nond e s t r u c t i v e Stren g t h Tes tin g (Cont ’d)

Review modules CVL 101.08 and 200.02 before performing thes e tes ts .

Ensure that the Swiss ham m e r or the Windsor probe is in good working

order and is properly calibra te d .

If using the Swiss ham m e r , take about 15 readings in each location and

averag e the 10 that are closes t to each other. This is the reading for that

area.

If using the Windsor probe, follow the directions in the manufactur e r ' s

instructions for the number of tes ts required in each location.

Warning: If the Windsor probe is used, ensure that it is used safely in accordance with the manufacturer’s instructions. It uses a powder- filled cartridge (like a blank cartridge used in a gun). It is very powerful and can be deadly at close range. Do not point it at yourself or anyone else while it is in use.

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Determine and record the results of the tests on the proper forms.

Make the proper entries in the logbook or inspection report form.

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WORK AID 4. HOW TO DOCUMENT THE INSPECTION RESULTS

Use the following information to help you docum e n t the results of your inspection.

1. Make a detailed field notes as you conduct your inspection.

2. After comple ting your inspection, make an entry into the Job Site Logbook or Project Inspection Report (PIR). Give specific details about the items you found which need correcting.

3. If action is taken on logbook or inspection report items within reason a ble time, comple t e a Projects Inspection Non-Conforma nc e Report (SAF 8213- ENG). Most inspectors consider two weeks to be more than reasona ble .

4. If action not taken to clear deficiencies after Projects Inspection Non- Conforma nc e Report is issued, comple t e a Projects Inspection Workshee t(SAF 8213- 1A-ENG).

5. For sending concre t e core specimen s and broken concre t e samples to the labora tory for testing, use SAF 8563, Field Test Report of Portland Cemen t Concre t e .

6. For sending water samples to the labora tory for sampling, use SAF 2325, Labora tory Report Form.

7. Use the appropria t e work aid to comple t e the required forms.

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WORK AID 4. HOW TO DOCUMENT THE INSPECTION RESULTS (CONT 'D)

Work Aid 4A. Make Field Not e s in a Field Logbo o k

This Work Aid will assist you in developing inspection field notes for future reporting. Follow the steps that apply to inspection items and record in your field notebook. Som e items may not imm ediat ely apply.

STEP INFORMATION REQUIRED ENTRY REQUIRED

1. Date and Time Date of inspection and time of day the inspection began

2. Location / Plant No. Exact location where inspection was performe d and plant number

3. Equipme n t Description Brief description of equipme n t to be inspect ed

4. Material / Thickness/Size Identify the material and thickness /size of the specime n

5. Standards / Codes Applicable codes and standards

6. Tm Limits / Type of Inspection

Identify minimu m thickness of equipme n t , if applicable and type on inspection performe d , e.g., VT, PT, MT, etc.

7. Inspection Equipme n t Used Tools and equipme n t used during inspection

8. Reason/Purpos e of Inspection

Purpose of the inspection

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9. Contact Person / Phone No. People to contac t and their phone numbers

10. Findings Discrepancies found during inspection

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WORK AID 4. HOW TO DOCUMENT THE INSPECTION RESULTS (CONT 'D)

Work Aid 4A. Make Field Not e s in a Field Logbo o k (Cont'd)

This Work Aid will assist you in developing inspection field notes for future reporting. Follow the steps that apply to inspection items and record in your field notebook. Som e items may not imm ediat ely apply.

11. Conclusions Inspector ' s decisions about the deficiency and cause

12. Recomm e n d a t ions Inspector ' s solution to the problem

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WORK AID 4. HOW TO DOCUMENT THE INSPECTION RESULTS (CONT 'D)

Work Aid 4A. How to Write Field Note s (Cont'd)

Figure 17. Number e d sample of field note sheet

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WORK AID 4. HOW TO DOCUMENT THE INSPECTION RESULTS (CONT 'D)

Work Aid 4B. Make Entrie s in the Sit e Logbo o k

This Work Aid is a checklist that will assist you in docu m e n t ing the Projects Inspection Logbook. Follow the steps in the following and enter the data required as indicated in the block entitled "Entry Required." Operations Inspection Logbook entries are normally made once you have made your field notes .

STEP INFORMATION REQUIRED ENTRY REQUIRED

1. Date/Log # Enter date (month/day/ye a r) and log numb er

2. Inspection Comme n t s Identify the type of inspection, the discrepa ncies and the standard/cod e it violates . Sign and date

3. Inspection Sign- Off Date Sign and date when job is comple t ed satisfactorily

Note: Include the work order number once it has been assigned.

Note: Enter closing remarks when the job is completed satisfactorily. Always sign legibly.

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WORK AID 4. HOW TO DOCUMENT THE INSPECTION RESULTS (CONT 'D)

Work Aid 4B. Make Entrie s in the Sit e Logbo o k (Cont'd)

Figure 18. Complet e d inspection logbook entries with numb er e d blocks

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WORK AID 4. HOW TO DOCUMENT THE INSPECTION RESULTS (CONT 'D)

Work Aid 4C. How to Compl e t e a Projec t s Insp e c t i o n Report (PIR)

Use this Work Aid as a checklist to make entries on a Projects Inspection Report (PIR) form. Refer with the comple t e d form in Figure 19.

STEP INFORMATION TITLE ENTRY REQUIRED

1. Section Words to identify your unit

2. Address The addres s of your unit

3. To: The name of addres s e e (the person who will get this report)

4. Address Address of the addres s e e

5. BI/JO No. Budget item/job order numb er

6. Project Title Title of the project such as,AIN DAR WIP-1, NEW PIPING

7. Report No. Next consecu tive number provided by the unit clerk

8. Job Location Location of the site inspection took place. Use only allowedabbrevia tions

9. Plant No./Equip. No. Number of the plant or equipme n t number

10. Date of Inspection Date the inspection was star ted

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11. Scope The main topic

12. Finding(s) Discrepancies found during the inspection

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WORK AID 4. HOW TO DOCUMENT THE INSPECTION RESULTS (CONT 'D)

Work Aid 4C. How to Compl e t e a Projec t s Insp e c t i o n Report (PIR) (Cont'd)

Use this Work Aid as a checklist to make entries on a Projects Inspection Report (PIR) form. Refer with the comple t e d form in Figure 19.

STEP INFORMATION TITLE ENTRY REQUIRED

13. Recomm e n d a t ion Necess a ry action required based n finding(s)

14. cc: Distribution

15. Inspector Your name

16. Date Date you sign the form, day/mon th /ye a r

17. Telephone number Your telephon e number

18. Signatur e You sign your name legibly

Note: Identify second and succeeding pages with a minimum of information as explained in the Information Sheet. Use another original form for the next page.

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WORK AID 4. HOW TO DOCUMENT THE INSPECTION RESULTS (CONT 'D)

Work Aid 4C. How to Compl e t e a Projec t s Insp e c t i o n Report (PIR) (Cont'd)

Figure 19. Complet e d Projects Inspection Report

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CVL 301.05 (SAP ID 40009511) PARTICIPANT GLOSSARY

GLOSSARYACI Abbrevia tion for the American Concre t e

Institute

ag gr e g a t e Sand or a combina tion of sand and small gravel use in mixing cemen t , mortar and grout.

ambi e n t tem p e r a t u r e The prevailing or existing atmosph e ric temp er a t u r e and meas ure d using either a Centigrad e or a Fahrenh ei t thermo m e t e r .

ASTM Abbrevia tion for the American Society for Testing and Materials

ble e d wat er Surplus water in concre t e that rises to the surface after screeding and leveling has been complet ed . This is caused by the weight of the particles in the mix pushing downward, forcing the water upward and outward.

bull float A hand- held tool rese mbling a large broom with a long handle for leveling and smoothing out wet concre t e .

com pr e s s i v e stren g t h The ability of concre t e to suppor t a load; meas ure d in pounds per square inch (psi) or megap a s c als (MPa)

crazin g Hairline cracks in the surface of newly harden e d concre t e caused by surface shrinkag e.

crow n A high spot in the middle of a slab of concre t e so that water will drain off toward each side of the slab.

curin g The time period immedia t ely after mixing when concre t e begins to harden.

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finishin g The phas e of concre t e place m e n t manipula ting the surface textur e .

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GLOSSARY (CONT 'D)flatn e s s An analysis of the eleva tion differences

for a slab of concre t e . You deter min e the data by meas uring the surface at 12 inch intervals and comparing it with the Floor Finish Tolerances specified in ACI 117 standards .

form e d surfac e s Surfaces of concre t e that are finished or trea t e d to improve appea r a nc e , serviceability, or water tightn e s s .

fres h condi t io n The first stage of newly- mixed concre t e .

gre e n concr e t e Newly- poured concre t e still having a high amoun t of water until full curing has taken place.

hon e y c o m b A defect occurring when concre t e paste does not comple t ely fill the space betwee n the coarse aggreg a t e particles.

hydratio n The reaction of water with an object to form a new compound, such as mixing water with a ceme n t mixture (burnt gypsu m and lime) to make concre t e .

leve ln e s s A factor you deter mine by taking consecu tive meas ur e m e n t s of elevation differences on a slab of concre t e at 10 ft intervals.

mec h a n i c a l vibrat or A motorized device, usually hand- held, for consolida ting freshly- poured concre t e .

mortar A mixture of cemen t , water, sand and aggreg a t e s that is smaller than 1/4 inch in size.

MSA A thin filler ceme n t used to streng th e n block wall.

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opaq u e Having the ability to block radiant energy, particularly light

plac e d concr e t e Wet concre t e that has been placed using a pneu m a tic pump and hose.

profilom e t e r A calibra t ed Instrume n t for meas uring the levelness for a slab of concre t e .

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GLOSSARY (CONT 'D)rebo u n d ham m e r te s t A surface hardnes s tes t performe d

on concre t e using a Schmidt or Swiss ham m e r .

scalin g Where the surface of harden e d concre t e slab breaks away for the rest of the slab to a depth of about 1/8 inch.

scre e d i n g A process requiring two workers using a 2" x 4" piece of lumber to skim and level the top surface of wet concre t e .

tolera n c e A meas ur a ble range of variation for concre t e surface textur e usually specified on construction plan shee t s .

tran s p ar e n t Having the proper ties to let light to pass through the surface.

uniform e d surfac e s Surfaces of concre t e that require a minimu m of finish for accep ta bility.

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CVL 301.05 (SAP ID 40009511) PARTICIPANT ADDENDUM

ADDENDUM A

SAEP- 115 0

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ADDENDUM B

SAES- Q-001

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ADDENDUM C

ACI 117- 90

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ADDENDUM D

ACI 308- 92

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ADDENDUM E

ASTM C 42

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ADDENDUM F

ASTM C 309

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ADDENDUM G

ASTM C 900

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