ACE/VCA SPECIFICATION GENERAL AIRPORT WORKS OPERATIONS

Scope: Slab Replacement works including saw cutting, drilling for lifting plates, demolition,
subgrade removal, dowel pin drilling, dowel pin placing, concrete production, placement
and finishing are performed to a minimum VCA/ACE requirement enabling the CTS Rapid Set
Concrete (CTS RSC) the opportunity to perform to its design capability and as per the works
Specification.

Sydney Airport Bay 84/85

Conditions: -
A. ACE/VCA minimum slab thickness for Airport slabs 500mm, Road Pavement slabs
200mm and Lean Mix Concrete Subgrade improvement 100mm.
B. All Volumetric Mixers approved and calibrated prior to any works project beginning.
C. All Aggregates and Sand to comply with AS 1289.1 and tested by NATA Accredited
Laboratory.
D. Concrete testing to be performed by NATA Accredited Laboratory.
E. Subgrade testing to be performed by NATA Accredited Laboratory.
F. All Raw Materials including CTS Rapid Set Cement, Aggregates, Sand and Admixtures
to be pre-loaded in Volumetric Mixers at the Melbourne Airport approved
Holding/Stabling yard.
G. All CTS Rapid Set slab replacement Operators to be Trained, Certified and approved
by CTS.
H. All CTS operations to be under supervision of ACE/VCA personnel.
I. All works to be monitored by APAM Superintendant.
J. ACE/VCA Works Supervisors/Leading Hands may direct duplicate work sections.
K. The weather will be monitored in conjunction with the works Superintendant. Any
delays/cancellations will be jointly agreed as per the specification requirements
L. Slab size, approximately 35m to 40m per slab/shift will be available via a minimum
of 6 x 7m capacity Volumetric Mixers.
M. Tool box meetings will be performed prior to every shift beginning. Appropriate
records will be available.
N. Refer ACE/VCA Programming timeline.
O. Lifting Plate plan to be detailed during drilling operations.

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1.0 Saw Cutting and lifting plates drilling: - (see conditions I, K and N)
1.1 Saw Cutting and drilling supervisor to direct operations. (See condition J)
1.2 Saw cutting operations, lifting plate drilling and locating operations are
performed in the scheduled work shifts prior to the slab removal and replacement
process beginning.
1.3 A sawing plan is prepared and adhered to taking into account the length, breadth
and width of the slab to be demolished calculating the mass of each section to be
raised. Note; lifting equipment rating to be considered when designing saw cut
pattern and size of sections for removal.
1.4 Locations of all numbered lifting plates to be recorded on a plan for easy
attachment during lifting process. (See condition O)

Pre-drilling lifting plates Saw cutting

2.0 Demolition / Lifting of slab sections: - (see conditions I, K, M and N)

2.1 Slab removal/replacement Supervisor to direct operations. (See condition J)
2.2 Lifting Equipment including chains, slings and machinery to be rated as per the
appropriate Australian Standard.
2.3 Lifting plates to be located as per plan from drilling operation. (See condition O)
2.4 Removed slabs to be placed into bins / tip trucks for removal to holding yard
(Hub) for disposal to a licensed facility.

Lifting slab sections Attaching Chains prior to lifting

3.0 Subgrade Removal /Compaction / Improvement: - (See conditions A, I, K, M and N)

3.1 Slab removal/replacement Supervisor to direct operations. (See condition J)
3.2 Subgrade to be inspected by APAM Representative for determining the amount
to be removed compacted or improved with CTS Rapid Set Lean Mix. Note: DCP
testing to be performed to determine existing subgrade suitability with results
logged for the site superintendant. (See conditions A and E)
3.3 If excavation of Subgrade material to accommodate new slab depth is required
compaction method of the subgrade as determined by Works Specification.

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 3.4 All excavated subgrade material to be taken from site in bin / tip truck and
deposited at the Hub and classified prior to disposal off site to an appropriate
registered facility.
3.5 Subgrade Improvement if required will be with CTS Rapid Set Concrete Lean Mix,
minimum 100mm depth. (See condition A)
3.6 Minimum requirement rework to the existing subgrade by loosening top 100mm
and recompaction.

Levelling subgrade Subgrade removal and compaction

4.0 Dowel Pin Drilling / Placement: - (See conditions I, K, M and N)

4.1 Slab removal/replacement Supervisor to direct operations. (See condition J)
4.2 Spacing () of dowel holes to be located as per Specification.
4.3 Minnich Operator to be fully instructed on locations and drill depths prior to
commencement of drilling.
4.4 Minnich Dowel Pin, minimum 2 Gang Drill, 6 drill steels and 6 drill bits available
as a minimum on site.
4.5 Operator must be fully trained in the equipment use and capable of setting up
the equipment prior to start. (See condition G)
4.6 Drilling operation to be continuous until all holes drilled.
4.7 Placement of Dowel Pins as per specification and to be performed as Dowel hole
drilling is performed.

Dowel hole drilling Completed Dowel pin placement

5.0 CTS Rapid Set Concrete Production /Placement / Finishing: - (See conditions A, I, K,
M and N)
5.1 CTS Rapid Set Concrete Supervisor to direct operations. (See condition J)
5.2 All Volumetric Mixers used on the project will be calibrated prior to
commencement of works at the ACE/VCA facility. (See special condition B)
5.3 All raw materials required for CTS Rapid Set Concrete manufacture will be
organised by the day shift Supervisor and on site in time to enable all necessary
equipment to be ready to move Airside at the scheduled time. (See condition C)

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 5.4 The quantity of raw materials required for the shift to be on site prior to works
commencement. All loading and priming operations to be completed prior to
Volumetric Mixers moving Airside. (See conditions B, F and C)
5.5 Volumetric Mixers will be set up as per calibration requirements, ready to
produce according to time line requirements. (See conditions B and F)
5.6 All Volumetric Mixers will be loaded and primed (ready to produce) prior to going
airside. (See conditions B, C and F)
5.7 The number of Volumetric Mixers to be used will be dependent on the quantity
of CTS Rapid Set Concrete required for the shift. (See condition L)
5.8 CTS Rapid Set Concrete production will commence after all demolition, subgrade
testing and preparation and dowel pin works are completed with appropriate
approval from the site superintendant as per the works Specification.
5.9 All concrete placing and finishing tools to be prepared and in place prior to CTS
Rapid Set Concrete production. Only VCA certified placing and finishing tools to be
used. Mechanical roller screed to be used in all applications. (See conditions G and
H)
5.10 Concrete crew to be instructed of duties prior to start of Concrete placement
operations. (See conditions G and M)
5.11 CTS Rapid Set Concrete production will be a continuous process until entire slab
area is placed. (See condition L)
5.12 Finishing as per specification will be commenced as initial set of the CTS Rapid
Set Concrete takes place. No attempt to finish after final set is reached to take place.
5.13 Water curing will commence as soon as the CTS Rapid Set Concrete is deemed
ready by the Concrete Supervisor and will be maintained as a minimum until the
curfew period is completed. If required by the Superintendant, the slab area will be
covered as per specification.
5.14 CTS Rapid Set concrete testing will be as per Specification and sampled and
tested according to Australian Standards. (See condition D)

Raw materials on site Volumetric Mixers prepared

Concreting equipment readied Concrete placement

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 Initial Finishing Final texturing

Final Texturing Water curing

6.0 Site Cleanup and Demobilisation: - (See conditions I, K and N)
6.1 Site cleanup is to be a continuous process throughout the works. All labour will
be instructed in the requirements prior to works commencing. A Vacuum truck will
be part of the equipment on site providing a continuous service. (See conditions J
and M)
6.2 Demobilisation of equipment will occur as soon as equipment is not required on
site.

Site cleanup Demobilisation of equipment

7.0 Hand over to client: - (See conditions I, K and N)

7.1 Hand over to client will occur as soon as the CTS Rapid Set Concrete is water
cured to the satisfaction of ACE/VCA, Airfield Operations and Airport representative.

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 Handover

Notes:
All information provided is general ACE/VCA scope for Airport works. Appropriate changes
allowing for Specification details are to be considered when editing document for specific
Airport Project Works.

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