03 30 00 - Cast-in-Place Concrete.pdf

03 30 00 - CAST-IN-PLACE CONCRETE

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SECTION 03 30 00 - CAST-IN-PLACE CONCRETE

PART 1 - GENERAL

1.1 SUMMARY

A. Section Includes Cast-in-Place Concrete for Following Items:

1. Manholes.

2. Pipe encasement.

3. Inlets.

4. Thrust blocks.

5. Anchors.

6. Pipe cradles.

B. Related Requirements:

1. Section 03 10 00 - Concrete Forming and Accessories: Formwork and accessories.

2. Section 03 20 00 - Concrete Reinforcing: Requirements for reinforcing steel and supports.

3. Section 03 39 00 - Concrete Curing: Curing of concrete floor surfaces.

1.2 REFERENCE STANDARDS

A. American Concrete Institute:

1. ACI 301 - Specifications for Structural Concrete.

2. ACI 305R - Guide to Hot Weather Concreting.

3. ACI 306.1 - Standard Specification for Cold Weather Concreting.

4. ACI 308.1 - Specification for Curing Concrete.

5. ACI 318 - Building Code Requirements for Structural Concrete.

B. ASTM International:

1. ASTM B221 - Standard Specification for Aluminum and Aluminum-Alloy Extruded

Bars, Rods, Wire, Profiles, and Tubes.

2. ASTM C31 - Standard Practice for Making and Curing Concrete Test Specimens in the Field.

3. ASTM C33 - Standard Specification for Concrete Aggregates.

4. ASTM C39 - Standard Test Method for Compressive Strength of Cylindrical

Concrete Specimens.

5. ASTM C42 - Standard Test Method for Obtaining and Testing Drilled Cores and

Sawed Beams of Concrete.

6. ASTM C94 - Standard Specification for Ready-Mixed Concrete.

7. ASTM C143 - Standard Test Method for Slump of Hydraulic-Cement Concrete.

8. ASTM C150 - Standard Specification for Portland Cement.

9. ASTM C172 - Standard Practice for Sampling Freshly Mixed Concrete.

10. ASTM C173 - Standard Test Method for Air Content of Freshly Mixed Concrete by the Volumetric Method.

11. ASTM C231 - Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method.

12. ASTM C260 - Standard Specification for Air-Entraining Admixtures for Concrete.

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13. ASTM C330 - Standard Specification for Lightweight Aggregates for Structural Concrete.

14. ASTM C494 - Standard Specification for Chemical Admixtures for Concrete.

15. ASTM C595 - Standard Specification for Blended Hydraulic Cements.

16. ASTM C618 - Standard Specification for Coal Fly Ash and Raw or Calcined Natural

Pozzolan for Use in Concrete.

17. ASTM C685 - Standard Specification for Concrete Made by Volumetric Batching and Continuous Mixing.

18. ASTM C845 - Standard Specification for Expansive Hydraulic Cement.

19. ASTM C989 - Standard Specification for Slag Cement for Use in Concrete and

Mortars.

20. ASTM C1017 - Standard Specification for Chemical Admixtures for Use in

Producing Flowing Concrete.

21. ASTM C1064 - Standard Test Method for Temperature of Freshly Mixed Hydraulic-

Cement Concrete.

22. ASTM C1107 - Standard Specification for Packaged Dry, Hydraulic-Cement Grout

(Nonshrink).

23. ASTM C1116 - Standard Specification for Fiber-Reinforced Concrete.

24. ASTM C1157 - Standard Performance Specification for Hydraulic Cement.

25. ASTM C1218 - Standard Test Method for Water-Soluble Chloride in Mortar and

Concrete.

26. ASTM C1240 - Standard Specification for Silica Fume Used in Cementitious

Mixtures.

27. ASTM D994 - Standard Specification for Preformed Expansion Joint Filler for

Concrete (Bituminous Type).

28. ASTM D1751 - Standard Specification for Preformed Expansion Joint Filler for

Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types).

29. ASTM D1752 - Standard Specification for Preformed Sponge Rubber Cork and Recycled PVC Expansion Joint Fillers for Concrete Paving and Structural Construction.

30. ASTM D6690 - Standard Specification for Joint and Crack Sealants, Hot Applied, for Concrete and Asphalt Pavements.

31. ASTM E96 - Standard Test Methods for Water Vapor Transmission of Materials.

32. ASTM E119 - Standard Test Methods for Fire Tests of Building Construction and

Materials.

33. ASTM E1643 - Standard Practice for Selection, Design, Installation, and Inspection of Water Vapor Retarders Used in Contact with Earth or Granular Fill Under Concrete Slabs.

34. ASTM E1745 - Standard Specification for Plastic Water Vapor Retarders Used in Contact with Soil or Granular Fill under Concrete Slabs.

C. California Department of Health Care Services:

1. CA/DHS/EHLB/R-174 - Standard Practice for the Testing of Volatile Organic

Emissions from Various Sources Using Small-Scale Environmental Chambers (includes Addendum 2004).

D. South Coast Air Quality Management District:

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1. SCAQMD Rule 1168 - Adhesive and Sealant Applications.

1.3 COORDINATION

A. Coordinate placement of joint devices with erection of concrete formwork and placement of form accessories.

1.4 SUBMITTALS

A. Section 01 33 00 - Submittal Procedures: Requirements for submittals.

B. Product Data: Submit data on joint devices, attachment accessories, and admixtures.

C. Design Data:

1. Submit concrete mix design for each concrete strength.

2. Submit separate mix designs if admixtures are required for following:

a. Hot and cold weather concrete Work.

b. Air entrained concrete Work.

3. Identify mix ingredients and proportions, including admixtures.

D. Manufacturer's Certificate: Certify that products meet or exceed specified requirements.

E. Manufacturer Instructions: Submit installation procedures and interfacing required with adjacent Work.

F. Field Quality-Control Submittals: Indicate results of Contractor-furnished tests and inspections.

1.5 CLOSEOUT SUBMITTALS

A. Project Record Documents: Record actual locations of embedded utilities and components concealed from view in finished construction.

1.6 QUALITY ASSURANCE

A. Perform Work according to ACI 301.

B. Comply with ACI 305R when pouring concrete during hot weather.

C. Comply with ACI 306.1 when pouring concrete during cold weather.

D. Acquire cement and aggregate from one source for Work.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Concrete:

1. Cement:

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a. Use for inlets, pipe encasement, thrust blocks, anchors, and pipe cradles:

Comply with ASTM C150, Type I – Normal.

b. Use for sewer manholes and sewer manhole channel fill: See Section 33 05 61.

c. Type: Portland.

2. Normal Weight Aggregates:

a. Comply with ASTM C33.

b. Coarse Aggregate Maximum Size: According to ACI 318.

3. Water:

a. Comply with ACI 318.

b. Potable, without deleterious amounts of chloride ions.

B. Admixtures:

1. Air Entrainment: Comply with ASTM C260.

2. Chemical:

a. Comply with ASTM C494 that contains less than 0.1% chloride ion.

1) Type A - Water Reducing.

2) Type D - Water Reducing and Retarding.

3) Type E - Water Reducing and Accelerating.

2.2 CONCRETE MIX

A. Select proportions for normal weight concrete according to ACI 301, Method 2.

B. Performance and Design Criteria for Non-structural Concrete:

1. Comply with PennDOT Class A Concrete.

2. Compressive Strength: 3,000 psi at 28-days.

3. Cement Type: Comply with Paragraph 2.1.A.1.

4. Minimum Cement Content: 564 lb./cu. yd.

5. Aggregate Type: Normal weight.

6. Maximum Water-Cement Ratio: 0.50 by weight.

7. Aggregate Size:

a. Maximum: one inch.

b. Minimum: comply with ASTM C33.

8. Air Content: 6 percent, plus or minus 1.5 percent.

9. Maximum Fly Ash Content: 20 percent of cementitious materials by weight.

10. Maximum Slag Content: 30 percent of cementitious materials by weight.

11. Slump: 4 inches, plus or minus 1 inch.

C. Performance and Design Criteria for Thrust Blocks, Deadman, and Anchors:

1. Comply with PennDOT Publication 408, Section 704, Class HES.

D. Performance and Design Criteria for Pipe Encasements:

1. Comply with PennDOT Publication 408, Section 220, Type B.

E. Performance and Design Criteria for Structural Concrete:

1. Comply with PennDOT Class AAAP Concrete.

2. Compressive Strength: 4,000 psi.

3. Cement Type: Comply with Paragraph 2.1.A.1.

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4. Minimum Cement Content: 560 lb./cu. yd.

5. Aggregate Type: Normal weight.

6. Maximum Water-Cement Ratio: 0.45 by weight.

7. Aggregate Size:

a. Maximum: one inch.

b. Minimum: comply with ASTM C33.

8. Air Content: 6 percent, plus or minus 1.5 percent.

9. Maximum Fly Ash Content: 20 percent of cementitious materials by weight.

10. Maximum Slag Content: 30 percent of cementitious materials by weight.

11. Slump: 4 inches, plus or minus 1 inch.

F. Admixtures:

1. Include admixture types and quantities indicated in concrete mix designs only if approved by Engineer.

2. Cold Weather:

a. Use accelerating admixtures in cold weather.

b. Use of admixtures will not relax cold-weather placement requirements.

3. Hot Weather: Use set-retarding admixtures.

4. Do not use calcium chloride or admixtures containing calcium chloride.

5. Add air entrainment admixture to concrete mix for Work exposed to freezing and thawing.

G. Average Compressive Strength Reduction: Not permitted.

H. Ready-Mixed Concrete: Mix and deliver concrete according to ASTM C94.

I. Site-Mixed Concrete: Mix concrete according to ACI 318.

2.3 ACCESSORIES

A. Bonding Agent:

1. Comply with PennDOT Publication 408, Section 706.

B. Non-shrink Grout:

1. Description: Premixed compound consisting of non-metallic aggregate, cement, and water-reducing and plasticizing agents.

2. Comply with ASTM C1107.

3. Minimum Compressive Strength: 1,000 psi in 48 hours and 4,000 psi in 28 days.

C. Curing Materials shall be in accordance with Section 03 39 00.

PART 3 - EXECUTION

3.1 GENERAL

A. Inspect work to receive cast-in-place concrete for deficiencies which would prevent proper execution of the finished work. Do not proceed with placing until such deficiencies are corrected.

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B. Embedded Items: Place piping and other embedded items required for adjoining work prior to concreting. Place accurately, and support against displacement:

1. Apply Epoxy Bonding Compound over prepared surfaces of embedded items where required under other Sections of these Specifications.

C. Production of Concrete (Ready-Mixed):

1. Batched, mixed and transported in accordance with ASTM C94.

2. Plant equipment and facilities shall conform to the Check List for Certification of

Ready Mixed Concrete Production Facilities of the National Ready Mixed Concrete Association.

3.2 PLACING

A. General: Conduct placement work in accordance with ACI 304R.

B. Preparation:

1. Prepare formwork in advance and remove snow, ice, water and debris from within forms.

2. Sprinkle subgrades sufficiently to eliminate water loss from concrete.

3. Do not place concrete on frozen ground.

C. Conveying:

1. Handle concrete from mixer to final deposit rapidly by methods which will prevent segregation or loss of ingredients to maintain required quality of concrete.

2. Do not convey concrete through aluminum or aluminum alloy.

3. Do not place concrete by pumps or other similar devices without prior written approval of Engineer.

D. Depositing:

1. Do not allow concrete to drop vertically more than 4 feet.

2. Deposit in approximately horizontal layers of 12 to 18 inches.

3. Do not allow concrete to flow laterally more than 3 feet.

4. Make placement continuously to produce monolithic unit.

5. Carry on placing at such a rate that concrete which is being integrated with fresh concrete is still plastic.

6. Do not deposit concrete on concrete which has hardened sufficiently to cause the formation of seams or planes of weakness within sections.

7. Do not use concrete which has partially hardened or has been contaminated by foreign materials.

8. Do not subject concrete to procedures which will cause segregation.

9. Do not place concrete in forms containing standing water.

E. Consolidation:

1. Consolidate concrete by mechanical vibration equipment, supplemented by spading, rodding or other manual methods. Work concrete around embedded items and eliminate air or stone pockets and other causes of honeycombing, pitting or planes of weakness.

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2. Use vibration equipment of internal type and not the type attached to forms and reinforcement.

3. Use vibrators capable of transmitting vibration to concrete in frequencies sufficient to provide satisfactory consolidation.

4. Do not leave vibrators in one spot long enough to cause segregation. Remove concrete segregated by vibrator operation.

5. Do not use vibrators to spread concrete.

6. Have sufficient reserve vibration equipment to guard against shutdown of work occasioned by failure of equipment in operation.

F. Cold Weather Concreting: In general, perform cold weather concrete work in accordance with ACI 306R; additional requirements as follows:

1. If water or aggregate is heated above 100 degrees F, combine water with aggregate in the mixer before cement is added. Do not mix cement with water or with mixtures of water and aggregate having a temperature greater than 100 degrees F.

2. Provide materials and methods for protecting concrete from freezing during freezing or near-freezing weather. Do not use frozen materials or materials containing snow or ice.

3. Surfaces which the concrete is to come in contact with must be free of frost, snow and ice.

4. Concrete placed in forms shall have a temperature of 50 degrees F or higher after placement.

G. Hot Weather Concreting: In general, perform hot weather concrete work in accordance with ACI 305R; additional requirements as follows:

1. Temperature of concrete delivered at the job-site shall not exceed 90 degrees F.

2. Cool ingredients before mixing to prevent temperature in excess of 90 degrees F.

3. Make provisions for windbreaks, shading, fog spraying, sprinkling or wet cover when necessary.

3.3 FINISHING

A. General: Finish exposed concrete surfaces true and even free from open or rough areas, depressions or projections. In vertical pours, place concrete to the required elevation, and strike-off with a straight edge and float surface to a level plane:

1. Comply with section requirements or PennDOT standards.

3.4 CURING AND PROTECTION

A. General: Immediately after placement, protect concrete from premature drying, excessive hot or cold temperatures and mechanical injury. Curing shall be by either water curing or sealing methods in accordance with ACI 308. Cure concrete continuously for a minimum of 7 days at ambient temperatures above 40 degrees F.

B. Hot Weather Curing: See Hot Weather Concreting this Section.

C. Cold Weather Curing: See Cold Weather Concreting this Section.

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D. Application Rate of Liquid Membrane-Forming Compounds: Compound shall restrict the loss of water to not more than 0.055 g/sq. cm of surface in 72 hours when tested in accordance with ASTM C156.

3.5 FIELD QUALITY CONTROL

A. Section 01 40 00 - Quality Requirements: Requirements for inspecting and testing.

B. Testing and Inspection: Perform field testing in accordance with ACI 301 and the following requirements:

1. Secure composite sample in accordance with ASTM C172.

2. Mold and cure six test specimens for each strength test in accordance with ASTM

C31.

3. Test specimens in accordance with ASTM C39. Test two specimens at 7 days, two at 28 days, and retain two specimens in reserve for later testing if required.

4. Make one strength test for each 50 cu. yd. of concrete, unless waived by the

Engineer, but not less than one test for each structure.

5. Make slump tests for each strength test and whenever consistency of concrete appears to vary in accordance with ASTM C143.

6. Make air content test for each strength test in accordance with ASTM C231 or

ASTM C173 except if aggregate with high absorptions are used, use the latter test method.

C. Evaluation and Acceptance:

1. The strength level of the concrete will be considered satisfactory if the averages of all sets of three consecutive strength test results equal or exceed specified strength and no individual test result is below specified strength by more than 500 psi.

2. If the strength of cylinders falls below specified compressive strengths, the Engineer shall have the right to order a change in the mix proportions for the remaining concrete being poured.

3. If required by the Engineer, obtain and test core specimens from hardened concrete in accordance with ASTM C42.

END OF SECTION