03 30 00 - Cast-in-Place Concrete.pdf
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This is a technical specification document for cast-in-place concrete work prepared by Herbert, Rowland & Grubic, Inc., applicable to the Elizabethtown Area Water Authority's Water Main Replacement Project Phase 4 (Contract No. WR-4). The specification establishes comprehensive requirements for concrete materials, mix design, placement, and quality control procedures. The document specifies two primary concrete strength classes: 3,000 psi at 28 days for pipe encasements, pipe cradles, and manhole channel fills, and 4,500 psi at 28 days for cast-in-place manholes, with PennDOT Class HES concrete required for thrust blocks and anchors. Concrete mixes must comply with ASTM and ACI standards, including specific requirements for cement type, aggregate specifications, water-cement ratios (maximum 0.50 for 3,000 psi concrete and 0.43 for 4,500 psi concrete), and minimum cement content (564 pounds per cubic yard for 3,000 psi and 640 pounds for 4,500 psi). The specification mandates air entrainment for exterior concrete with 6±1% air content, allows water-reducing admixtures with provisions for retarding or accelerating admixtures based on temperature conditions, and establishes slump limits not exceeding 4 inches for vibration-consolidated concrete or 5 inches for manually consolidated concrete.
Contractors must submit concrete mix designs for each strength class prior to commencement of work and notify the testing laboratory and engineer at least 24 hours before concrete placement operations begin. Quality control requirements include sampling procedures complying with ASTM C172, with one set of three cylinders required for every 50 cubic yards or less of each concrete class placed daily, and for every 5,000 square feet of surface area for slabs and walls. Cylinder testing is mandated at seven days and 28 days, with two additional cylinders retained for engineer-requested testing. If cylinder strength falls below specified compressive strengths, the engineer may order changes to mix proportions for remaining concrete. Curing must be performed by either water curing or sealing methods per ACI 308, with liquid membrane-forming compounds restricted to water loss of no more than 0.055 g/sq cm in 72 hours per ASTM C 156. The specification prohibits calcium chloride admixtures and requires epoxy bonding compounds for previously placed concrete surfaces, with approved manufacturers including A.C. Horn EPOXTITE BINDER, Sika Chemical SIKADUR-HI-MOD, and Euclid Chemical Company products or equal alternatives.
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03 30 00 – CAST-IN-PLACE CONCRETE
Herbert, Rowland & Grubic, Inc. 03 30 00 - 1 009280.0426
SECTION 03 30 00 – CAST-IN-PLACE CONCRETE
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes Cast-in-Place Concrete
B. Related Requirements:
1. Section 03 20 00 – Concrete Reinforcing: Requirements for reinforcing steel and supports.
2. 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 C31 - Standard Practice for Making and Curing Concrete Test Specimens in the Field.
2. ASTM C33 - Standard Specification for Concrete Aggregates.
3. ASTM C39 - Standard Test Method for Compressive Strength of Cylindrical Concrete Spec-imens.
4. ASTM C42 - Standard Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete.
5. ASTM C94 - Standard Specification for Ready-Mixed Concrete.
6. ASTM C143 - Standard Test Method for Slump of Hydraulic-Cement Concrete.
Herbert, Rowland & Grubic, Inc. 03 30 00 - 2 009280.0426
7. ASTM C150 - Standard Specification for Portland Cement.
8. ASTM C172 - Standard Practice for Sampling Freshly Mixed Concrete.
9. ASTM C173 - Standard Test Method for Air Content of Freshly Mixed Concrete by the Volumetric Method.
10. ASTM C260 - Standard Specification for Air-Entraining Admixtures for Concrete.
11. ASTM C330 - Standard Specification for Lightweight Aggregates for Structural Concrete.
12. ASTM C494 - Standard Specification for Chemical Admixtures for Concrete.
1.3 COORDINATION
A. Section 01 10 00 – Project Summary
B. Coordinate placement of joint devices with erection of concrete formwork and placement of form accessories.
1.4 SUBMITTALS
Only request submittals needed to verify compliance with Project requirements.
A. Section 01 33 00 – Submittal Procedures: Requirements for submittals.
B. 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.
PART 2 - PRODUCTS
2.1 MATERIALS
A. Concrete:
1. Cement:
a. Comply with ASTM C150C150M, Type I - Normal.
Herbert, Rowland & Grubic, Inc. 03 30 00 - 3 009280.0426
b. Type: Portland.
c. Use for thrust blocks and anchors
2. Cement:
a. Comply with ASTM C150 (C150M), Type II - Moderate Sulfate Resistant.
b. Type: Portland.
c. Use for sanitary sewer manholes and sanitary sewer manhole channel fill.
3. Normal Weight Aggregates:
a. Comply with ASTM C33C33M. Do not use aggregates containing spalling-cowing, deleterious substances.
4. Water:
a. Potable, without deleterious amounts of chloride ions.
B. Admixtures:
1. Calcium Chloride: Not permitted.
2. Air Entrainment: Comply with ASTM C260C260M.
3. Chemical:
a. Comply with ASTM C494C494M.
b. Type A - Water Reducing.
c. Type D - Water Reducing and Retarding.
d. Type E - Water Reducing and Accelerating.
2.2 CONCRETE MIX
A. Performance and Design Criteria:
1. Compressive Strength: 3,000 psi at 28-days, use for pipe encasements, pipe cradles, and manhole channel fills.
2. Compressive Strength: 4,500 psi at 28 days. use for cast-in-place manholes
3. PennDOT Class HES, as specified in PennDOT Publication 408, Section 704: Use for thrust blocks and anchors.
4. Selection of Proportions for Normal weight Concrete: ACI 211.1.
5. Proportions of Ingredients: Establish proportions on the basis of field experience, with the materials specified herein.
Herbert, Rowland & Grubic, Inc. 03 30 00 - 4 009280.0426
a. Field Experience: ACI 301, Method 2 and ACI 318.
6. Water-Cement Ratio: Maximum permissible water-cement ratio will be as follows:
a. 3,000 psi concrete – maximum w/c = 0.50.
b. 4,500 psi concrete – maximum w/c =0.43.
E. Minimum Cement Content:
a. 3,000 psi concrete: 564 pounds minimum per cubic yard.
b. 4,500 psi concrete: 640 pounds minimum per cubic yard.
B. ADMIXTURES
1. Add air-entraining agency to normal weight concrete mix for work exposed to exterior.
Design the mix to have an air content of 6+ 1%.
2. Water Reducing Admixture: Unless high temperatures occur and/or placing conditions dictate a change, all concrete shall contain the water reducing admixture.
3. Water Reducing and Retarding Admixture: When high temperatures occur and/or placing conditions dictate, the Contractor may request a change from the water reducing admix-ture (Type A) to a water reducing and retarding admixture (Type D).
4. Water Reducing and Accelerating Admixture: When low temperatures occur and/or plac-ing conditions dictate, the Contractor may request a change from the water reducing ad-mixture (Type A) to a water reducing and accelerating admixture (Type E).
5. Slump: Proportion and produce concrete to have a slump, not to exceed 4 in. if consoli-dated by vibration. Slump, not to exceed 5 in. if consolidated by rodding, spading or other manual methods.
6. Coarse Aggregate Size: maximum size of coarse aggregate shall not exceed:
a. One fifth narrowest dimension between sides of forms within which concrete is to be cast.
b. One third the slab or mass concrete thickness.
2.3 ACCESSORIES
A. Epoxy Bonding Compound:
1. Manufacturers: Use product such as A. C. Horn, Inc. EPOXTITE BINDER; Sika Chemical SIKADUR-HI-MOD or equal.
a. Euclid Chemical Company (The); an RPM company.
Herbert, Rowland & Grubic, Inc. 03 30 00 - 5 009280.0426
PART 3 - EXECUTION
3.1 EXAMINATION
A. Verify requirements for concrete cover over reinforcement.
B. Verify that anchors, seats, plates, reinforcement, and other items to be cast into concrete are accurately placed, positioned securely, and will not interfere with placing concrete.
3.2 PREPARATION
A. Previously Placed Concrete:
1. Prepare previously placed concrete by cleaning with steel brush and applying bonding agent.
2. Remove laitance, coatings, and unsound materials.
B. In locations where new concrete is doweled to existing work, drill holes in existing concrete, insert steel dowels, and pack solid with non-shrink grout.
C. Remove debris and ice from formwork, reinforcement, and concrete substrates.
Concrete can be placed underwater using tremie method.
D. Remove water from areas receiving concrete before concrete is placed.
3.3 INSTALLATION
A. Placing Concrete:
1. Place concrete according to ACI 304.
2. Notify testing laboratory and Engineer minimum 24 hours prior to commencement of op-erations.
3. Ensure that reinforcement, inserts, embedded parts, formed expansion and contraction joints are not disturbed during concrete placement.
4. Lap joints minimum 6 inches and seal watertight.
5. Deposit concrete at final position, preventing segregation of mix.
6. Place concrete in continuous operation for each panel or section as determined by pre-determined joints.
7. Consolidate concrete.
Herbert, Rowland & Grubic, Inc. 03 30 00 - 6 009280.0426
8. Maintain records of concrete placement, including date, location, quantity, air tempera-ture, and test samples taken.
9. Place concrete continuously between predetermined expansion, control, and construc-tion joints.
B. Curing and Protection:
1. Immediately after placement, protect concrete from premature drying, excessively hot or cold temperatures, and mechanical injury.
2. Protect concrete footings from freezing for minimum of five days.
3. Maintain concrete with minimal moisture loss at relatively constant temperature for pe-riod as necessary for hydration of cement and hardening of concrete.
4. Curing shall be by either water curing or sealing methods in accordance with ACI 308.
5. 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 ac-cordance with ASTM C 156.
3.4 FIELD QUALITY CONTROL
A. Perform inspection and testing according to ACI 301.
B. Provide unrestricted access to Work and cooperate with appointed testing and inspection firm.
C. Submit proposed mix design of each class of concrete to inspection and testing firm for review prior to commencement of Work.
D. Strength Test Samples:
1. Sampling Procedures: Comply with ASTM C172C172M.
2. Cylinder Molding and Curing Procedures:
a. Comply with ASTM C3C31M9.
3. Sample concrete and make one set of three cylinders for every 50 cu. yd. or less of each class of concrete placed each day, and for every 5,000 sq. ft.of surface area for slabs and walls.
E. Field Testing:
1. Slump Test Method: Comply with ASTM C143C143M.
2. Air Content Test Method: Comply with ASTM C173C173M.
Herbert, Rowland & Grubic, Inc. 03 30 00 - 7 009280.0426
3. Temperature Test Method: Comply with ASTM C1064C1064M.
F. Cylinder Compressive Strength Testing:
1. Test Method: Comply with ASTM C39.
2. Test Acceptance: According to ACI 318.
3. Test two cylinders at seven days.
4. Test two cylinders at 28 days.
5. Retain two cylinders for testing when requested by Engineer.
6. 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.
7. If required by the Engineer, obtain and test core specimens from hardened concrete in accordance with ASTM C 42.
END OF SECTION 03 30 00
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