03 30 00 – Cast-In-Place Concrete

1.0 General

1.1 Summary

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

1. Manholes.

2. Thrust blocks.

3. Pipe encasement.

4. Anchors.

5. Pipe cradles.

1.2 Reference Standards

A. American Association of State Highway and Transportation Officials, AASHTO M182

Burlap cloth made from Jute or Kenaf.

B. American Concrete Institute:

1. ACI 211.1 – Standard Practice for Selecting Proportions for Normal, Heavyweight, and Mass Concrete.

2. ACI 301 – Specifications for Structural Concrete.

3. ACI 304R – Guide for Measuring, Mixing, Transporting, and Placing Concrete.

4. ACI 305R – Guide to Hot Weather Concreting.

5. ACI 306R – Guide to Cold Weather Concreting.

6. ACI 308 – Specification for Curing Concrete.

7. ACI 318 – Building Code Requirements for Structural Concrete.

C. American Society for Testing and Materials:

1. ASTM C31 – Standard Method of Making and Curing Concrete Test Specimens in the Field.

2. ASTM C33 – Specification for Concrete Aggregates.

3. ASTM C39 – Standard Test Method for Compressive Strength of Cylindrical

Concrete Specimens.

4. ASTM C42 – Standard Method of 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 Portland Cement Concrete.

7. ASTM C150 – Standard Specification for Portland Cement.

8. ASTM C156 – Test Method for Water Retention by Concrete Curing Materials.

9. ASTM C171 – Standard Specification for Sheet Materials for Curing Concrete.

10. ASTM C172 – Standard Method of Sampling Freshly Mixed Concrete.

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

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

13. ASTM C260 – Standard Specification for Air Entraining Admixtures for Concrete.

14. ASTM C309 – Standard Specification for Liquid Membrane - Forming Compounds for Curing Concrete.

15. ASTM C494 – Standard Specification for Chemical Admixtures for Concrete.

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

(Nonshrink).

D. PennDOT, Publication 408.

1.3 COORDINATION

A. Section 01 31 13 – Project Coordination: Requirements for coordination.

B. 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: The Contractor shall submit data on joint devices, attachment accessories, and admixtures.

C. Design Data- the Contractor shall:

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.

4. Identify chloride content of admixtures and whether or not chlorides were added during manufacture.

D. Manufacturer's Certificate: The Contractor shall certify that products meet or exceed specified requirements.

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

1.5 Closeout Submittals

A. Section 01 77 00 – Closeout Procedures: Requirements for submittals.

B. Project Record Documents: The Contractor shall record actual locations of embedded utilities and components concealed from view in finished construction.

1.6 Quality Assurance

A. The Contractor shall perform Work according to ACI 301.

B. The Contractor shall comply with ACI 305R when pouring concrete during hot weather.

C. The Contractor shall comply with ACI 306.1 when pouring concrete during cold weather.

D. The Contractor shall acquire cement and aggregate from one source for Work.

1.7 AMBIENT CONDITIONS

A. Section 01 50 00 – Temporary Facilities And Controls: Requirements for ambient condition control facilities for product storage and installation.

B. Maintain concrete temperature after installation at minimum 50 degrees F for minimum seven days.

2.0 Products

2.1 Materials

A. Concrete:

1. Cement:

a. Comply with ASTM C150, Type II – Moderate Sulfate Resistant.

b. Type: Portland.

2. Blended Cement

a. Comply with ASTM C595.

b. Type: IP(MS) or IL(MS).

c. Color: Gray

3. Normal Weight Aggregates:

a. Comply with ASTM C33.

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

4. Water:

a. Comply with ACI 318.

b. Potable, without deleterious amounts of chloride ions.

B. Admixtures:

1. Furnish materials according to PennDOT standards.

2. Air Entrainment: Comply with ASTM C260.

3. Chemical:

a. Comply with ASTM C494.

b. Type A – Water Reducing.

c. Type B – Retarding

d. Type D – Water Reducing and Retarding.

e. Type E – Water Reducing and Accelerating.

f. Type F – Water Reducing, High Range.

g. Type G – Water Reducing, High Range, and Retarding.

4. Fly Ash: Comply with ASTM C618, Class F.

5. Silica Fume: Comply with ASTM C1240.

6. Slag:

a. Description: Ground-granulated blast-furnace slag.

b. Comply with ASTM C989.

c. Grade 100 or 120.

7. Plasticizing:

a. Comply with ASTM C1017.

b. Type II, plasticizing, and retarding.

8. Waterproofing:

a. Waterproofing admixture shall be “ADMIX C-Series” manufactured by Xypex

Chemical Corporation, Richmond, B.C., Canada – no substitutes.

9. Anti-Microbial:

a. Anti-Microbial admixture shall be “Bio-San C500” manufactured by Xypex

Chemical Corporation, Richmond, B.C., Canada – no substitutes.

C. Joint Devices and Filler:

1. Joint Filler, Type A:

a. Description: Asphalt-impregnated fiberboard or felt.

b. Comply with ASTM D1751.

c. Thickness: ½ inch.

2. Joint Filler, Type C:

a. Description: Pre-molded sponge rubber.

b. Comply with ASTM D1752.

c. Thickness: ½ inch.

2.2 Concrete Mix

A. The Contractor shall select proportions for normal weight concrete according to ACI

301, Method 1.

B. Performance and Design Criteria for Pipe Cradles:

1. Compressive Strength: 3,000 psi.

2. Cement Type: ASTM C150.

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

4. Aggregate Type: Normal weight.

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

6. Air Content: 6 percent, plus or minus 1 percent.

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

C. Performance and Design Criteria for Manholes, Structural Concrete, 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. 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.

6. For concrete exposed to deicing chemicals, limit fly ash, pozzolans, silica fumes, and slag content as required by applicable code.

F. Average Compressive Strength Reduction: Not permitted.

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

H. 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 24 hours and 4,000 psi in 28 days.

C. Concrete Admixtures:

1. Calcium Chloride: Not permitted.

2. Provide admixtures produced and serviced by established, reputable manufacturers and use in compliance with manufacturer's recommendations.

3. Air Entraining Admixture: Use a product conforming to requirements of ASTM

C260.

4. Water Reducing Admixture: Use a product conforming to requirements of ASTM

C494 Type A and that contains less than 0.1% chloride ion.

5. Water Reducing and Retarding Admixture: Use a product conforming to requirements of ASTM C494 Type D and that contains less than 0.1% chloride ion.

6. Water Reducing and Accelerating Admixture: Use a product conforming to requirements of ASTM C 494 Type E and that contains less than 0.1% chloride ion.

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

3.0 Execution

3.1 General

A. The Contractor shall 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.

B. Embedded Items: The Contractor shall 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: The Contractor shall conduct placement work in accordance with ACI 304R.

B. Preparation- the Contractor shall:

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- the Contractor shall:

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- the Contractor shall:

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

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

3. Do not allow concrete to flow laterally more than three (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- the Contractor shall:

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.

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, the Contractor shall 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, the Contractor shall 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: The Contractor shall 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, the Contractor shall 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 seven (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.

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. Testing and Inspection: The Contractor shall 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 (2) specimens at seven (7) days, two (2) at 28 days, and retain two (2) specimens in reserve for later testing if required.

4. Make one (1) strength test for each 50 cu. yd. of concrete, unless waived by the

Engineer, but not less than one (1) 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.

B. Evaluation and Acceptance:

1. The strength level of the concrete will be considered satisfactory if the averages of all sets of three (3) 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 that the Contractor make a change in the mix proportions for the remaining concrete being poured, at no additional cost to the Owner.

3. If required by the Engineer, the Contractor shall obtain and test core specimens from hardened concrete in accordance with ASTM C42, at no additional cost to the

Owner.

END OF SECTION