03300_-_Cast-in-Place_Structural_Concrete.pdf

Sewer Manhole Rehabilitation Project 03300-1 Project No. 07693 City of Hayward Cast-in-Place Structural Concrete November 2025

SECTION 03300

CAST-IN-PLACE STRUCTURAL CONCRETE

PART 1 - GENERAL

1.01 Summary

A. Section Includes

1. Cast-in-place structural reinforced concrete

2. Concrete accessories

1.02 References

A. American Concrete Institute (ACI)

ACI 117 Standard Tolerances for Concrete Construction and Materials

ACI 301 Specifications for Structural Concrete for Buildings

ACI 304 Guide for Measuring, Mixing, Transporting, and Placing Concrete

ACI 305 Hot Weather Concreting

ACI 306 Cold Weather Concreting

ACI 308 Guide to Curing Concrete

ACI 309 Consolidation of Concrete

ACI 318 Building Code Requirements for Structural Concrete

ACI 350 Environmental Engineering Concrete Structures

B. American Society for Testing and Materials (ASTM)

ASTM C31 Practices for Making and Curing Concrete Test Specimens in the Field

ASTM C33 Specification for Concrete Aggregates

ASTM C39 Test Method for Compressive Strength of Cylindrical Concrete Specimens

ASTM C94 Specification for Ready-Mixed Concrete

ASTM C143 Test Method for Slump of Portland Cement Concrete

ASTM C150

Specification for Portland Cement

ASTM C157 Test Method for Length Change of Hardened Hydraulic Cement Mortar and Concrete

ASTM C172 Standard Method of Sampling Freshly Mixed Concrete

ASTM C192 Method of Making and Curing Concrete Test Specimens in the Laboratory

ASTM C260 Specification for Air-Entraining Admixtures for Concrete

ASTM C289 Test Method For Potential Reactivity of Aggregates (Chemical Method)

ASTM C309 Specifications for Liquid Membrane-Forming Compounds for Curing Concrete

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ASTM C494 Specification for Chemical Admixtures for Concrete

ASTM C618 Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

ASTM C1077 Standard Practice for Laboratories Testing Concrete and Concrete Aggregates for use in Construction & Criteria for Laboratory Evaluation

1.03 Definitions

A. “Contractor” includes the general contractor in direct contract with the owner, subcontractor, or any tradesman responsible for construction.

B. “Owner’s Representative” or “City’s Representative” includes the Inspector, Engineer of Record, or Construction Manager representing the owner’s or City’s interests, and not directly compensated by the Contractor.

C. “Cold Weather” is defined as a period when, for more than 3 consecutive days, the following conditions exist:

1. Average daily air temperature is less than 40 F degrees (5 C) and

2. Air temperature is not greater than 50 F degrees (10 C) for more than one-half of any 24-hour period.

D. “Hot weather” is defined by any one of the following conditions:

1. Ambient air temperature above 90 F degrees (32 C).

E. “Mass Concrete” refers to single pour cast-in-place concrete that is greater than 2’-10” thick, or is 2’-6” thick or greater, with an area larger than 500 square feet.

1.04 Submittals

A. General: All submittals must be provided for City’s Representative approval at least 3 weeks prior to construction.

B. Submit concrete mix design for each concrete type per ACI 301:

1. Mix proportions

2. Concrete materials

3. Admixtures

4. Water test results

5. Waterstop samples

C. Curing methods and product data per ACI 301.

D. Repair procedures for repair per ACI 224.1 and ACI 301.

E. Special procedures for hot weather concreting.

F. Special procedures for cold weather concreting.

G. Special procedures for mass concrete.

1.05 Quality Assurance

A. Qualifications: All foremen supervising construction shall have a minimum of 3 years experience in similar work, and at least 3 previous projects of similar type, and shall be familiar with ACI 301.

B. Field Testing

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1. Daily inspection written reports shall be provided to the City’s Representative providing detailed information of work completed within 24 hours.

2. During concrete placement, the following duties shall be performed by the Inspector:

a. Ambient air temperature test

b. Concrete temperature test

c. Concrete slump test

d. Collection of samples for lab testing

e. Confirm accuracy of batch ticket

3. Pre-pour conference: after submittals have been provided and before construction has been commenced, a concrete conference shall be coordinated between the Inspector and Contractor.

C. Lab Testing

1. Compression testing per ACI 318 chapter 5.

2. Shrinkage testing per ASTM C157 for hydraulic structures.

a. One shrinkage test is required for the first batch of concrete, and every 500 cubic yards of fresh concrete thereafter.

b. Acceptance criteria is 0.035% (0.00035) shrinkage at 28 days.

1.06 Project Conditions

A. Soil subgrade

1. Prior to setting reinforcing and pouring concrete on soil, the City’s Representative shall approve of the soil.

B. Environmental Requirements:

1. Concrete placement shall be limited to temperature ranges per ACI 301.

2. Concrete placement shall be limited to weather conditions per ACI 301.

PART 2 - PRODUCTS

2.01 General

A. Except as noted below, all products and materials used in proportioning, mixing, transport, placement, consolidation, curing, and repair shall satisfy ACI 301 and the Construction Drawings.

B. Cast-in-place structural concrete shall be 6 sack (minimum), containing not less than 564 pounds of cementitious material per cubic yard, 4-inch maximum slump, and shall have developed a minimum compressive strength of 4,000 pounds per square inch at 28 days.

2.02 Materials

A. Concrete materials

1. Aggregate per ACI 301

2. Cementious materials per ACI 301

a. Cement shall be Portland cement.

Sewer Manhole Rehabilitation Project 03300-4 Project No. 07693

b. Fly ash shall be provided at 15% minimum, 25% maximum of cementious materials.

3. Admixtures

a. Provide as necessary to meet design and workability requirements

B. Water shall be potable, and have the following limitations:

1. Chlorides (as Cl) no more than 250 mg/L per EPA method 300.

2. Sulfates (as S04) no more than 250 mg/L per EPA method 300.

3. Total dissolved solids no more than 500 mg/L per EPA method 160.

4. Water quality shall be analyzed by EPA methods. Test results shall be provided to the City’s Representative for the first batch of concrete, and every 500 cubic yards of fresh concrete thereafter.

C. Curing compounds per ACI 301.

D. Miscellaneous Materials

1. Waterstops are Greenstreak PVC 6” tall flat ribbed.

2. Plugs for formwork wall tie holes are Dayton Sureplug A-58.

3. For formwork ties that are left in place, provide plastic cone spacers for 1.5 inch breakback.

2.03 Equipment

A. Equipment shall conform to ACI 301.

PART 3 - EXECUTION

3.01 Preparation

A. Construction shall not be commenced until the applicable submittals have been approved by the City’s Representative.

B. Reinforcing, embedded items, sleeves, and inserts shall be set and secured prior to fresh concrete placement. Interconnect anchor bolt groups with steel templates.

C. Construction Joints:

1. Construction joints shall be water-blasted prior to casting fresh concrete against existing concrete.

2. New concrete shall not be placed adjacent to existing concrete younger than 2 days old.

D. Bonding agent shall not be used except where allowed by City’s Representative.

E. Formwork temperature is verified per ACI 301.

F. Subgrade or hardened concrete to be cast against conforms to ACI 301.

3.02 Installation

A. Placement of fresh concrete in forms per ACI 301.

B. Placement of fresh concrete on soil per ACI 301.

C. Placement of fresh concrete shall be limited to weather constraints per ACI 301.

D. Depositing fresh concrete per ACI 301 with the following requirements:

Sewer Manhole Rehabilitation Project 03300-5 Project No. 07693

1. For hot weather conditions, maximum time from batching to discharge shall not exceed 45 minutes.

2. For normal weather conditions, maximum time from batching to discharge shall not exceed 60 minutes.

3. Time between lift placement shall not exceed 30 minutes for hot weather placement; 60 minutes otherwise.

E. Consolidate fresh concrete per ACI 301.

F. Finishing formed surfaces

1. Exposed edges shall have 5/8 inch chamfers.

2. Filling Tie Holes:

a. No sooner than 14 days after formwork removal, clean and roughen the entire tie hole, and cone taper zone where exists, using an aggressive wire brush.

b. Use Dayton Sure Plug A-58 to plug round tie holes on both wall faces.

c. Recess plug back 1.0 inches deeper than face of wall or recess cone taper.

d. Use Sikatop 123 Plus mortar or approved equal to fill and patch hole.

G. Finishing Unformed Surfaces:

1. Fresh concrete placement per ACI 301.

2. Finishes definitions per ACI 301 with the following requirements:

a. Broom finish coarseness shall not exceed 1/16 inch amplitude, and shall be applied perpendicular to the predominate slope of the finished concrete.

b. Scratch Finish may also be termed “Roughened Surface”.

3. Finish schedule

a. Scratch Finish shall be applied to:

1) Construction joints.

2) Surfaces intended to received bonded cementious mixtures.

b. Boom Finish shall be applied to:

1) Exterior walking surfaces with more than 2 percent slope.

H. Curing shall conform to ACI 301 with the following additional requirements

1. Where a protective coating will be applied to the concrete after curing, liquid (“membrane”) curing compounds shall not be used.

2. Where a liquid curing compound is used, the compound shall be pigmented. Pigmentation shall be removable without special chemicals.

I. Tolerances per ACI 117.

3.03 Protection

A. Protection shall be per ACI 301.

Sewer Manhole Rehabilitation Project 03300-6 Project No. 07693

3.04 Repair

A. Repair shall be per ACI 301 with the following requirements:

1. Patching mortar shall be Sikatop 123 Plus or approved equal.

2. Use Sikadur 32 HiMod bonding agent or approved equal.

3. Honeycombs and defects deeper than 38 mm (1.5 inches) shall require approval by Engineer of Record prior to commencing repair work.

4. Cracks wider than 1 mm (0.04 inches) shall be repaired.

**END OF SECTION**