033000 Cast-in-Place Concrete.pdf

PARKING GARAGE PROJECT NUMBER 693-222

DEPARTMENT OF VETERANS AFFAIRS

WILKES-BARRE, PENNSYLVANIA

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SECTION 033000 CAST-IN-PLACE CONCRETE

PART 1 – GENERAL

1.1 DESCRIPTION:

This section specifies cast-in-place structural concrete and materials and mixes for other concrete.

1.2 RELATED WORK:

A. Materials testing and inspection during construction: Refer to Division 01 for requirements.

B. Concrete roads, walks, and similar exterior site work: Section 32 05 23, CEMENT AND

CONCRETE FOR EXTERIOR IMPROVEMENTS.

1.3 TESTING AGENCY FOR CONCRETE MIX DESIGN:

A. Testing agency for the trial concrete mix design retained and reimbursed by the Contractor and approved by COR. For all other applicable testing, refer to Division 01.

B. Testing agency maintaining active participation in Program of Cement and Concrete Reference Laboratory (CCRL) of National Institute of Standards and Technology.

Accompany request for approval of testing agency with a copy of Report of Latest Inspection of Laboratory Facilities by CCRL.

C. Testing agency shall furnish equipment and qualified technicians to establish proportions of ingredients for concrete mixes.

1.4 TOLERANCES:

A. Formwork: ACI 117, except the elevation tolerance of formed surfaces before removal of shores is +0 mm (+0 inch) and -20 mm (-3/4 inch).

B. Reinforcement Fabricating and Placing: ACI 117, except that fabrication tolerance for bar sizes Nos. 10, 13, and 16 (Nos. 3, 4, and 5) (Tolerance Symbol 1 in Fig. 2.1(a), ACI,

117) used as column ties or stirrups is +0 mm (+0 inch) and -13 mm (-1/2 inch) where gross bar length is less than 3600 mm (12 feet), or +0 mm (+0 inch) and -20 mm (-3/4 inch) where gross bar length is 3600 mm (12 feet) or more.

C. Cross-Sectional Dimension: ACI 117, except tolerance for thickness of slabs 12 inches or less is +20 mm (+3/4 inch) and - 6 mm (-1/4 inch). Tolerance of thickness of beams more than 300 mm (12 inch) but less than 900 mm (3 feet) is +20 mm (+3/4 inch) and - 10 mm (-3/8 inch).

D. 1.5 REGULATORY REQUIREMENTS:

A. ACI SP-66 – ACI Detailing Manual.

B. ACI 318 - Building Code Requirements for Reinforced Concrete.

C. ACI 301 – Standard Specifications for Structural Concrete.

1.6 SUBMITTALS:

A. Submit in accordance with Division 01 requirements.

B. Shop Drawings: Reinforcing steel: Complete shop drawings C. Mill Test Reports:

1. Reinforcing Steel.

2. Cement.

D. Manufacturer's Certificates:

1. Abrasive aggregate.

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3. Air-entraining admixture.

4. Chemical admixtures, including chloride ion content.

5. Waterproof paper for curing concrete.

6. Liquid membrane-forming compounds for curing concrete.

7. Non-shrinking grout.

9. Waterstops.

10. Expansion joint filler.

11. Adhesive binder.

E. Testing Agency for Concrete Mix Design: Approval request including qualifications of principals and technicians and evidence of active participation in program of Cement and Concrete Reference Laboratory (CCRL) of National Institute of Standards and Technology and copy of report of latest CCRL, Inspection of Laboratory.

F. Test Report for Concrete Mix Designs: Trial mixes including water-cement fly ash ratio curves, concrete mix ingredients, and admixtures.

1.7 DELIVERY, STORAGE, AND HANDLING:

A. Conform to ACI 304. Store aggregate separately for each kind or grade, to prevent segregation of sizes and avoid inclusion of dirt and other materials.

B. Deliver cement in original sealed containers bearing name of brand and manufacturer, and marked with net weight of contents. Store in suitable watertight building in which floor is raised at least 300 mm (1 foot) above ground. Store bulk cement and fly ash in separate suitable bins.

C. Deliver other packaged materials for use in concrete in original sealed containers, plainly marked with manufacturer's name and brand, and protect from damage until used.

1.8 PRE-CONCRETE CONFERENCE:

A. General: At least 15 days prior to submittal of design mixes, conduct a meeting to review proposed methods of concrete construction to achieve the required results.

B. Agenda: Includes but is not limited to:

1. Submittals.

2. Coordination of work.

3. Availability of material.

4. Concrete mix design including admixtures.

5. Methods of placing, finishing, and curing.

6. Finish criteria required to obtain required levelness.

7. Timing of floor finish measurements.

8. Material inspection and testing.

C. Attendees: Include but not limited to representatives of Contractor; subcontractors involved in supplying, conveying, placing, finishing, and curing concrete; admixture manufacturers; COR; Consulting Engineer; testing laboratories for concrete testing.

D. Minutes of the meeting: Contractor shall take minutes and type and distribute the minutes to attendees within five days of the meeting.

1.9 MOCK-UP:

A. In addition to the other specified samples and tests, construct a mock-up using the materials, reinforcing, forming system and construction methods proposed for use in exposed architectural concrete.

B. Construct the mock-up with at least a 2.5 m by 2.5 m (8 feet by 8 feet) exposed surface and suitable foundations. Include the following where applicable: Control joints, reglets, recesses or other typical architectural details.

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C. Before casting the mock-up, submit full detailed Shop Drawings of the mock-up formwork for review by the Architect. Perform all necessary preliminary tests to ensure that concrete used for the mock-up will exactly match the approved sample in color and texture.

D. Perform the surface treatment proposed for use on one or more areas not less than 300 mm by 300 mm (1 foot by 1 foot) on the back side of the mock-up to establish the texture of finish required by the Architect. Repeat as required until a sample satisfactory to the Architect has been obtained.

E. Treat the finished front surface of the mock-up to produce a uniform appearance similar in every respect to the approved sample area.

F. The completed mock-up shall be inspected by the Architect. Failure of the mock-up to match the approved sample will require the construction of further mock-ups until approval is obtained. Remove rejected mock-ups immediately.

G. Maintain the approved mock-ups in good condition at the job site until all architectural concrete surfaces have been completed and approved by the Architect. Remove the mock-up from the site after completion of the above.

1.10 APPLICABLE PUBLICATIONS:

A. Publications listed below form a part of this specification to extent referenced.

Publications are referenced in text by basic designation only.

B. American Concrete Institute (ACI):

117-10 ................................... Specifications for Tolerances for Concrete Construction and Materials and Commentary 211.1-91(R2009) ................... Standard Practice for Selecting Proportions for Normal, Heavyweight, and Mass Concrete 211.2-98(R2004) ................... Standard Practice for Selecting Proportions for Structural

Lightweight Concrete 214R-11 ................................ Guide to Evaluation of Strength Test Results of Concrete 301-10 ................................... Standard Practice for Structural Concrete 304R-00(R2009) ................... Guide for Measuring, Mixing, Transporting, and Placing

Concrete 305.1-06 ................................ Specification for Hot Weather Concreting 306.1-90(R2002) ................... Standard Specification for Cold Weather Concreting 308.1-11 ................................ Specification for Curing Concrete 309R-05 ................................ Guide for Consolidation of Concrete 318-11 ................................... Building Code Requirements for Structural Concrete and

Commentary 347-04 ................................... Guide to Formwork for Concrete SP-66-04 ............................... ACI Detailing Manual

C. American National Standards Institute and American Hardboard Association

(ANSI/AHA):

A135.4-2004 .......................... Basic Hardboard

D. American Society for Testing and Materials (ASTM):

A82/A82M-07 ........................ Standard Specification for Steel Wire, Plain, for Concrete

Reinforcement A185/185M-07 ....................... Standard Specification for Steel Welded Wire

Reinforcement, Plain, for Concrete A615/A615M-09 .................... Standard Specification for Deformed and Plain Carbon

Steel Bars for Concrete Reinforcement

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A653/A653M-11 .................... Standard Specification for Steel Sheet, Zinc Coated (Galvanized) or Zinc Iron Alloy Coated (Galvannealed) by the Hot Dip Process

A706/A706M-09 .................... Standard Specification for Low Alloy Steel Deformed and Plain Bars for Concrete Reinforcement

A767/A767M-09 .................... Standard Specification for Zinc Coated (Galvanized) Steel Bars for Concrete Reinforcement

A775/A775M-07 .................... Standard Specification for Epoxy Coated Reinforcing Steel Bars

A820-11 ................................. Standard Specification for Steel Fibers for Fiber Reinforced Concrete

A996/A996M-09 .................... Standard Specification for Rail Steel and Axle Steel Deformed Bars for Concrete Reinforcement

C31/C31M-10 ........................ Standard Practice for Making and Curing Concrete Test Specimens in the field

C33/C33M-11A ..................... Standard Specification for Concrete Aggregates C39/C39M-12 ........................ Standard Test Method for Compressive Strength of

Cylindrical Concrete Specimens C94/C94M-12 ........................ Standard Specification for Ready Mixed Concrete C143/C143M-10 .................... Standard Test Method for Slump of Hydraulic Cement

Concrete C150-11 ................................ Standard Specification for Portland Cement C171-07 ................................ Standard Specification for Sheet Materials for Curing

Concrete C172-10 ................................ Standard Practice for Sampling Freshly Mixed Concrete C173-10... ............................. Standard Test Method for Air Content of Freshly Mixed

Concrete by the Volumetric Method C192/C192M-07 .................... Standard Practice for Making and Curing Concrete Test

Specimens in the Laboratory C231-10 ................................ Standard Test Method for Air Content of Freshly Mixed

Concrete by the Pressure Method C260-10 ................................ Standard Specification for Air Entraining Admixtures for

Concrete C309-11 ................................ Standard Specification for Liquid Membrane Forming

Compounds for Curing Concrete C330-09 ................................ Standard Specification for Lightweight Aggregates for

Structural Concrete C494/C494M-11 .................... Standard Specification for Chemical Admixtures for

Concrete C618-12 ................................ Standard Specification for Coal Fly Ash and Raw or

Calcined Natural Pozzolan for Use in Concrete C666/C666M-03(R2008) ....... Standard Test Method for Resistance of Concrete to Rapid

Freezing and Thawing C881/C881M-10 .................... Standard Specification for Epoxy Resin Base Bonding

Systems for Concrete C1107/1107M-11 .................. Standard Specification for Packaged Dry, Hydraulic-

Cement Grout (Non-shrink) C1315-11 .............................. Standard Specification for Liquid Membrane Forming

Compounds Having Special Properties for Curing and Sealing Concrete

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D6-95(R2011) ....................... Standard Test Method for Loss on Heating of Oil and Asphaltic Compounds

D297-93(R2006) ................... Standard Methods for Rubber Products Chemical Analysis D412—06AE2 ....................... Standard Test Methods for Vulcanized Rubber and

Thermoplastic Elastomers - Tension D1751-04(R2008) ................. Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Non-extruding and Resilient Bituminous Types)

D4263-83(2012) .................... Standard Test Method for Indicating Moisture in Concrete by the Plastic Sheet Method.

D4397-10 .............................. Standard Specification for Polyethylene Sheeting for Construction, Industrial and Agricultural Applications

E1155-96(R2008) .................. Standard Test Method for Determining FF Floor Flatness and FL Floor Levelness Numbers

F1869-11 ............................... Standard Test Method for Measuring Moisture Vapor Emission Rate of Concrete Subfloor Using Anhydrous Calcium Chloride.

E. American Welding Society (AWS):

D1.4/D1.4M-11 ...................... Structural Welding Code - Reinforcing Steel

F. Concrete Reinforcing Steel Institute (CRSI):

Handbook 2008

G. National Cooperative Highway Research Program (NCHRP):

Report On .............................. Concrete Sealers for the Protection of Bridge Structures

H. U. S. Department of Commerce Product Standard (PS):

PS 1 ...................................... Construction and Industrial Plywood PS 20 .................................... American Softwood Lumber

I. U. S. Army Corps of Engineers Handbook for Concrete and Cement:

CRD C513 ............................. Rubber Waterstops CRD C572 ............................. Polyvinyl Chloride Waterstops

PART 2 – PRODUCTS:

2.1 FORMS:

A. Wood: PS 20 free from loose knots and suitable to facilitate finishing concrete surface specified; tongue and grooved.

B. Plywood: PS-1 Exterior Grade B-B (concrete-form) 16 mm (5/8 inch), or 20 mm (3/4 inch) thick for unlined contact form. B-B High Density Concrete Form Overlay optional.

F. Form Lining:

1. Hardboard: ANSI/AHA A135.4, Class 2 with one (S1S) smooth side)

2. Plywood: Grade B-B Exterior (concrete-form) not less than 6 mm (1/4 inch) thick.

3. Plastic, fiberglass, or elastomeric capable of reproducing the desired pattern or texture.

G. Form Ties: Develop a minimum working strength of 13.35 kN (3000 pounds) when fully assembled. Ties shall be adjustable in length to permit tightening of forms and not have any lugs, cones, washers to act as spreader within form, nor leave a hole larger than 20 mm (3/4 inch) diameter, or a depression in exposed concrete surface, or leave metal closer than 40 mm (1 1/2 inches) to concrete surface. Wire ties not permitted. Cutting ties back from concrete face not permitted.

2.2 MATERIALS:

A. Portland Cement: ASTM C150 Type I or II.

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B. Fly Ash: ASTM C618, Class C or F including supplementary optional requirements relating to reactive aggregates and alkalies, and loss on ignition (LOI) not to exceed 5 percent.

C. Coarse Aggregate: ASTM C33.

1. Size 67 or Size 467 may be used for footings and walls over 300 mm (12 inches) thick.

2. Coarse aggregate for applied topping shall be Size 7.

3. Maximum size of coarse aggregates not more than one-fifth of narrowest dimension between sides of forms, one-third of depth of slabs, nor three-fourth of minimum clear spacing between reinforcing bars.

E. Fine Aggregate: ASTM C33. Fine aggregate for applied concrete floor topping shall pass a 4.75 mm (No. 4) sieve, 10 percent maximum shall pass a 150 µm (No. 100) sieve.

F. Mixing Water: Fresh, clean, and potable.

G. Admixtures:

1. Water Reducing Admixture: ASTM C494, Type A and not contain more chloride ions than are present in municipal drinking water.

2. Water Reducing, Retarding Admixture: ASTM C494, Type D and not contain more chloride ions than are present in municipal drinking water.

3. High-Range Water-Reducing Admixture (Superplasticizer): ASTM C494, Type F or G, and not contain more chloride ions than are present in municipal drinking water.

4. Non-Corrosive, Non-Chloride Accelerator: ASTM C494, Type C or E, and not contain more chloride ions than are present in municipal drinking water. Admixture manufacturer must have long-term non-corrosive test data from an independent testing laboratory of at least one year duration using an acceptable accelerated corrosion test method such as that using electrical potential measures.

5. Air Entraining Admixture: ASTM C260.

COR7. Calcium Nitrite corrosion inhibitor: ASTM C494 Type C.

8. Prohibited Admixtures: Calcium chloride, thiocyanate or admixtures containing more than 0.05 percent chloride ions are not permitted.

9. Certification: Written conformance to the requirements above and the chloride ion content of the admixture prior to mix design review.

H. Vapor Barrier: ASTM D4397, //0.25 mm (10 mil)//0.38 mm (15 mil).

I. Reinforcing Steel: ASTM A615, or ASTM A996, deformed, grade as shown.

J. Welded Wire Fabric: ASTM A185.

K. Reinforcing Bars to be Welded: ASTM A706.

L. Galvanized Reinforcing Bars: ASTM A767.

M. Epoxy Coated Reinforcing Bars: ASTM A775.

Q. Supports, Spacers, and Chairs: Types which will hold reinforcement in position shown in accordance with requirements of ACI 318 except as specified.

R. Expansion Joint Filler: ASTM D1751.

S. Sheet Materials for Curing Concrete: ASTM C171.

T. Liquid Membrane-forming Compounds for Curing Concrete: ASTM C309, Type I, with fugitive dye, and shall meet the requirements of ASTM C1315.Compound shall be compatible with scheduled surface treatment, such as paint and resilient tile, and shall not discolor concrete surface.

U. Abrasive Aggregate: Aluminum oxide grains or emery grits.

X. Penetrating Sealer: For use on parking garage ramps and decks. High penetration silane sealer providing minimum 95 percent screening per National Cooperative Highway

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Research Program (NCHRP) No. 244 standards for chloride ion penetration resistance.

Requires moist (non-membrane) curing of slab.

Y. Non-Shrink Grout:

1. ASTM C1107, pre-mixed, produce a compressive strength of at least 18 MPa at three days and 35 MPa (5000 psi) at 28 days. Furnish test data from an independent laboratory indicating that the grout when placed at a fluid consistency shall achieve 95 percent bearing under a 1200 mm x 1200 mm (4 foot by 4 foot) base plate.

2. Where high fluidity or increased placing time is required, furnish test data from an independent laboratory indicating that the grout when placed at a fluid consistency shall achieve 95 percent under a 450 mm x 900 mm (18 inch by 36 inch) base plate.

Z. Adhesive Binder: ASTM C881.

AA. Waterstops:

1. Polyvinyl Chloride Waterstop: CRD C572.

2. Rubber Waterstops: CRD C513.

3. Bentonite Waterstop: Flexible strip of bentonite 25 mm x 20 mm (1 inch by 3/4 inch), weighing 8.7 kg/m (5.85 lbs. per foot) composed of Butyl Rubber Hydrocarbon (ASTM D297), Bentonite (SS-S-210-A) and Volatile Matter (ASTM D6).

4. Non-Metallic Hydrophilic: Swellable strip type compound of polymer modified chloroprene rubber that swells upon contact with water shall conform to ASTM D412 as follows: Tensile strength 420 psi minimum; ultimate elongation 600 percent minimum. Hardness shall be 50 minimum on the type A durameter and the volumetric expansion ratio in in 70 deg water shall be 3 to 1 minimum.

BB. Porous Backfill: Crushed stone or gravel graded from 25 mm to 20 mm (1 inch to 3/4 inch).

CC. Fibers:

1. Synthetic Fibers: Monofilament or fibrillated polypropylene fibers for secondary reinforcing of concrete members. Use appropriate length and 0.9 kg/m3 (1.5 lb. per cubic yard). Product shall have a UL rating.

2. Steel Fibers: ASTM A820, Type I cold drawn, high tensile steel wire for use as primary reinforcing in slab-on-grade. Minimum dosage rate 18 kg/m3 (30 lb. per cubic yard).

DD. Epoxy Joint Filler: Two component, 100 percent solids compound, with a minimum shore D hardness of 50.

EE. Bonding Admixture: Non-rewettable, polymer modified, bonding compound.

FF. Architectural Concrete: For areas designated as architectural concrete on the Contract

Documents, use colored cements and specially selected aggregates as necessary to produce a concrete of a color and finish which exactly matches the designated sample panel.

2.3 CONCRETE MIXES:

A. Mix Designs: Proportioned in accordance with Section 5.3, "Proportioning on the Basis of Field Experience and/or Trial Mixtures" of ACI 318.

1. If trial mixes are used, make a set of at least 6 cylinders in accordance with ASTM

C192 for test purposes from each trial mix; test three for compressive strength at 7 days and three at 28 days.

2. Submit a report of results of each test series, include a detailed listing of the proportions of trial mix or mixes, including cement, fly ash, admixtures, weight of fine and coarse aggregate per m3 (cubic yard) measured dry rodded and damp loose, specific gravity, fineness modulus, percentage of moisture, air content, water-cement -fly ash ratio, and consistency of each cylinder in terms of slump.

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3. Prepare a curve showing relationship between water-cement -fly ash ratio at 7-day and 28-day compressive strengths. Plot each curve using at least three specimens.

4. If the field experience method is used, submit complete standard deviation analysis.

B. Fly Ash Testing: Submit certificate verifying conformance with ASTM 618 initially with mix design and for each truck load of fly ash delivered from source. Submit test results performed within 6 months of submittal date. Notify COR immediately when change in source is anticipated.

1. Testing Laboratory used for fly ash certification/testing shall participate in the

Cement and Concrete Reference Laboratory (CCRL) program. Submit most recent CCRL inspection report.

C. After approval of mixes no substitution in material or change in proportions of approval mixes may be made without additional tests and approval of COR or as specified.

Making and testing of preliminary test cylinders may be carried on pending approval of cement and fly ash, providing Contractor and manufacturer certify that ingredients used in making test cylinders are the same. COR may allow Contractor to proceed with depositing concrete for certain portions of work, pending final approval of cement // and fly ash // and approval of design mix.

D. Cement Factor: Maintain minimum cement factors in Table I regardless of compressive strength developed above minimums. Use Fly Ash as an admixture with 20% replacement by weight in all structural work. Increase this replacement to 40% for mass concrete, and reduce it to 10% for drilled piers and caissons. Fly ash shall not be used in high-early mix design.

TABLE I - CEMENT AND WATER FACTORS FOR CONCRETE

Concrete Strength Non-Air- Entrained

Air-Entrained

Min. 28 Day Comp. Str.

MPa (psi)

Min. Cement kg/m3 (lbs/c. yd)

Max. Water Cement Ratio

Min. Cement kg/m3 (lbs/c.

yd)

Max. Water Cement

Ratio

35 (5000)1,3 375 (630) 0.45 385 (650) 0.40

30 (4000)1,3 325 (550) 0.55 340 (570) 0.50

25 (3000)1,3 280 (470) 0.65 290 (490) 0.55

25 (3000)1,2 300 (500) * 310 (520) *

1. If trial mixes are used, the proposed mix design shall achieve a compressive strength

8.3 MPa (1200 psi) in excess of f'c. For concrete strengths above 35 Mpa (5000 psi), the proposed mix design shall achieve a compressive strength 9.7 MPa (1400 psi) in excess of f’c.

3. For concrete exposed to high sulfate content soils maximum water cement ratio is 0.44.

4. Determined by Laboratory in accordance with ACI 211.1.

E. Maximum Slump: Maximum slump, as determined by ASTM C143 with tolerances as established by ASTM C94, for concrete to be vibrated shall be as shown in Table II.

TABLE II - MAXIMUM SLUMP, MM (INCHES)*

Type of Construction Normal Weight Concrete

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Reinforced Footings and Substructure Walls

75mm (3 inches)

Slabs, Beams, Reinforced Walls, and Building Columns

100 mm (4 inches)

F. Slump may be increased by the use of the approved high-range water-reducing admixture (superplasticizer). Tolerances as established by ASTM C94. Concrete containing the high-range-water-reducing admixture may have a maximum slump of 225 mm (9 inches). The concrete shall arrive at the job site at a slump of 50 mm to 75 mm (2 inches to 3 inches). This should be verified, and then the high-range-water-reducing admixture added to increase the slump to the approved level.

G. Air-Entrainment: Air-entrainment of normal weight concrete shall conform with Table III.

Determine air content by either ASTM C173 or ASTM C231.

TABLE III - TOTAL AIR CONTENT

FOR VARIOUS SIZES OF COARSE AGGREGATES (NORMAL CONCRETE)

Nominal Maximum Size of Total Air Content

Coarse Aggregate, mm (Inches) Percentage by Volume

10 mm (3/8 in).6 to 10 13 mm (1/2 in).5 to 9

20 mm (3/4 in).4 to 8 25 mm (1 in).3-1/2 to 6-1/2

40 mm (1 1/2 in).3 to 6

H. High early strength concrete, made with Type III cement or Type I cement plus non-corrosive accelerator, shall have a 7-day compressive strength equal to specified minimum 28-day compressive strength for concrete type specified made with standard Portland cement.

J. Concrete slabs placed at air temperatures below 10 degrees C (50 degrees Fahrenheit) use non-corrosive, non-chloride accelerator. Concrete required to be air entrained use approved air entraining admixture. Pumped concrete, synthetic fiber concrete, architectural concrete, concrete required to be watertight, and concrete with a water/cement ratio below 0.50 use high-range water-reducing admixture (superplasticizer).

K. Durability: Use air entrainment for exterior exposed concrete subjected to freezing and thawing and other concrete shown or specified. For air content requirements see Table III or Table IV.

L. Enforcing Strength Requirements: Test during the progress of the work. Seven-day tests may be used as indicators of 28-day strength. Average of any three 28-day consecutive strength tests of laboratory-cured specimens representing each type of concrete shall be equal to or greater than specified strength. No single test shall be more than 3.5 MPa (500 psi) below specified strength. Interpret field test results in accordance with ACI 214.

Should strengths shown by test specimens fall below required values, COR may require any one or any combination of the following corrective actions, at no additional cost to the Government:

1. Require changes in mix proportions by selecting one of the other appropriate trial mixes or changing proportions, including cement content, of approved trial mix.

2. Require additional curing and protection.

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3. If five consecutive tests fall below 95 percent of minimum values given in Table I or if test results are so low as to raise a question as to the safety of the structure, COR may direct Contractor to take cores from portions of the structure. Use results from cores tested by the Contractor retained testing agency to analyze structure.

4. If strength of core drilled specimens falls below 85 percent of minimum value given in Table I, COR may order load tests, made by Contractor retained testing agency, on portions of building so affected. Load tests in accordance with ACI 318 and criteria of acceptability of concrete under test as given therein.

5. Concrete work, judged inadequate by structural analysis, by results of load test, or for any reason, shall be reinforced with additional construction or replaced, if directed by the COR.

2.4 BATCHING AND MIXING:

A. General: Concrete shall be "Ready-Mixed" and comply with ACI 318 and ASTM C94, except as specified. Batch mixing at the site is permitted. Mixing process and equipment must be approved by COR. With each batch of concrete, furnish certified delivery tickets listing information in Paragraph 16.1 and 16.2 of ASTM C94. Maximum delivery temperature of concrete is 380C (100 degrees Fahrenheit). Minimum delivery temperature as follows:

Atmospheric Temperature Minimum Concrete Temperature

-1. degrees to 4.4 degrees C (30 degrees to 40 degrees F)

15.6 degrees C (60 degrees F.)

-17 degrees C to -1.1 degrees C (0 degrees to 30 degrees F.)

21 degrees C (70 degrees F.)

CORCORPART 3 – EXECUTION

3.1 FORMWORK:

A. General: Design in accordance with ACI 347 is the responsibility of the Contractor. The Contractor shall retain a registered Professional Engineer to design the formwork, shores, and reshores.

1. Form boards and plywood forms may be reused for contact surfaces of exposed concrete only if thoroughly cleaned, patched, and repaired and COR approves their reuse.

2. Provide forms for concrete footings unless COR determines forms are not necessary.

3. Corrugated fiberboard forms: Place forms on a smooth firm bed, set tight, with no buckled cartons to prevent horizontal displacement, and in a dry condition when concrete is placed.

B. Treating and Wetting: Treat or wet contact forms as follows:

1. Coat plywood and board forms with non-staining form sealer. In hot weather, cool forms by wetting with cool water just before concrete is placed.

2. Clean and coat removable metal forms with light form oil before reinforcement is placed. In hot weather, cool metal forms by thoroughly wetting with water just before placing concrete.

3. Use sealer on reused plywood forms as specified for new material.

C. Size and Spacing of Studs: Size and space studs, wales and other framing members for wall forms so as not to exceed safe working stress of kind of lumber used nor to develop deflection greater than 1/270 of free span of member.

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D. Unlined Forms: Use plywood forms to obtain a smooth finish for concrete surfaces.

Tightly butt edges of sheets to prevent leakage. Back up all vertical joints solidly and nail edges of adjacent sheets to same stud with 6d box nails spaced not over 150 mm (6 inches) apart.

E. Lined Forms: May be used in lieu of unlined plywood forms. Back up form lining solidly with square edge board lumber securely nailed to studs with all edges in close contact to prevent bulging of lining. No joints in lining and backing may coincide. Nail abutted edges of sheets to same backing board. Nail lining at not over 200 mm (8 inches) on center along edges and with at least one nail to each square foot of surface area; nails to be 3d blued shingle or similar nails with thin flatheads.

F. Architectural Liner: Attach liner as recommended by the manufacturer with tight joints to prevent leakage.

G. Wall Form Ties: Locate wall form ties in symmetrically level horizontal rows at each line of wales and in plumb vertical tiers. Space ties to maintain true, plumb surfaces. Provide one row of ties within 150 mm (6 inches) above each construction joint. Space through-ties adjacent to horizontal and vertical construction joints not over 450 mm (18 inches) on center.

1. Tighten row of ties at bottom of form just before placing concrete and, if necessary, during placing of concrete to prevent seepage of concrete and to obtain a clean line.

Ties to be entirely removed shall be loosened 24 hours after concrete is placed and shall be pulled from least important face when removed.

2. Coat surfaces of all metal that is to be removed with paraffin, cup grease or a suitable compound to facilitate removal.

H. Inserts, Sleeves, and Similar Items: Flashing reglets, steel strips, masonry ties, anchors, wood blocks, nailing strips, grounds, inserts, wire hangers, sleeves, drains, guard angles, forms for floor hinge boxes, inserts or bond blocks for elevator guide rails and supports, and other items specified as furnished under this and other sections of specifications and required to be in their final position at time concrete is placed shall be properly located, accurately positioned, and built into construction, and maintained securely in place.

1. Locate inserts or hanger wires for furred and suspended ceilings only in bottom of concrete joists, or similar concrete member of overhead concrete joist construction.

2. Install sleeves, inserts and similar items for mechanical services in accordance with drawings prepared specially for mechanical services. Contractor is responsible for accuracy and completeness of drawings and shall coordinate requirements for mechanical services and equipment.

3. Do not install sleeves in beams, joists or columns except where shown or permitted by COR. Install sleeves in beams, joists, or columns that are not shown, but are permitted by the COR, and require no structural changes, at no additional cost to the Government.

4. Minimum clear distance of embedded items such as conduit and pipe is at least three times diameter of conduit or pipe, except at stub-ups and other similar locations.

5. Provide recesses and blockouts in floor slabs for door closers and other hardware as necessary in accordance with manufacturer's instructions.

I. Construction Tolerances:

1. Set and maintain concrete formwork to assure erection of completed work within tolerances specified and to accommodate installation of other rough and finish materials. Accomplish remedial work necessary for correcting excessive tolerances.

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Erected work that exceeds specified tolerance limits shall be remedied or removed and replaced, at no additional cost to the Government.

2. Permissible surface irregularities for various classes of materials are defined as "finishes" in specification sections covering individual materials. They are to be distinguished from tolerances specified which are applicable to surface irregularities of structural elements.

3.2 PLACING REINFORCEMENT:

A. General: Details of concrete reinforcement in accordance with ACI 318 unless otherwise shown.

B. Placing: Place reinforcement conforming to CRSI DA4, unless otherwise shown.

1. Place reinforcing bars accurately and tie securely at intersections and splices with

1.6 mm (16 gauge) black annealed wire. Use epoxy-coated tie wire with epoxy-coated reinforcing. Secure reinforcing bars against displacement during the placing of concrete by spacers, chairs, or other similar supports. Portions of supports, spacers, and chairs in contact with formwork shall be made of plastic in areas that will be exposed when building is occupied. Type, number, and spacing of supports conform to ACI 318. Where concrete slabs are placed on ground, use concrete blocks or other non-corrodible material of proper height, for support of reinforcement.

Use of brick or stone supports will not be permitted.

2. Lap welded wire fabric at least 1 1/2 mesh panels plus end extension of wires not less than 300 mm (12 inches) in structural slabs. Lap welded wire fabric at least 1/2 mesh panels plus end extension of wires not less than 150 mm (6 inches) in slabs on grade.

3. Splice column steel at no points other than at footings and floor levels unless otherwise shown.

C. Spacing: Minimum clear distances between parallel bars, except in columns and multiple layers of bars in beams shall be equal to nominal diameter of bars. Minimum clear spacing is 25 mm (1 inch) or 1-1/3 times maximum size of coarse aggregate.

D. Splicing: Splices of reinforcement made only as required or shown or specified.

Accomplish splicing as follows:

1. Lap splices: Do not use lap splices for bars larger than Number 36 (Number 11).

Minimum lengths of lap as shown.

2. Welded splices: Splicing by butt-welding of reinforcement permitted providing the weld develops in tension at least 125 percent of the yield strength (fy) for the bars.

Welding conform to the requirements of AWS D1.4. Welded reinforcing steel conform to the chemical analysis requirements of AWS D1.4.

a. Submit test reports indicating the chemical analysis to establish weldability of reinforcing steel.

b. Submit a field quality control procedure to insure proper inspection, materials and welding procedure for welded splices.

c. Testing agency shall test a minimum of three splices, for compliance, locations selected by COR.

3. Mechanical Splices: Develop in tension and compression at least 125 percent of the yield strength (fy) of the bars. Stresses of transition splices between two reinforcing bar sizes based on area of smaller bar. Provide mechanical splices at locations indicated. Use approved exothermic, tapered threaded coupling, or swaged and threaded sleeve. Exposed threads and swaging in the field not permitted.

a. Initial qualification: In the presence of COR, make three test mechanical splices of each bar size proposed to be spliced. Testing laboratory will perform load test.

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b. During installation: Furnish, at no additional cost to the Government, one companion (sister) splice for every 50 splices for load testing. Testing laboratory will perform the load test.

E. Bending: Bend bars cold, unless otherwise approved. Do not field bend bars partially embedded in concrete, except when approved by COR.

F. Cleaning: Metal reinforcement, at time concrete is placed, shall be free from loose flaky rust, mud, oil, or similar coatings that will reduce bond.

G. Future Bonding: Protect exposed reinforcement bars intended for bonding with future work by wrapping with felt and coating felt with a bituminous compound unless otherwise shown.

3.3 VAPOR BARRIER:

A. Except where membrane waterproofing is required, interior concrete slab on grade shall be placed on a continuous vapor barrier.

1. Place 100 mm (4 inches) of fine granular fill over the vapor barrier to act as a blotter for concrete slab.

2. Vapor barrier joints lapped 150 mm (6 inches) and sealed with compatible waterproof pressure-sensitive tape.

3. Patch punctures and tears.

3.4 SLABS RECEIVING RESILIENT COVERING

A. Slab shall be allowed to cure for 6 weeks minimum prior to placing resilient covering.

After curing, slab shall be tested by the Contractor for moisture in accordance with ASTM D4263 or ASTM F1869. Moisture content shall be less than 3 pounds per 1000 sf prior to placing covering.

B. In lieu of curing for 6 weeks, Contractor has the option, at his own cost, to utilize the Moisture Vapor Emissions & Alkalinity Control Sealer as follows:

1. Sealer is applied on the day of the concrete pour or as soon as harsh weather permits, prior to any other chemical treatments for concrete slabs either on grade, below grade or above grade receiving resilient flooring, such as, sheet vinyl, vinyl composition tile, rubber, wood flooring, epoxy coatings and overlays.

2. Manufacturer’s representative will be on the site the day of concrete pour to install or train its application and document. He shall return on every application thereafter to verify that proper procedures are followed.

a. Apply Sealer to concrete slabs as soon as final finishing operations are complete and the concrete has hardened sufficiently to sustain floor traffic without damage.

b. Spray apply Sealer at the rate of 20 m2 (200 square feet) per gallon. Lightly broom product evenly over the substrate and product has completely penetrated the surface.

c. If within two (2) hours after initial application areas are subjected to heavy rainfall and puddling occurs, reapply Sealer product to these areas as soon as weather condition permits.

3.5 CONSTRUCTION JOINTS:

A. Unless otherwise shown, location of construction joints to limit individual placement shall not exceed 24,000 mm (80 feet) in any horizontal direction, except slabs on grade which shall have construction joints shown. Allow 48 hours to elapse between pouring adjacent sections unless this requirement is waived by COR.

B. Locate construction joints in suspended floors near the quarter-point of spans for slabs, beams or girders, unless a beam intersects a girder at center, in which case joint in

033000 - 14 girder shall be offset a distance equal to twice width of beam. Provide keys and inclined dowels as shown. Provide longitudinal keys as shown.

C. Place concrete for columns slowly and in one operation between joints. Install joints in concrete columns at underside of deepest beam or girder framing into column.

D. Allow 2 hours to elapse after column is cast before concrete of supported beam, girder or slab is placed. Place girders, beams, grade beams, column capitals, brackets, and haunches at the same time as slab unless otherwise shown.

E. Install polyvinyl chloride or rubber water seals, as shown in accordance with manufacturer's instructions, to form continuous watertight seal.

3.6 EXPANSION JOINTS AND CONTRACTION JOINTS:

A. Clean expansion joint surfaces before installing premolded filler and placing adjacent concrete.

B. Install polyvinyl chloride or rubber water seals, as shown in accordance with manufacturer's instructions, to form continuous watertight seal.

C. Provide contraction (control) joints in floor slabs as indicated on the contract drawings.

Joints shall be tooled to the indicated depth after the surface has been finished. Protect joints from intrusion of foreign matter.

3.7 PLACING CONCRETE:

A. Preparation:

1. Remove hardened concrete, wood chips, shavings and other debris from forms.

2. Remove hardened concrete and foreign materials from interior surfaces of mixing and conveying equipment.

3. Have forms and reinforcement inspected and approved by COR before depositing concrete.

4. Provide runways for wheeling equipment to convey concrete to point of deposit.

Keep equipment on runways which are not supported by or bear on reinforcement.

Provide similar runways for protection of vapor barrier on coarse fill.

B. Bonding: Before depositing new concrete on or against concrete which has been set, thoroughly roughen and clean existing surfaces of laitance, foreign matter, and loose particles.

1. Preparing surface for applied topping:

a. Remove laitance, mortar, oil, grease, paint, or other foreign material by sand blasting. Clean with vacuum type equipment to remove sand and other loose material.

b. Broom clean and keep base slab wet for at least four hours before topping is applied.

c. Use a thin coat of one part Portland cement, 1.5 parts fine sand, bonding admixture; and water at a 50: 50 ratio and mix to achieve the consistency of thick paint. Apply to a damp base slab by scrubbing with a stiff fiber brush. New concrete shall be placed while the bonding grout is still tacky.

C. Conveying Concrete: Convey concrete from mixer to final place of deposit by a method which will prevent segregation. Method of conveying concrete is subject to approval of

COR.

D. Placing: For special requirements see Paragraphs, HOT WEATHER and COLD

WEATHER.

1. Do not place concrete when weather conditions prevent proper placement and consolidation, or when concrete has attained its initial set, or has contained its water or cement content more than 1 1/2 hours.

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2. Deposit concrete in forms as near as practicable in its final position. Prevent splashing of forms or reinforcement with concrete in advance of placing concrete.

3. Do not drop concrete freely more than 3000 mm (10 feet) for concrete containing the high-range water-reducing admixture (superplasticizer) or 1500 mm (5 feet) for conventional concrete. Where greater drops are required, use a tremie or flexible spout (canvas elephant trunk), attached to a suitable hopper.

4. Discharge contents of tremies or flexible spouts in horizontal layers not exceeding 500 mm (20 inches) in thickness, and space tremies such as to provide a minimum of lateral movement of concrete.

5. Continuously place concrete until an entire unit between construction joints is placed.

Rate and method of placing concrete shall be such that no concrete between construction joints will be deposited upon or against partly set concrete, after its initial set has taken place, or after 45 minutes of elapsed time during concrete placement.

6. On bottom of members with severe congestion of reinforcement, deposit 25 mm (1 inch) layer of flowing concrete containing the specified high-range water-reducing admixture (superplasticizer). Successive concrete lifts may be a continuation of this concrete or concrete with a conventional slump.

E. Consolidation: Conform to ACI 309. Immediately after depositing, spade concrete next to forms, work around reinforcement and into angles of forms, tamp lightly by hand, and compact with mechanical vibrator applied directly into concrete at approximately 450 mm (18 inch) intervals. Mechanical vibrator shall be power driven, hand operated type with minimum frequency of 5000 cycles per minute having an intensity sufficient to cause flow or settlement of concrete into place. Vibrate concrete to produce thorough compaction, complete embedment of reinforcement and concrete of uniform and maximum density without segregation of mix. Do not transport concrete in forms by vibration.

1. Use of form vibration shall be approved only when concrete sections are too thin or too inaccessible for use of internal vibration.

2. Carry on vibration continuously with placing of concrete. Do not insert vibrator into concrete that has begun to set.

3.8 HOT WEATHER:

Follow the recommendations of ACI 305 or as specified to prevent problems in the manufacturing, placing, and curing of concrete that can adversely affect the properties and serviceability of the hardened concrete. Methods proposed for cooling materials and arrangements for protecting concrete shall be made in advance of concrete placement and approved by COR.

3.9 COLD WEATHER:

Follow the recommendations of ACI 306 or as specified to prevent freezing of concrete and to permit concrete to gain strength properly. Use only the specified non-corrosive, non-chloride accelerator. Do not use calcium chloride, thiocyantes or admixtures containing more than 0.05 percent chloride ions. Methods proposed for heating materials and arrangements for protecting concrete shall be made in advance of concrete placement and approved by COR.

3.10 PROTECTION AND CURING:

A. Conform to ACI 308: Initial curing shall immediately follow the finishing operation.

Protect exposed surfaces of concrete from premature drying, wash by rain and running water, wind, mechanical injury, and excessively hot or cold temperatures. Keep concrete

033000 - 16 not covered with membrane or other curing material continuously wet for at least 7 days after placing, except wet curing period for high-early-strength concrete shall be not less than 3 days. Keep wood forms continuously wet to prevent moisture loss until forms are removed. Cure exposed concrete surfaces as described below. Other curing methods may be used if approved by CORCOR.

1. Liquid curing and sealing compounds: Apply by power-driven spray or roller in accordance with the manufacturer’s instructions. Apply immediately after finishing.

Maximum coverage 10m2/L (400 square feet per gallon) on steel troweled surfaces and 7.5m2/L (300 square feet per gallon) on floated or broomed surfaces for the curing/sealing compound.

2. Plastic sheets: Apply as soon as concrete has hardened sufficiently to prevent surface damage. Utilize widest practical width sheet and overlap adjacent sheets 50 mm (2 inches). Tightly seal joints with tape.

3. Paper: Utilize widest practical width paper and overlap adjacent sheets 50 mm (2 inches). Tightly seal joints with sand, wood planks, pressure-sensitive tape, mastic or glue.

3.11 REMOVAL OF FORMS:

A. Remove in a manner to assure complete safety of structure after the following conditions have been met.

1. Where structure as a whole is supported on shores, forms for beams and girder sides, columns, and similar vertical structural members may be removed after 24 hours, provided concrete has hardened sufficiently to prevent surface damage and curing is continued without any lapse in time as specified for exposed surfaces.

2. Take particular care in removing forms of architectural exposed concrete to insure surfaces are not marred or gouged, and that corners and arises are true, sharp and unbroken.

B. Control Test: Use to determine if the concrete has attained sufficient strength and curing to permit removal of supporting forms. Cylinders required for control tests taken in accordance with ASTM C172, molded in accordance with ASTM C31, and tested in accordance with ASTM C39. Control cylinders cured and protected in the same manner as the structure they represent. Supporting forms or shoring not removed until strength of control test cylinders have attained at least 70 percent of minimum 28-day compressive strength specified. Exercise care to assure that newly unsupported portions of structure are not subjected to heavy construction or material loading.

3.12 CONCRETE SURFACE PREPARATION:

A. Metal Removal: Unnecessary metal items cut back flush with face of concrete members.

B. Patching: Maintain curing and start patching as soon as forms are removed. Do not apply curing compounds to concrete surfaces requiring patching until patching is completed. Use cement mortar for patching of same composition as that used in concrete. Use white or gray Portland cement as necessary to obtain finish color matching surrounding concrete. Thoroughly clean areas to be patched. Cut out honeycombed or otherwise defective areas to solid concrete to a depth of not less than 25 mm (1 inch). Cut edge perpendicular to surface of concrete. Saturate with water area to be patched, and at least 150 mm (6 inches) surrounding before placing patching mortar. Give area to be patched a brush coat of cement grout followed immediately by patching mortar. Cement grout composed of one part Portland cement, 1.5 parts fine sand, bonding admixture, and water at a 50:50 ratio, mix to achieve consistency of thick paint. Mix patching mortar approximately 1 hour before placing and remix occasionally during this period without addition of water. Compact mortar into place and screed

033000 - 17 slightly higher than surrounding surface. After initial shrinkage has occurred, finish to match color and texture of adjoining surfaces. Cure patches as specified for other concrete. Fill form tie holes which extend entirely through walls from unexposed face by means of a pressure gun or other suitable device to force mortar through wall. Wipe excess mortar off exposed face with a cloth.

C. Upon removal of forms, clean vertical concrete surface that is to receive bonded applied cementitious application with wire brushes or by sand blasting to remove unset material, laitance, and loose particles to expose aggregates to provide a clean, firm, granular surface for bond of applied finish.

3.13 CONCRETE FINISHES:

A. Vertical and Overhead Surface Finishes:

1. Unfinished areas: Vertical and overhead concrete surfaces exposed in pipe basements, elevator and dumbwaiter shafts, pipe spaces, pipe trenches, above suspended ceilings, manholes, and other unfinished areas will not require additional finishing.

2. Interior and exterior exposed areas to be painted: Remove fins, burrs and similar projections on surfaces flush, and smooth by mechanical means approved by COR, and by rubbing lightly with a fine abrasive stone or hone.