SECTION_03_30_00_-_Cast_in_Place_Concrete_R2_0003.pdf

BUREAU OF INDIAN AFFAIRS OGLALA DAM SPILLWAY AND OUTLET WORKS

OGLALA DAM SPILLWAY AND OUTLET WORKS SECTION 03 30 00

JUNE 2023 CAST-IN-PLACE CONCRETE

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SECTION 03 30 00

CAST-IN-PLACE CONCRETE

PART 1 GENERAL

1.01 SCOPE OF WORK

A. This Section specifies the requirements for all cast-in-place concrete for the spillway and appurtenant structures, including mass concrete and the following items:

1. Submittals and quality control and assurance.

2. Product requirements for concrete materials, concrete mix design, reinforcing steel, embedded items, formwork materials, and miscellaneous materials.

3. Execution requirements for preparation of concrete placement; concrete manufacturing, handling, placing, finishing, and curing; cold and hot weather procedures; care and repair of concrete, and post-installed items.

1.02 REFERENCES

A. American Concrete Institute (ACI)

1. ACI 117 Standard Specifications for Tolerances for Concrete Construction and Materials

2. ACI 211.1 Standard Practice for Selecting Proportions for Normal, Heavyweight, or Mass Concrete

3. ACI 211.5R Guide for Submittal of Concrete Proportions

4. ACI 214R Evaluation of Strength Test Results of Concrete

5. ACI 301 Specifications for Structural Concrete

6. ACI 304.2R Placing Concrete by Pumping Methods

7. ACI 305.1 Hot Weather Concreting

8. ACI 305R Guide to Hot Weather Concreting

9. ACI 306.1 Cold Weather Concreting

10. ACI 306R Guide to Cold Weather Concreting

11. ACI 311.5R Batch Plant Inspection and Field Testing of Ready-Mixed Concrete

12. ACI 315 Details and Detailing of Concrete Reinforcement

13. ACI 318 Building Code Requirements for Reinforced Concrete

14. ACI 347 Guide to Formwork for Concrete

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B. American Association of State Highway and Transportation Officials (AASHTO)

1. AASHTO M 182 Standard Specification for Burlap Cloth Made from Jute or Kenaf and Cotton Mats

C. ASTM International (ASTM)

1. ASTM A82 Steel Wire, Plain, for Concrete Reinforcement

2. ASTM A615 Deformed and Plain Billet-Steel Bars for Concrete Reinforcement

3. ASTM A706 Standard Specification for Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement

4. ASTM A775 Standard Specification for Epoxy-Coated Steel Reinforcing Bars

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

6. ASTM C33 Standard Specification for Concrete Aggregates

7. ASTM C39 Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

8. ASTM C40 Standard Test Method for Organic Impurities in Fine Aggregates for Concrete

9. ASTM C94 Standard Specification for Ready-Mixed Concrete

10. ASTM C114 Standard Test Methods for Chemical Analysis of Hydraulic Cement

11. ASTM C117 Standard Test Method for Materials Finer than 75-μm (No. 200) Sieve in Mineral Aggregates by Washing

12. ASTM C123 Standard Test Method for Lightweight Particles in Aggregate

13. ASTM C127 Standard Test Method for Density, Relative Density (Specific Gravity), and Absorption of Coarse Aggregate

14. ASTM C128 Standard Test Method for Density, Relative Density (Specific Gravity), and Absorption of Fine Aggregate

15. ASTM C131 Standard Test Method for Resistance to Degradation of Small- Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

16. ASTM C136 Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates

17. ASTM C142 Standard Test Method for Clay Lumps and Friable Particles in Aggregates

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

19. ASTM C150 Standard Specification for Portland Cement

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20. ASTM C156 Standard Test Method for Water Retention by Concrete Curing Materials

21. ASTM C171 Standard Specification for Sheet Materials for Curing Concrete

22. ASTM C172 Standard Practice for Sampling Freshly Mixed Concrete

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

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

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

26. ASTM C494 Standard Specification for Chemical Admixtures for Concrete

27. ASTM C511 Standard Specification for Mixing Rooms, Moist Cabinets, Moist Rooms, and Water Storage Tanks Used in the Testing of Hydraulic Cements and Concretes

28. ASTM C535 Standard Test Method for Resistance to Degradation of Large- Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

29. ASTM C566 Standard Test Method for Total Evaporable Moisture Content of Aggregate by Drying

30. ASTM C595 Standard Specification for Blended Hydraulic Cements

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

32. ASTM C684 Making, Accelerated Curing, and Testing Concrete Compression Test Specimens

33. ASTM C881 Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete

34. ASTM C920 Standard Specification for Elastomeric Joint Sealants

35. ASTM C928 Packaged, Dry, Rapid-Hardening Cementitious Materials for Concrete Repairs

36. ASTM C937 Grout Fluidifier for Preplaced-Aggregate Concrete

37. ASTM C989 Standard Specification for Ground Granulated Blast-Furnace Slag for Use in Concrete and Mortars

38. ASTM C1064 Standard Test Method for Temperature of Freshly Mixed Hydraulic-Cement Concrete

39. ASTM C1059 Standard Specification for Latex Agents for Bonding Fresh to Hardened Concrete

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40. ASTM C1077 Standard Practice for Laboratories Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Laboratory Evaluation

41. ASTM C1107 Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Nonshrink)

42. ASTM C1260 Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar-Bar Method)

43. ASTM C1567 Standard Test Method for Potential Alkali-Silica Reactivity of Combinations of Cementitious Materials and Aggregate (Accelerated Mortar-Bar Method)

44. ASTM D1752 Preformed Sponge Rubber and Cork Expansion Joint Fillers for Concrete Paving and Structural Construction.

45. ASTM D3665 Random Sampling of Construction Materials

46. ASTM D4791 Flat Particles, Elongated Particles, or Flat and Elongated Particles in Coarse Aggregate

47. ASTM E11 Wire Cloth and Sieves for Testing Purposes

D. Design Basis Building Code: International Building Code 2021

E. National Institute of Standards and Technology (NIST)

1. NIST HB 44 Specifications, Tolerances, and other Technical Requirements for Weighing and Measuring Devices

F. National Ready Mixed Concrete Association (NRMCA)

1. CPMB 100 Concrete Plant Standards

G. NSF International (NSF)

1. NSF/ANSI 61 Drinking Water System Components - Health Effects

H. U.S. Army Corps of Engineers (USACE)

1. COE CRD-C 100 Method of Sampling Concrete Aggregate and Aggregate Sources, and Selection of Material for Testing

2. COE CRD-C 104 Method of Calculation of the Fineness Modulus of Aggregate

3. COE CRD-C 130 Standard Recommended Practice for Estimating Scratch Hardness of Coarse Aggregate Particles

4. COE CRD-C 143 Specifications for Meters for Automatic Indication of Moisture in Fine Aggregates

5. COE CRD-C 400 Requirements for Water for Use in Mixing or Curing Concrete

6. COE CRD-C 521 Standard Test Method for Frequency and Amplitude of Vibrators for Concrete

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7. COE CRD-C 55 Test Method for Within-Batch Uniformity of Freshly Mixed Concrete

8. COE CRD-C 94 Specification for Surface Retarders

9. EM 1110-2-2000 Standard Practice for Concrete for Civil Works Structures Change 2

10. ER 1110-1-2002 Cement, Slag, and Pozzolan Acceptance Testing

I. Other

1. U.S. Product Standard PS 20 American Softwood Lumber Standard

1.03 DEFINITIONS

A. Surfaces Subject to High-Velocity Water Flow

1. The exposed faces of the inlet structure.

2. The top surface of the Ogee Crest section, steps within the spillway chute, and the stilling basin.

3. The vertical faces of the steps within the spillway chute.

4. The inside vertical faces of the Non-Overflow sections and chute walls.

5. The dentates and sill within the stilling basin.

B. Mass Concrete: Any portion of a single concrete placement in which the least dimension is greater than 3 feet or greater, regardless of whether or not the concrete is reinforced.

C. Classes of Structural Concrete. The classes of structural concrete described below are to be used in the locations indicated unless otherwise specifically designated on the Drawings.

1. Class A: Typical concrete structures having sections 7-1/2 inches or less in width, slabs 4 inches or less in thickness, or any section with a clear distance between reinforcement less than 2-1/4 inches. This Class of concrete will be used for security fence footings in soil.

2. Class B: Typical concrete structures having sections greater than 7-1/2 inches in width, and slabs 4 inches or greater in thickness, but with widths and thicknesses less than those defined below for Class C concrete. However, Class B concrete shall not be used in any section in which the clear distance between reinforcement is less than 2-1/4 inches. This Class of concrete will be used for RCC CVC facing, the stilling basin slab, and inlet tower.

3. Class C: Unreinforced sections over 12 inches in width, reinforced sections over 36 inches in width, and slabs greater than 36 inches or greater in thickness. However, Class C concrete shall not be used in any section in which the clear distance between reinforcing bars is less than 4-1/2 inches. This Class of concrete is specifically intended for Mass Concrete sections where low heat of hydration is advantageous with respect to temperature control during curing. This Class of concrete will be used for

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placements including the Ogee Crest section and Non-overflow sections above RCC as shown on the Drawings. Class C placements may be reduced or eliminated if RCC construction is extended higher limiting the thickness of conventional concrete placements above RCC material at CONTRACTOR option.

4. Class D: Second stage concrete infill. This Class of concrete shall be designed with a shrinkage compensating admixture to ensure tight contact with the adjacent concrete placements. This Class of concrete will be used for the outlet works pipe encasement for Project Work.

5. Class E: Dental concrete for foundation preparation and protection. This Class of concrete is intended to be used for treatment of the foundation surfaces and for the mud mat.

6. Class F: Lean mix concrete. This Class of concrete is intended to be used as a leveling course concrete and for the emergency spillway cutoff walls for Project Work.

D. Supplementary Cementitious Materials (SCMs): Materials that when used in conjunction with portland cement, portland limestone cement or blended cements, contribute to the properties of hardened concrete through hydraulic and/or pozzolanic activity. SCMs are considered to include Fly Ash and Ground Granulated Blast Furnace Slag (GGBFS) for this project.

1.04 SUBMITTALS

A. Shop Drawings

1. Concrete Quality Control Program that includes concrete quality control inspection, testing, procedures, manuals, and description of the organization, methods, procedures and processes to be used on the contact.

2. General concrete placement shop drawings showing the location and type of joints for each structure.

3. Concrete Lifts: A lift drawing and bill of materials shall be furnished for each lift of concrete. (Only one lift shall be shown on a drawing). These drawings shall be to scale and shall show all embedded items in sufficient detail for the proper installation and production of the Work. All embedded electrical and/or mechanical items shall be identified. The drawings shall be printable in not less than 22 by 34 inches in size and the scale used shall be sufficiently large to clearly show all details of the structure covered by these drawings. A note shall be included on each lift drawing indicating all Contract Drawings from which the lift drawing was prepared.

4. Detailed shop drawings of the falsework proposed to be used. Such shop drawings shall be in sufficient detail to indicate the layout, sizes of members, anticipated stresses, grade of materials to be used in the falsework, and typical foundation conditions.

5. Shop drawings, bending diagrams, and placing lists for reinforcing steel. Details of reinforcing steel for fabrication and erection shall conform to ACI 315 and the requirements herein. The shop bending diagrams shall show the actual lengths of bars

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to the nearest inch measured to the intersection of the extensions (tangents for bars of circular cross section) of the outside surface. Include bar placement diagrams which clearly indicate the dimensions of each bar splice. Where mechanical couplers are required or permitted to be used to splice reinforcing steel, submit shop drawings that show the location of each coupler with details of how they are to be installed in the formwork.

6. Batch Plant, if proposed: Shop drawings showing the arrangement and details and data on the concrete batch plant, including details of the make, type, capacity, and number of the concrete mixers proposed for use, shall be submitted at least 60 days prior to assembly to the BIA Representative for conformance review with the requirements of Paragraph 1.04A Item No. 11 EQUIPMENT listed below.

7. Batch Plant Layout Drawings, if proposed: Drawings showing the layout of the plant CONTRACTOR proposes to use on the Work shall be submitted at least 60 days prior to plant setup by CONTRACTOR for review. The drawings shall show the locations of the principal components of the construction plant; offices; shop and storage building; and storage areas and yards which CONTRACTOR proposes to construct at the site of the Work and elsewhere. Also furnish for review drawings showing the general features of CONTRACTOR’s aggregate processing plant, if processing is conducted on site; aggregate transporting; storage and reclaiming facilities; aggregate rinsing and dewatering plant; coarse aggregate rescreening plant; concrete batching and mixing plant; concrete conveying and placing plant; and the cooling plant. The drawings shall appropriately show the capacity of each major feature of the plant including the rated capacity of the aggregate production plant in tons (2000 lbs) per hour of fine and coarse aggregates; rated capacity of the aggregate transporting, storage and reclaiming facilities; volume of aggregate storage; capacity of cement and supplementary cementitious material (SCM)pozzolan storage; rated capacity of the concrete batching and mixing plant in cubic yards per hour; rated capacity of the concrete transporting and placing plant in cubic yards per hour; and, when used, rated capacity of plant for precooling of concrete. Drawings showing any changes in plant made during design and erection or after the plant is in operation shall be submitted for review. Upon completion of the Work, CONTRACTOR will supply to the COR complete Record Drawings of the plant and all major components, including stockpiles.

8. Hot Weather Concreting Plan: Shall be in accordance with Paragraph 3.08 HOT WEATHER PROCEDURES and submitted for review at least 60 days before concrete placement begins.

9. Cold Weather Concreting Plan: Shall be in accordance with Paragraph 3.07 COLD WEATHER PROCEDURES and submitted for review at least 60 days before concrete placement begins.

10. Thermal Control Plan

a. A thermal control plan for massive concrete placements will not be necessary if previous performance of the selected massive concrete mix demonstrates conformance with thermal requirements for similarly sized placements.

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a.b. A thermal control plan will not be required for the CVC facing portion of the spillway structure placed concurrent with RCC materials.

b.c. If required, a minimum of 30 days prior to massive concrete placement, submit for approval a mass concrete temperature control plan that includes:

1) Location and identification of temperature monitoring sensors.

2) Product data for automated temperature sensors and recording equipment.

3) Cooling pipe layout diagram with sizes and materials, if used.

4) Proposed insulation materials and associated R-values.

5) Anticipated form removal schedule and curing procedures.

6) Maximum allowable concrete placement temperature for the range of anticipated ambient temperatures based on thermal modeling.

7) Monitoring procedures and contingency plans.

c.d. Concrete placement temperature shall be based on results of thermal modeling for the element incorporating: the heat of hydration and specific heat capacity for the concrete mixture, solar gain, and heat transfer to the environment through formwork, insulation, and cooling techniques.

d.e. Mass concrete temperature control shall be monitored using automated temperature recording devices that allow wireless transmission of data to an on-site host computer for real-time monitoring of temperatures.

e.f. Temperature control sensor layout for each placement shall be provided with individual sensor ID identified.

f.g. Minimum sensor requirements include at least two sensors for each placement located as follows:

1) The geometric center of the element cross-section.

2) Ambient temperature sensors placed in a shaded location.

g.h. Procedures for installing, protecting sensors during placement, and testing sensors a minimum of 24 hours prior to concrete placement shall be provided.

Initiate sensor recording at least 2 hours prior to placement. Verify function of all sensors prior to and upon completion of concrete placing operations.

h.i. Submit procedures for controlling concrete temperatures within the following limits

1) Maximum temperature shall be less than 160°F.

2) Temperature control procedures shall remain in effect until the differential between the ambient low temperature and mean of all functioning center sensor temperatures is less than 36°F.

11. Equipment: The methods and description of the equipment proposed for transporting, handling, and depositing the concrete shall be submitted for review at least 60 days before concrete placement begins. The data submitted shall include site drawings or sketches with locations of equipment and placement site.

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12. CONTRACTOR Laboratory: CONTRACTOR shall submit final design of CONTRACTOR’s laboratory, if on-site laboratory proposed, at least 60 days before the initial concrete placement is planned to occur.

13. Product Data:

a. Cementitious Materials, Aggregate, Admixtures, and Curing Materials - General Requirements:

1) Notify the BIA Representative of the source, brand name, type, and quantity of all materials to be used in the manufacture and curing of the concrete at least 60 days in advance of submitting samples for mixture proportioning studies.

2) Assist the BIA Representative in obtaining samples of each material.

Sampling and testing as determined appropriate will be performed by and at the expense of CONTRACTOR.

3) If cement or SCMspozzolan are to be obtained from more than one source, the notification shall state the estimated amount of cement or SCMspozzolan to be obtained from each source and the proposed schedule of shipments.

When SCMpozzolan other than fly ash is used, it shall be from one source.

b. Cementitious Materials: Cementitious Materials, including Cement, and SCMPozzolan, and Ground Granulated Blast-Furnace Slag will be accepted on the basis of the manufacturer's certification of compliance, accompanied by mill test reports that materials meet the requirements of the Specification under which they are furnished, including but not limited to all tests specified under Paragraph 2.01 CONCRETE MATERIALS. Certification and mill test reports shall be from samples taken from the specific lot furnished. Data on cementitious materials shall be summarized as stated above. No cementitious materials shall be used until notice of acceptance has been given by the COR.

Cementitious materials will be subject to check testing from samples obtained at the source, at transfer points, or at the Project site, as scheduled by the BIA Representative, and such sampling will be by or under the supervision of the COR as part of the AGENCY’s Quality Assurance. Material not meeting Specifications shall be promptly removed from the site of Work at no cost to the

AGENCY.

c. Aggregate: Include sources of coarse and fine aggregate materials and test data demonstrating compliance with the specified gradation and quality requirements.

d. Air-Entraining Admixture: Air-Entraining Admixture shall be certified for compliance with all Specification requirements.

e. Other Chemical Admixtures: Other Chemical Admixtures shall be certified for compliance with all Specification requirements.

f. Membrane-Forming Curing Compound: Membrane-Forming Curing Compound shall be certified that the material complies with the requirements of

ASTM C309.

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g. Sheet Curing: If sheet curing is used, a manufacturer's certificate shall be furnished certifying that the material complies with the requirements of ASTM C171.

h. Nonshrink Grout: Descriptive literature of the grout proposed for use containing certified laboratory test results showing that it meets ASTM C1107 shall be submitted 60 days prior to its use together with a certificate from the manufacturer stating that the grout is suitable for the application or exposure for which it is being considered. In addition, a detailed plan shall be submitted for review, showing equipment and procedures for use in mixing and placing the grout.

i. Bonding Agents: Descriptive literature and certification in advance of their use.

j. Mechanical Couplers: Where mechanical couplers are required or permitted to be used to splice reinforcing steel, submit manufacturer’s literature which contains instructions and recommendations for installation for each type of coupler used and certified test reports which verify the load capacity of each type and size of coupler used.

k. Joint Filler Materials: Submit manufacturer’s data for joint filler materials.

l. Elastomeric Joint Sealant: Submit manufacturer’s data for joint sealant.

m. Mastic Joint Sealer: Submit manufacturer’s data for joint sealer.

n. Epoxy-Coated Bars: Submit written certifications for coating material and coated bars, sample of coating material, and 1.5 pounds of patching material.

14. Mix Design:

a. Submit the following in accordance with Paragraph 2.02C PROPORTIONING

STUDIES:

1) Preliminary concrete mix designs for each class of concrete.

2) Report for trial batch test results and Class C test pour proposal.

3) Class C test pour data, conclusions and final Class C mix parameters. Submit evidence of the ability of the mix design and proposed placements to comply with thermal limits.

b. Submit evidence of the ability of the mix design to comply with the concrete mixture requirements per ACI 318 26.4.4 and following guidelines in ACI

211.1 and 211.5R.

c. Submit data for each mix design for each class of concrete:

1) Weights per cubic yard and volumes of materials with aggregates at saturated surface-dry condition.

2) Water-cementitious materials ratio, by weight.

3) 7-day and 28-day compressive strengths.

4) Air content.

5) Slump.

6) Unit Weight.

7) Certified aggregate test reports demonstrating compliance with ASTM C33.

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8) Manufacturer’s certification that cementitious materials and admixtures comply with specified requirements.

d. Submit concrete mix designs for COR review and approval.

15. Methods and Procedures:

a. Construction Joint Treatment: The method and equipment proposed for joint cleanup and waste disposal shall be submitted for review at least 30 days before concrete placement begins.

b. Curing and Protection: The curing media and methods to be used shall be submitted for review at least 30 days before concrete placement begins.

c. Cold Weather Protection: When concrete is to be placed under cold-weather conditions, a description of the materials and methods proposed for protection of the concrete shall be furnished at least 60 days in advance of anticipated need date for review.

d. Hot-Weather Placing: When concrete is to be placed under hot-weather conditions, a description of the materials and methods proposed for protection of the concrete shall be furnished at least 60 days in advance of anticipated need date for review. Include procedures for transporting, placing, protecting, curing, and monitoring temperature of concrete during hot weather.

e. Method of restraining pipe during placement of encasement concrete to prevent any movement of the installed pipe.

B. Administrative

1. Statement of Qualifications:

a. Mix Designer.

b. Concrete Field Testing Technicians.

c. Concrete Construction Special Inspector.

d. Testing Laboratory.

e. CONTRACTOR’s resident superintendent for concrete placement.

C. Quality Control

1. Manufacturer’s Certificates of Compliance and mill test certificates:

a. Portland Cement.

b. SCMPozzolans

c. Coarse Aggregate.

d. Fine Aggregate.

e. Admixtures.

2. Recordkeeping

a. Batch tickets.

b. Test Reports: Submit field quality control testing reports within two working days of performing the tests. Provide the following information for all test reports:

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1) Sample identification, including mix design.

2) Date and time of sample preparation, including curing conditions, curing period, and sample dimensions.

3) Date, time, and type of test.

4) Strength of each core specimen.

5) Name and signature of individual performing the test.

6) Date, time, quantity, and location of concrete applied, with sketches.

7) Observations during production and placement.

8) Description of placement equipment.

9) Batch number(s), if applicable.

10) Maximum and minimum air temperature.

11) Description of any special conditions or problems encountered.

12) Foreman’s name and signature.

3. Results of quality control tests and charts. Production work test results should be submitted on a daily basis with CONTRACTOR’s daily report including:

a. Aggregates.

b. Fresh Concrete.

c. Compressive Strength Testing.

4. Equipment Quality Control:

a. Scales: Submit records of calibration monthly.

b. Batch-Plant Control Report: Submit report daily.

c. Mixer uniformity test results and corrective actions.

d. Vibrator details and frequency and amplitude test results.

5. Concrete Operations Quality Control:

a. Inspection Before Placing:

1) CONTRACTOR’s completed pre-placement inspection form shall be submitted to the BIA Representative daily.

b. Concrete Placement:

1) CONTRACTOR’s completed placement inspection form shall be submitted to the BIA Representative daily.

c. Curing:

1) CONTRACTOR shall submit documentation of the Moist Curing Inspections daily.

2) CONTRACTOR shall submit documentation of the Membrane Curing Inspections to the BIA Representative daily.

3) CONTRACTOR shall submit documentation of the Sheet Curing Inspections to the BIA Representative daily.

d. Cold Weather Protection and Sealed Insulation Curing:

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1) Documentation of CONTRACTOR’s inspections shall be submitted to the BIA Representative daily.

e. Hot Weather Concreting

1) CONTRACTOR shall submit records of temperature measurements of concrete as deposited in forms.

6. Water Quality:

a. If raw water is used, submit water quality test results every 90 days.

7. Reports:

a. A report shall be submitted daily during concrete placement including:

1) All results of tests or inspections.

2) Type, batch weight, and source of cement used.

3) Type, batch weight, and source of SCMpozzolan or slag used.

4) Type, amount, and source of admixtures used.

5) Aggregate batch weights and sources.

6) Water batch weight and source.

7) Required aggregate and water weights per cubic yard.

8) Amount of water as free moisture in each size of aggregate.

9) Batch aggregate and water weights per cubic yard for each class of concrete batched during plant operation.

10) Temperatures.

11) Volume of concrete placed for each class of concrete.

b. A report shall be submitted weekly updating control charts covering the entire period from the start of the construction season through the current week.

c. A separate submittal shall be submitted weekly updating the record of compression strength testing covering the entire period from the start of the construction season through the current week.

d. Submit certified ready-mix delivery tickets at the time of delivery for each load of concrete, if ready-mix concrete is used.

1.05 QUALITY CONTROL

A. Qualifications

1. Mix designer shall be a licensed Professional Engineer registered in the State of South Dakota or an SDDOT approved concrete mix designer, with a minimum of 5 years of experience in the design of concrete mixes, and shall have demonstrated experience in the successful design of mass concrete mixes.

2. Batch plant shall be currently certified by the National Ready Mixed Concrete Association.

3. The individuals who sample and test concrete or the constituents of concrete as required in this Specification shall have demonstrated a knowledge and ability to

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perform the necessary test procedures equivalent to the ACI minimum guidelines for certification of Concrete Field Testing Technicians, Grade I.

4. The individual who performs the inspection shall have demonstrated a knowledge and ability equivalent to the ACI minimum guidelines for certification of Concrete Construction Special Inspector (CCSI).

5. The laboratory performing the tests shall be on-site and shall conform with the requirements given in ASTM C1077. The COR will inspect the laboratory, equipment, and test procedures prior to start of concreting operations and at least once per year thereafter for conformance with ASTM C1077.

B. Materials Quality Control Testing

1. Cement:

a. Cement will be sampled and tested by CONTRACTOR under the supervision of the BIA Representative. The cement shall be tested for conformance with ASTM C150 Portland Cement or ASTM C595 Blended Hydraulic Cements and the requirements specified herein. The cement will also be evaluated in accordance with ER 1110-1-2002. The cement will be tested under the guidelines used to establish a qualified cement source as outlined in Appendix A of ER 1110-1-2002, Cement Quality Management System. The cement producer will be required to submit samples for physical and chemical testing, as well as historic quality control data.

b. No cement shall be used until notice has been given by the COR that test results for chemical and physical requirements as well as acceptance testing requirements are satisfactory. Release for shipment and approval for use will be contingent on continuing compliance with these and other requirements of the Specifications as allowed by the COR.

2. Fly Ash:

a. Fly ash will be sampled and tested by CONTRACTOR under the supervision of the BIA Representative. The fly ash shall be tested for conformance with ASTM C618 and the requirements specified herein. The fly ash will also be evaluated in accordance with ER 1110-1-2002. The fly ash will be tested under the guidelines used to establish a qualified fly ash source as outlined in Appendix B, Pozzolan Quality Management System. The fly ash producer will be required to submit samples for physical and chemical testing, as well as historic quality control data.

b. No fly ash shall be used until notice has been given by the COR that test results for chemical and physical requirements as well as acceptance testing requirements are satisfactory. Release for shipment and approval for use will be contingent on continuing compliance with these and other requirements of the Specifications as allowed by the COR.

3. Ground Granulated Blast-Furnace Slag (if used):

a. Ground Granulated Blast Furnace Slag (GGBFS) will be sampled and tested by CONTRACTOR under the supervision of the BIA Representative. The GGBFS

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shall be tested for conformance with ASTM C989 and the requirements specified herein. The GGBFS will also be evaluated in accordance with ER 1110-1-2002. The GGBFS will be tested under the guidelines used to establish a qualified cement source as outlined in Appendix A, Cement Quality Management System. The GGBFS producer will be required to submit samples for physical and chemical testing, as well as historic quality control data.

b. No GGBFS shall be used until notice has been given by the COR that test results for chemical and physical requirements as well as acceptance testing requirements are satisfactory. Release for shipment and approval for use will be contingent on continuing compliance with these and other requirements of the Specifications as allowed by the COR.

4. Chemical Admixtures: Provide satisfactory facilities for ready procurement of adequate test samples.

5. Aggregates:

a. Aggregate Quality:

1) Frequency of Quality Tests - Prior to submitting samples for mixture proportioning studies and not less than 90 days prior to the start of concrete placement, perform the tests for aggregate quality in the following list. In addition, after the start of concrete placement, perform tests for aggregate quality in accordance with the following frequency schedule. Samples tested after the start of concrete placement shall be taken immediately prior to entering the concrete mixer.

Property Frequency Fine

Aggregate

Frequency Coarse

Aggregate Test

Specific Gravity Every month Every month

ASTM C127

ASTM C128

Absorption Every month Every month

ASTM C127

ASTM C128

Clay Lumps and Friable Particles

Every 3 months Every 3 months ASTM C142

Material Finer than the 75-μm (No. 200) Sieve

Daily Daily ASTM C117

Organic Impurities Every 6 months Not applicable ASTM C40

L.A. Abrasion Not applicable Every 3 months

ASTM C131

ASTM C535

Soft and Friable (Scratch Hardness)

Not applicable Every 3 months

COE CRD-C

Coal and Lignite, less than 2.00 specific gravity Every 3 months Every 3 months ASTM C123

2) Corrective Action for Aggregate Quality - If the result of a quality test fails to meet the requirements for quality during submittal of samples for mixture-proportioning studies or immediately prior to start of concrete placement, FOR BID REV 1 PAGE 16 OF 60 production procedures or materials shall be changed and additional tests shall be performed until the material meets the quality requirements prior to proceeding with either mixture-proportioning studies or starting concrete placement. After concrete placement commences, whenever the result of a test for quality fails the requirements, the test shall be rerun immediately. If the second test fails the quality requirement, the fact shall be reported and immediate steps taken to rectify the situation.

b. Fine Aggregate:

1) Grading - At least once during each shift when the concrete plant is operating, there shall be one sieve analysis and fineness modulus determination in accordance with ASTM C136, ASTM C117 and COE CRD- C 104 for the fine aggregate or for each fine aggregate if it is batched in more than one size or classification. The location at which samples are taken may be selected by CONTRACTOR as the most advantageous for control.

However, CONTRACTOR is responsible for delivering fine aggregate to the mixer within Specification limits. The results shall be recorded on a sheet on which are also shown the Specification limits applicable to the Project.

2) Fineness Modulus Control Chart - Results for fineness modulus shall be grouped in sets of three consecutive tests, and the average and range of each group shall be plotted on a control chart. The upper and lower control limits for average shall be drawn 0.10 units above and below the target fineness modulus, and the upper control limit for range shall be 0.20 units above the target fineness modulus.

3) Corrective Action for Fine Aggregate Grading - When the amount passing any sieve is outside the Specification limits, the fine aggregate shall be immediately resampled and retested. If there is another failure for any sieve, the fact shall immediately be reported. Whenever a point on the fineness modulus control chart, either for average or range, is beyond one of the control limits, the frequency of testing shall be doubled. If two consecutive points are beyond the control limits, the process shall be considered out of control and concreting shall be stopped. Notify the BIA Representative and take immediate steps to rectify the situation. After two consecutive points have fallen within the control limits, testing at the normal frequency may be resumed.

4) Moisture Content Testing - When in the opinion of the BIA Representative the electric moisture meter is not operating satisfactorily, there shall be at least four tests for moisture content in accordance with ASTM C566 during each 8-hour period of mixing plant operation. The times for the tests shall be selected randomly within the 8-hour period. An additional test shall be made whenever the slump is shown to be out of control or excessive variation in workability is reported by the placing foreman. When an electric moisture meter is operating satisfactorily, at least two direct measurements of moisture content shall be made per week to check the calibration of the meter. The results of tests for moisture content shall be used to adjust the added water in the control of the batch plant.

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5) Moisture Content Corrective Action - Whenever the moisture content of the fine aggregate changes by 0.5 percent or more, the scale settings for the fine-aggregate batcher and water batcher shall be adjusted (directly or by means of a moisture compensation device).

c. Coarse Aggregate:

1) Grading - At least once during each shift in which the concrete plant is operating, there shall be a sieve analysis in accordance with ASTM C136 for each size of coarse aggregate. The location at which samples are taken may be selected by CONTRACTOR as the most advantageous for production control. However, deliver the aggregate to the mixer within Specification limits. A test record of samples of aggregate taken at the same locations shall show the results of the current test as well as the average results of the five most recent tests including the current test. CONTRACTOR may adopt limits for control coarser than the Specification limits for samples taken other than as delivered to the mixer to allow for degradation during handling.

When facilities are available to test samples five times as large as those required in ASTM C136, no averaging shall be done.

2) Corrective Action for Grading - When the amount passing any sieve is outside the Specification limits, the coarse aggregate shall be immediately resampled and retested. If the second sample fails on any sieve, that fact shall be reported. Where two consecutive averages of five tests (or two consecutive tests where large samples are used) are outside Specification limits, the operation shall be considered out of control, and that fact shall be reported, concreting shall be stopped, and immediate steps shall be taken to correct the grading.

3) Coarse Aggregate Moisture Content - A test for moisture content of each size group of coarse aggregate shall be made at least once per shift. When two consecutive readings for smallest size coarse aggregate differ by more than

1.0 percent, frequency of testing shall be increased to that specified previously for fine aggregate.

4) Coarse Aggregate Moisture Corrective Action - Whenever the moisture content of any size of coarse aggregate changes by 0.5 percent or more, the scale setting for the coarse aggregate batcher and the water batcher shall be adjusted to compensate for this.

d. Particle Shape Testing:

1) Testing frequency in accordance with ASTM D4791 shall be not less than once per day when the concrete plant is operating.

2) Particle Shape Corrective Action - Two consecutive failures in the same sieve size shall be immediately reported to the BIA Representative and to CONTRACTOR Quality Control Inspector, who shall determine what corrective action is needed.

e. Material Finer than the 75-μm (No. 200) Sieve

1) Tests shall be made in accordance with ASTM C117 when the concrete plant is operating.

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2) Corrective Action for Material Finer than the 75-μm (No. 200) Sieve - When material finer than the 75-μm (No. 200) sieve exceeds 0.5 percent of the weight of the aggregate finer than 1-1/2 inches or 0.25 percent of the weight of the aggregate coarser than 3/4 inches, the BIA Representative shall be notified and steps, such as modifications to the washing facilities, increased water pressure or flow, or other corrective action, shall be initiated immediately.

6. Fresh Concrete:

a. Air Content - At least two tests for air content shall be made on randomly selected batches of each concrete mixture produced during each 8-hour period of concrete production. Additional tests shall be made when excessive variation in workability is reported. Tests shall be made in accordance with ASTM C231.

The average of each set of two tests for each mixture shall be plotted on control charts on which the average percent and upper and lower limits are set in accordance with Paragraph 2.02 CONCRETE MIX DESIGN for each NMSA.

The range between two consecutive tests for each mixture shall be plotted on a control chart on which the upper control limit is 3.0 percent. Samples for air content shall normally be taken at the mixer; however, CONTRACTOR is responsible for delivering the concrete to the forms at the proper air content.

Additional samples shall also be taken at the placement site as often as required, depending on CONTRACTOR’s delivery method, to determine any air loss.

b. Air Content Corrective Action - Whenever points on the control chart approach the upper or lower control limits, an adjustment shall be made in the amount of air-entraining admixture batched. If a single test result is outside the Specification limit, immediate adjustment is mandatory. As soon as practical after each adjustment, another test shall be made to verify the correction of the adjustment. Whenever a point falls above the upper control for range, the dispenser shall be calibrated to ensure that it is operating correctly and with good reproducibility. Whenever two consecutive points, either for average or range are outside the control limits, the BIA Representative shall be notified.

c. Slump Testing - At least one slump test per truck shall be made in accordance with ASTM C143 on each concrete mixture produced during each 8-hour period or less of concrete production each day. Additional tests shall be made when excessive variation in workability is reported. The result of each test for each mixture shall be plotted on a control chart on which the upper and lower limits are set as specified in Paragraph 2.02 CONCRETE MIX DESIGN. The range shall be plotted on a control chart on which the upper control limit is 2 inches.

Samples for slump shall be taken at the mixer; however, CONTRACTOR is responsible for delivering the concrete to the placement site at the stipulated slump. If CONTRACTOR's materials or transportation methods cause slump loss between the mixer and the placement, samples shall be taken at the placement site as often as required by the COR.

d. Slump Corrective Action - Whenever points on the control chart approach the upper or lower control limits, an adjustment shall be made in the batch weights of water and fine aggregate. The adjustments are to be made so that the total

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water content does not exceed that amount specified in the mixture proportions provided based on the free water available with the aggregates and that amount of water batched. If the adjustments to the batch weights of water and aggregates do not satisfactorily produce the required slump, the COR may request CONTRACTOR to adjust the mixture proportions if the fine-aggregate moisture content is stable and within the required limits. When a single slump is outside the control limits, such adjustment is mandatory. As soon as practical after each adjustment, another test shall be made to verify the correctness of the adjustment. Whenever two consecutive individual slump tests, made during a period when there was no adjustment of batch weights, produce a point on the control chart for range above the upper control limits, the slump shall be considered to be out of control, the concreting operation halted, and the additional testing for aggregate moisture content required shall be undertaken, and action taken immediately to correct the problem.

7. Compressive Strength Testing:

a. At least one set of test cylinders shall be made for every 100 cubic yards of each different concrete mixture placed during each shift. Additional sets of test cylinders shall be made, as directed, when the mixture proportions are changed or when low strengths have been detected.

b. A random sampling plan shall be developed by the COR prior to start of construction. The plan shall assure that sampling is done in a completely random and unbiased, not just haphazard, manner. The sampling plan shall be developed in accordance with the requirements of ASTM D3665.

c. Cylinders will be prepared for testing. Class 1 will be 6 by 12 inch cylinders and will be used for all classes of concrete.

d. Cylinders will be made for every 100 cubic yards produced as described above.

e. A set of Class 1 cylinders shall consist of five cylinders, two to be tested at 7 days and two at 28 days, with one reserved and tested at 56 days if 28-day-strength is not met.

f. All compressive strength tests shall be reported immediately. Quality control charts shall be kept for individual strength tests, moving average for strength and moving average for range for each mixture. The charts shall be similar to those found in ACI 214R.

C. Equipment Quality Control Testing

1. Scales:

a. Weighing Accuracy - The accuracy of the scales shall be checked by test weights at least once a month for conformance with the applicable requirements of Paragraph 3.02A.4 BATCHING EQUIPMENT. Such tests shall also be made as directed whenever there are variations in properties of the fresh concrete that could result from batching errors.

b. Batching and Recording Accuracy - Once a week the accuracy of each batching and recording device shall be checked during a weighing operation by noting and recording the required weight, recorded weight, and the actual weight

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batched. Confirm that the calibration devices described in Paragraph 3.04A.4 BATCHING EQUIPMENT for checking the accuracy of dispensed admixtures are operating properly.

c. Scales Corrective Action - When either the weighing accuracy or batching accuracy does not comply with specification requirements, the plant shall not be operated until necessary adjustments or repairs have been made. Discrepancies in recording accuracies shall be communicated to the BIA Representative and corrected immediately.

2. Batch-Plant Control:

a. The measurement of all constituent materials including cementitious materials, each size of aggregate, water, and admixtures shall be continuously controlled.

The aggregate weights and amount of added water shall be adjusted as necessary to compensate for free moisture in the aggregates. The amount of air-entraining agent shall be adjusted to control air content within specified limits.

A report shall be prepared indicating type and source of cement used, type and source of SCMpozzolan or slag used, amount and source of admixtures used, aggregate source, the required aggregate and water weights per cubic yard, amount of water as free moisture in each size of aggregate, and the batch aggregate and water weights per cubic yard for each class of concrete batched during plant operation.

3. Mixer Uniformity:

a. Stationary Mixers - Prior to the start of concrete placing and once every 6 months when concrete is being placed interval uniformity of concrete mixing shall be determined in accordance with Paragraph 3.02A.7 MIXERS. The initial and every fourth set of tests shall be regular tests performed on three batches of concrete. Intermediate uniformity tests shall be abbreviated tests performed on a single batch of concrete. If the mixer fails the abbreviated test, a regular test shall be immediately performed. Whenever adjustments in a mixer or increased mixing time are required because of failure of a uniformity test, the mixer shall be reevaluated by a regular test after the adjustments have been completed. If CONTRACTOR proposes to reduce a mixing time, a regular test shall be performed to evaluate the proposed time. Additional testing shall be performed when directed when there is visible evidence of possible improper mixer performance. Results of all uniformity tests shall be reported in writing.

b. Truck Mixers - Prior to the start of concrete placing and at least once every 6 months when concrete is being placed, uniformity of concrete shall be determined in accordance with ASTM C94. The truck mixers shall be selected randomly for testing. When satisfactory performance is found in one truck mixer, the performance of mixers of substantially the same design and condition of the blades may be regarded as satisfactory. Results of tests shall be reported in writing.

c. Mixer Uniformity Corrective Action - When a mixer fails to meet mixer uniformity requirements, either the mixing time shall be increased, batching sequence changed, batch size reduced, or adjustments shall be made to the

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mixer until compliance is achieved. Report modifications made to the BIA Representative immediately after they are completed.

4. Vibrators:

a. Vibrator Testing and Use - The frequency and amplitude of each vibrator shall be determined in accordance with COE CRD-C 521 prior to initial use and at least once a month when concrete is being placed.