Amend_2_-_Attach_8_-_03_30_00_Cast-in-place_Concrete_0002.pdf

DIVISION 03 – CONCRETE

SECTION 03 30 00 – CAST-IN-PLACE CONCRETE

Klamath Falls N.F.H. 03 30 00-1 New National Fish Hatchery

GENERAL

1.01 DESCRIPTION OF WORK

A. The extent and location of the “Cast-in-Place Concrete” work is indicated on the drawings and includes, but is not limited to kettles, foundations, and baffles and walls within drain and water control structures. The work includes the requirements for providing all cast-in-place concrete and associated work including formwork, falsework, reinforcing, and finishing in conformance with these specifications and as indicated on the drawings.

1.02 RELATED DOCUMENTS

A. General Provisions of the Contract, including General Conditions and other Division 01 Specification Sections apply to this Section

1.03 CODES AND REFERENCES

A. Applicable provisions of the following standards shall apply to the work of this Section, except as modified herein, and are hereby made part of these Contract Specifications to the extent required.

1. American Concrete Institute ACI 301-16: Specifications for Structural Concrete.

2. American Concrete Institute ACI 305R-10: Hot Weather Concreting.

3. American Concrete Institute ACI 306R-10: Cold Weather Concreting.

4. American Concrete Institute ACI 308R-16: Guide to Curing Concrete.

5. American Concrete Institute SP-66(04): ACI Detailing Manual (including

ACI 315-99).

6. Modification of ACI 305R, 306R, and 308R: accomplish work in accordance with these guides except as modified herein. Consider the advisory or recommended provisions to be mandatory. Interpret reference to the "Building Official," the "Structural Engineer," and the "Architect/Engineer" to mean the Owner.

7. American Concrete Institute ACI 318-14: Building Code Requirements for Structural Concrete and Commentary.

8. Concrete Reinforcing Steel Institute (CRSI) Manual of Standard Practice (MSP), 2018, 28th Edition.

9. American Society for Testing Materials (ASTM), Standard Specifications and Standard Test Methods, designated by basic reference in this section (use the most current edition at the time of bid unless otherwise indicated).

10. Oregon Structural Specialty Code, 2019 Edition.

SUBMITTALS

A. Documentation demonstrating the qualifications and experience of supervisors and directors of work, as described in section 2.02 QUALITY ASSURANCE.

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B. Contractor designed formwork and falsework indicating designed support for the appropriate construction loads.

C. Proposed concrete design mixes, indicating all material contents per cubic yard of concrete, including certificates of specification compliance. Written evidence that the ready-mix concrete plant is approved and certified by the NRMCA and other organizations.

D. Test certificates for compressive strength, yield, air content, and slump of the proposed concrete mix. Report strength test results in accordance with ACI 301.

E. Manufacturer’s name, address, catalog number, and specifications for all proposed admixtures, concrete bonding agents, curing compounds, etc.

F. Identify all aggregate supply pit names and locations. Submit certificates of specification compliance for materials to be used including aggregate alkali-silica reactivity (ASR).

G. Proposed curing methods including manufacturer’s data for curing membranes, evaporation retardants, accelerated cure methods, etc. Submit detailed plans for concreting in ambient temperatures below 40 degrees F. Describe the specific methods and procedures used for substrate preparation, concrete placement, curing, and protection. Provide specific references to ACI 306R and ACI 308R.

H. Shop drawings showing pour sequences, construction joints, expansion joints, etc. Manufacturer’s data for proposed pre-fabricated construction joint systems and hardware.

I. Concrete delivery tickets for each truck delivered to the site. Submit delivery tickets to the Owner’s on-site representative before unloading at the site and in accordance with ASTM C 94, Section 14.

J. Detailed shop drawings that are coordinated and checked for all concrete reinforcement prior to casting concrete.

1. Do not deliver concrete reinforcement to the site prior to acceptance of the shop drawings.

2. The shop drawings shall include, but not be limited to, material specifications, bar lengths, bar bending schedules, order lists, splice lengths, and proposed splice locations.

K. Mill certificates for each heat of reinforcing steel and threaded bars to be furnished, indicating specification compliance, yield strength, ultimate strength, and chemistry.

L. Qualified weld procedure specification (WPS) including all information contained in Annex A of AWS D1.4.

2.02 QUALITY ASSURANCE

A. All concrete work shall conform to the requirements of ACI 301, unless otherwise noted in the drawings or the specifications.

B. Inspection and Testing: The Owner will provide inspection and testing as required. The Contractor shall provide all necessary access and assistance in carrying out such inspections and tests at its own expense. The contractor will

Klamath Falls N.F.H. 03 30 00-3 be provided testing agency information at the pre-construction meeting and will be required to call for inspection and provide all required coordination. The Contractor may obtain results of tests performed from the Owner. If the Contractor is not ready for inspection or is required due to the contractor’s actions to not be ready and fees are charged, the Contractor will be required to pay these expenses and costs will be deducted from pay applications.

C. Qualifications of Supplier: Ready-mixed concrete plants shall be approved and certified by the National Ready Mix Concrete Association (NRMCA) or qualified by the Oregon Department of Transportation (ODOT). Ready-mixed concrete shall be batched in accordance with the applicable portions of ASTM C 94.

D. Qualifications of Personnel:

1. Provide at least one qualified person who shall be present at all times during execution of this portion of the work, who shall be thoroughly trained and experienced in placing the types of concrete specified, and who shall direct all work performed under this section. Qualified personnel shall have at least five (5) years experience performing the work described in this section.

2. Trained and experienced journeyman concrete finishers having at least five (5) years experience shall be responsible for finishing all exposed surfaces.

E. Building Code: All concrete shall meet the requirements of the Oregon Structural Specialty Code. Where provisions of pertinent codes and standards conflict with this specification, the more stringent provisions shall govern, as determined by the Owner.

PRODUCTS

3.01 FORMWORK

A. Wood Forms:

1. For all exposed concrete forms, Grade B-B or B-C Plywood shall be used.

2. All forms shall be mortar-tight.

3. Forms shall remain in place until the concrete has reached 80 percent of the specified 28-day strength.

3.02 CONCRETE

A. General:

1. All concrete, unless otherwise specifically permitted by the Owner, shall be batched and mixed at the approved Ready-Mix plant. Batching, mixing, and delivery of ready-mix concrete shall conform to ASTM C 94.

2. The mix proportions shall be selected in accordance with ACI 301.

B. Cementitious Materials:

1. All cement shall be Portland cement conforming to ASTM C 150 or ASTM C595.

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2. Portland cement for use in mixes without fly ash shall be Type I-II or Type II conforming to ASTM C 150 except that the cement shall not contain more than 0.75 percent alkalies by weight calculated as Na20 plus 0.658 K20 and the content of Tricalcium aluminate (C3A) shall not exceed 8 percent by weight.

3. Portland cement for use in mixes with fly ash shall be Type I or Type I-II conforming to ASTM C 150.

4. Fly ash, if used, shall meet the requirements of ASTM C 618, Type F, with the added provision that the loss on ignition shall not exceed 1 percent, and that the fly ash is stored in a separate silo from the cement.

Split bins are not acceptable.

C. Aggregates:

1. Aggregates shall conform to ASTM C 33. All coarse and fine aggregate shall consist of hard, tough, durable particles free from foreign and deleterious materials, and shall be stored in such a manner as to prevent segregation, excessive breakage, and the introduction of foreign material.

2. Evaluate and test fine and coarse aggregates to be used in all concrete for alkali-aggregate reactivity in accordance with ASTM C 1260 or ASTM C 1293. Test both coarse aggregate size groups if from different sources.

Test results of the combination shall have a measured expansion equal to or less than 0.10 percent at 16 days after casting when aggregates are tested in accordance with ASTM C 1260 or 0.04 percent for aggregates tested in accordance with ASTM C 1293.

3. Grading shall conform to ASTM C33 Standard Specification for Concrete Aggregates Maximum nominal aggregate size shall be ¾ inch, unless approved by the Owner.

4. The maximum size of coarse aggregate shall not be larger than three fourths of the minimum clear spacing between reinforcing bars, between reinforcing bars and side forms, and between reinforcing bars and top or bottom surface of the concrete.

5. The maximum size of aggregate for “pea gravel” concrete shall be 3/8 inch.

D. Potable water shall be used for mixing concrete.

E. Admixtures: All admixtures shall be supplied by one manufacturer approved by the Owner.

1. Air-entraining admixtures shall conform to ASTM C 260. Dosage rates shall be in accordance with the manufacturer’s recommendations to meet the air content specified herein.

2. Water-reducing admixtures shall conform to the requirements of ASTM C

494. Dosage rates shall be in accordance with the manufacturer’s recommendations.

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3. Water reducing admixture shall be Type A, D, F, or G. The amount shall control the desired workability and water/cement ratio of the mix and shall be within the manufacturer’s recommended range.

3.03 OTHER MATERIALS

A. All other materials not specifically described but required for a complete and proper installation of cast-in-place concrete shall be selected by the Contractor subject to the approval of the Owner.

3.04 MIX PROPORTIONS AND STRENGTH

A. The mix proportions shall produce a mixture that will readily work into all corners, sides, and angles of the forms, around reinforcement and embedded items, with no segregation, and prevent free water from collecting on the surface.

B. The mix proportions shall be selected in accordance with ACI 301.

1. Test data representing thirty recent consecutive tests for each design shall be submitted to establish the standard deviation used in Section 4.2.3.

2. The criteria for acceptance of submitted tests shall be accordance with Section 4.2.3.1. Section 4.2.3.1 shall be amended to read, “… 500 psi of f’c”, instead of 1000 psi.

3. Where 30 recent consecutive tests are not available, the standard deviation may be determined by records based on no less than 15 tests as described in Section 4.2.3.2.

4. Where no previous data are available, the mix or mixes shall be overdesigned in accordance with Section 4.2.3.1.

5. When consecutive test data have been established during the project the overdesign criteria may be relaxed in accordance with Section 4.2.3.6.

6. Deviation from any reviewed design mix without approval of the Owner will not be permitted.

C. Concrete minimum 28-day compressive strength shall be 4,000 psi.

1. Concrete mixtures shall conform to the most restrictive requirements of ACI 318-14 for exposure classes for each structure type and meet the following requirements: Slump: Maximum 8 inches, and chosen to enhance workability without violating the maximum water/cement ratio requirement.

a. Metal Building: F1, S1, W0, and C1

b. All other elements: F2, S1, W0, and C1

3.05 REINFORCEMENT

A. All reinforcing bars, except as noted below, shall be deformed billet-steel bars conforming to ASTM A 615, Grade 60, deformed. Bars conforming to ASTM A 706 may be substituted for ASTM A 615 reinforcing bars at the Contractor’s option.

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B. All welded reinforcing bars shall conform to ASTM A 706, Grade 60, deformed.

All reinforcement shall be new and free from rust, grease, oil, wax, paint, soil, dirt, kinks, bends, or other defects. Store in a manner to prevent corrosion, or fouling with bond-breaking or deleterious coatings.

3.06 EPOXY ADHESIVE:

A. Epoxy adhesive for post installed anchors shall be Hilti HIT-HY 200 or equivalent selected by the Contractor subject to approval of the Owner.

EXECUTION

4.01 PREPARATORY WORK

A. General:

1. Prior to casting, inspect the installed work of all other trades and verify it is complete to the point where this installation may commence.

2. Verify that all items to be embedded in concrete are in place, properly oriented, located, and secured.

3. Verify that concrete may be placed to the lines and elevations indicated on the drawings with all required clearances for reinforcement.

4. All areas in which concrete is to be placed shall be thoroughly cleaned to remove wood debris, sawdust, tie wire cuttings, and all other deleterious material.

5. Tie wire ends shall be bent back so they do not encroach into the specified clear cover of the concrete.

6. Concrete forms which have not been treated with oils, waxes, or other bond breakers shall be thoroughly wet prior to placing concrete.

7. Clean and roughen existing concrete or concrete from previous pours to provide a bondable surface.

8. All transporting and handling equipment shall be cleaned of all hardened concrete and other debris.

9. Details of bending, placing, and splicing of all reinforcing steel shall conform to ACI 318, except as modified herein.

B. Notification: Notify the Owner at least 48 hours in advance of any concrete pour.

Notify the Owner when inspection by the Contractor is complete. In the event of discrepancy, immediately notify the Owner. Do not proceed with installation until all discrepancies have been fully resolved.

4.02 TRANSPORTING AND PLACING CONCRETE

A. Placement:

1. Concrete that does not reach its final position in the forms within 1-1/2 hours after the addition of cement shall not be used. During hot weather, this time limit shall be reduced in accordance with ACI 305R.

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2. Place concrete as soon as possible after mixing. Concrete which has developed initial set or partially hardened shall not be re-tempered or remixed.

3. The method and manner of placing concrete shall not allow segregation of the aggregates or displacement of reinforcement and embedded objects.

4. When using concrete pumps as the placing system, the pump priming slurry shall be discarded before placement into the forms. Initial acceptance testing may be delayed until the pump priming slurry has been eliminated. No pump shall be used that allows free water to flow past the piston. Aluminum conduits or tremies shall not be used for pumping or placing concrete.

5. Place concrete in continuous horizontal layers, or lifts, not exceeding 18 inches and compact so that there will be no line of separation between layers. Carefully fill each part of the forms by depositing concrete directly in its final destination.

6. When concrete must be dropped more than five feet into the forms, it shall be deposited through a sheet metal or other approved conduit.

Approved conduit shall also be used to place concrete in sloping forms or in other locations, as directed by the Owner, to prevent concrete from sliding around reinforcing or other embedded objects.

7. The methods of depositing and compacting concrete shall produce compact, dense, impervious concrete with the required surface finishes and no segregation. Remove defective concrete as directed by the Owner at no additional cost to the Owner .

B. Hot/Cold Weather Placement: Do not place concrete on frozen ground or against frosted reinforcing steel or forms. Do not mix or place concrete while the atmospheric temperature is below 40° F. If air temperature exceeds 90°F, provide water spray or other approved methods to cool contact surfaces to less than 90°F. Hot and cold-weather concrete placement shall follow the respective recommendations in ACI 305R and ACI 306R.

C. Consolidation of Concrete:

1. Provide suitable internal vibrators for use in compacting all concrete. The vibrators shall be of the type designed to be placed directly in the concrete, and their frequency of vibration shall not be less than 7,000 impulses per minute when in actual operation.

2. Vibration shall be such that the concrete becomes uniformly plastic. Insert vibrators to a depth sufficient to vibrate the bottom of each layer effectively, but do not penetrate partially hardened concrete. Do not apply the vibrators directly to steel which extends into partially hardened concrete. The intervals between points of insertion shall be not less than 2 feet, nor more than 3 feet.

3. Do not continue vibration in any one spot such that pools of cement or cement and sand are formed. In vibrating and finishing top surfaces which are exposed to weather or wear, avoid drawing water or laitance to the

Klamath Falls N.F.H. 03 30 00-8 surface. In relatively high lifts, the top layer shall be comparatively shallow and the concrete mix shall be as stiff as can be effectively vibrated into place and properly finished.

4. Do not use vibrators to transport or move concrete inside the form.

5. A sufficient number of vibrators shall be supplied to effectively vibrate all of the concrete placed. Hand-tamping or rodding shall be required wherever necessary to secure a smooth and dense concrete on the outside surfaces.

D. Concrete trucks shall not be washed out onsite unless contained within a concrete wash-out area that complies with the requirements of the latest version of the City of Klamath Falls Public Works Engineering Standards and the Central Oregon Stormwater Manual.

E. Any delivered load of concrete that is rejected shall be completely disposed of offsite.

4.03 CONSTRUCTION JOINTS

A. Joints and stoppages, except as specifically shown on the drawings, shall conform to ACI 318, Chapter 26. Wire mesh or similar materials shall not be used.

B. Submit for the Owner’s approval all requests for additional, deleted, or relocated construction joints. Changes as a result of such requests shall be at the Contractor’s expense and will be deducted from the contractors application for payment.

C. Thoroughly clean and roughen all joint surfaces and remove loose concrete, gravel, sediment, laitance, and all other deleterious substances.

D. Thoroughly wet and condition all joint surfaces to a saturated surface dry (SSD) condition for a minimum twelve hour period immediately prior to placing fresh concrete.

E. Unless otherwise noted, joints requiring roughened surfaces shall have grooves ½-inch to 1-inch wide, ¼-inch to ½-inch deep, which are spaced at twice the width of the groove.

4.04 CURING CONCRETE

A. Follow ACI 308R.

B. Concrete shall be maintained above 40° F and in a moist condition for at least the first seven days (168 hours) after placement.

C. Do not use curing compounds on surfaces to receive additional concrete.

D. Where permitted, apply an ASTM C 309, Type 1, Class A or B curing compound to the fresh concrete immediately after finishing the concrete and as soon as the visible bleed water has evaporated or as directed by the Owner. Apply according to the manufacturer’s recommendations. The rate of coverage shall be at least one gallon per 100 square feet and be sufficient to effectively obscure the original color of the concrete.

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E. Apply the curing compound in two applications to ensure full coverage of the concrete, with the second coat applied in a direction perpendicular to that of the first application.

F. Do not apply curing compound to construction joint surfaces, reinforcing steel, or embedments in the concrete. Curing compound on construction joints, reinforcing steel, or embedments shall be completely removed before the following concrete pour.

G. Supply backup spray equipment and sufficient workers to properly apply the curing compound.

H. Within 12 hours following the application of the curing compound, the top surfaces shall be covered with cotton mats, an approved vapor proof curing paper, or white polyethylene sheeting. If the covering used is cotton mats, it shall be kept continuously wet day and night for the period of time specified above, and if curing paper or plastic film is used, it shall be left in place for the same length of time.

I. Curing paper and white polyethylene sheeting shall be kept tightly in place by taping and weighting joints, or other methods for the prescribed length of time.

J. Membrane curing compounds which leave a waxy film on the concrete shall not be used.

K. After the concrete has cured for the required time, the top surfaces shall be swept clean.

L. All concrete shall be protected from damage and accelerated drying. No fire or excessive heat shall be permitted near the concrete at any time.

M. In lieu of curing compounds the Contractor may use wet burlap or other wet cure methods as approved by the Owner.

N. Only wet cure methods shall be used on concrete surfaces against which additional concrete will be cast.

O. Wet cure methods shall be continuous for the prescribed duration of the curing period.

4.05 FINISHING CONCRETE

A. Finish: All permanently exposed surfaces, unless specifically noted otherwise, shall be free from local bulging and all ridges or lips shall be removed to leave a smooth, flat surface. Patching mortar, if used, shall be of the same color as the surrounding concrete. White Portland cement shall be added to the patching mortar for color matching. A test section, approved by the Owner, shall be completed prior to production work.

B. Protect finished surfaces from damage, stains and abrasion. Surfaces or edges damaged during construction shall be repaired at the Contractor’s expense.

C. Defects:

1. Surface defects include honeycomb, rock pockets, spalls, chips, air bubbles, voids, pinholes, bug holes, and indentations greater than or equal to 1/4 inch in depth, or greater than or equal to 1/2 inch in width, Klamath Falls N.F.H. 03 30 00-10 length, or diameter. These defects shall be chipped out to reveal sound concrete and then shall be patched. Surface cracks greater than or equal to 0.007 inches in width. These cracks shall be patched.

2. Surface irregularities include embedded objects, embedded debris, lift lines, sand lines, bleed lines, segregation, form pop-outs, fins, form leakage, texture irregularities, stains and other discolorations that cannot be removed by water blast cleaning. These defects shall be repaired as specified in this Section unless otherwise directed by the Owner.

D. Vertical Surfaces and Walls:

1. Immediately after removal of forms or form linings, inspect the concrete surfaces for defects and irregularities.

2. All defects, defective concrete, and tie rod holes shall be repaired immediately after the forms are removed unless otherwise directed by the Owner. Exposed tie wires shall be removed (chipped out) and the resulting holes patched. The repair mortar shall be BASF EMACO R350 CI or an epoxy mortar approved by the Owner applied according to the manufacturer’s instructions by experienced personnel qualified by the manufacturer of the repair material.

3. All vertical surfaces, against which concrete will be cast, are construction joints, and shall be thoroughly cleaned and roughened to an amplitude of 1/4 inch. Roughening shall be accomplished using methods in accordance with the construction permits and approved by the Owner, to expose sound concrete without undercutting around the edges of the larger aggregate particles or cracking the concrete to remain.

E. Horizontal Surfaces:

1. Exposed horizontal surfaces shall have a heavy broom finish.

4.06 TESTING

A. Testing of concrete will be performed by an accredited testing agency retained by the Owner. Methods of sampling, testing, evaluation, and acceptance will conform to ACI 301. The Contractor shall assist the Owner with access to collect samples.

B. Testing as described above will be at the discretion of Owner and in no way relieves the Contractor of any obligations.

C. Tests performed by the Owner will be done at no cost to the Contractor, except as noted below.

1. Additional testing and inspection required because of changes in materials, proportions, and procedures requested by the Contractor.

2. Additional testing of materials or concrete when either fails to meet the specification requirements when tested in accordance with the ACI standards outlined and the appropriate ASTM standards contained therein.

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4.07 REINFORCING STEEL BARS

A. Order Lists: Before ordering material, furnish all order lists and bending diagrams for approval by the Owner; reinforcement placing drawings submitted for approval shall conform to the CRSI MSP. Do not order material until such lists and bending diagrams have been approved. The approval of order lists and bending diagrams by the Owner shall in no way relieve the Contractor of responsibility for the correctness of such lists and diagrams.

B. General Fabrication Requirements for Reinforcing Bars: Bend all bars cold to the shapes indicated on the drawings unless otherwise approved by the Owner. Do not field-bend bars partially embedded in concrete except as indicated on the drawings or as approved by the Owner. Make bends and hooks in accordance with the applicable portions of the CRSI MSP.

C. Carefully handle and install coated bars to minimize job site patching. Use the same precautions as described above for delivery, handling, and storage when placing coated reinforcement. Do not drag coated bars over other bars or over abrasive surfaces. Keep coated bars free of dirt and grit. When possible, assemble coated reinforcement as tied cages prior to final placement into the forms. Support assembled cages on padded supports.

D. Placing and Fastening:

1. Place all steel reinforcement accurately and hold firmly in the position indicated on the drawing during the placing and setting of concrete. Tie bars at all intersections.

2. Minimum concrete cover to reinforcement shall be as listed below or otherwise indicated on the drawings:

a. Exposed to earth or weather: 2 inches.

b. Cast against earth: 3 inches.

3. Maintain the minimum distance from the forms by means of stays, blocks, ties, hangers, or other approved supports.

a. Holding reinforcement from contact with the forms shall be by approved metal or plastic chairs. Metal chairs which are in contact with the exterior surface of the concrete shall be plastic-coated for the full depth of the indicated concrete cover.

b. Separate layers of bars by plastic chairs, by precast mortar blocks of compressive strength not less than 3750 pounds per square inch, spacing bars, or by other devices approved equal.

c. The minimum spacing between bars, except at lap splices, shall not be less than one bar diameter or one inch minimum, but not less than 1-1/3 times the maximum size of the coarse aggregate.

4. In the event that conduits, anchor bolts, piping, inserts, sleeves, embedded objects, headed studs, or other items interfere with placing reinforcement as indicated on the drawings, or as otherwise required, immediately contact the Owner and obtain approval of a new procedure before placing concrete.

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4.08 SPLICING

A. Furnish all reinforcement in the full lengths indicated on the drawings, except that reinforcement over forty feet in length may be spliced.

B. Splicing of bars, except reinforcement over forty feet in length and when indicated on the drawings, will not be permitted without approval of the Engineer.

When approved, splices shall be staggered with no more than fifty percent of any particular bar type being spliced at any one location. Minimum length of lap splice shall be per the schedule of minimum lap splice lengths in the drawings unless noted otherwise on the drawings. Minimum distance between spliced zones shall be three lap lengths.

4.09 CLEANING REINFORCEMENT

A. Steel reinforcement, at the time concrete is placed around it, shall be free from loose rust or mill scale, oil, paint, and all other coatings which will destroy, impair, or reduce the bond between steel and concrete.

END OF SECTION