CAVE 169636 SpecificationsVol 1.pdf

National Parks Service, Denver Service

Center

NPS CAVE 169636 - Electrical Design

Contains the following Projects herein under CAVE 169636:

CAVE 169636 - Replace Old/Failing Primary

Electrical Distribution Infrastructure

CAVE 287291 - Install Generator For Primary

Electric Distribution

Project Manual – Volume 1

100% Final Construction Documents Package

06/12/2020

CAVE-169636

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Table of Contents

TABLE OF CONTENTS

DIVISION 03 — CONCRETE

03 09 00 - CONCRETE

03 15 00 – ANCHORAGE TO CONCRETE

DIVISION 04 – MASONRY

04 05 13 – MASONRY MORTAR AND GROUT

04 05 23 – MASONRY ACCESSORIES

04 05 50 – COLD AND HOT WEATHER MASONRY CONSTRUCTION

04 22 00 – CONCRETE MASONRY

DIVISION 05 — METALS

05 50 00 - METAL FABRICATIONS

DIVISION 06 — WOOD, PLASTICS, AND COMPOSITES

NOT USED

DIVISION 07 — THERMAL AND MOISTURE PROTECTION

07 84 00 - FIRESTOPPING

07 92 00 - JOINT SEALING

DIVISION 08 — OPENINGS

NOT USED

DIVISION 09 — FINISHES

09 24 24 – PORTLAND CEMENT STUCCO

09 96 00 – HIGH PERFORMANCE INDUSTRIAL COATINGS

DIVISION 10 — SPECIALTIES

10 14 00 - IDENTIFICATION DEVICES

DIVISION 26 — ELECTRICAL

26 05 00 - ELECTRICAL - BASIC REQUIREMENTS

26 05 13 – MEDIUM VOLTAGE CABLE

26 05 19 - WIRE AND CABLE - 600 VOLT AND BELOW

26 05 43 - ELECTRICAL EXTERIOR UNDERGROUND

26 05 74 - SHORT CIRCUIT AND COORD. STUDY, AND ARC FLASH REPORT

26 08 13 - ACCEPTANCE TESTING

26 13 16 – MV LOAD BREAK

26 23 00 - SWITCHGEAR

26 24 13 - SWITCHBOARDS

26 27 26 – WIRING DEVICES

26 28 00 – OVERCURRENT AND SHORT CIRCUIT DEVICES

26 32 14 – ENGINE GENERATOR DIESEL

26 36 00 – TRANSFER SWITCHES

DIVISION 31 — EARTHWORK

31 23 00 – EARTHWORK

31 23 17 – ROCK EXCAVATON

31 23 33 – TRENCHING BACKFILLING & COMPACTING FOR UTILITIES

31 25 00 – SOIL EROSION & SEDIMENT CONTROL

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DIVISION 32 — EXTERIOR IMPROVEMENTS

32 12 16 – ASPHALTIC CONCRETE VEHICULAR PAVING

33 05 15 – PRECASE CONCRETE UTILITY STRUCTURES

33 52 10 – SERVICE PIPING – FUEL SYSTEMS

33 56 16 – FUEL DAY TANK SYSTEMS

DIVISION 40 — PROCESS INTERCONNECTIONS

40 63 43 - PROGRAMMABLE LOGIC CONTROLLER (PLC) CONTROL SYSTEM

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CONCRETE

SECTION 03 09 00

CONCRETE

PART 1 - GENERAL

1.1 SUMMARY

A. Section Includes:

1. Cast-in-place concrete and grout.

B. Related Specification Sections include but are not necessarily limited to:

1. Division 1-Specifications.

2. Section 03 15 19 - Anchorage to Concrete.

1.2 QUALITY ASSURANCE

A. Referenced Standards:

1. American Concrete Institute (ACI):

a. 117, Specification for Tolerances for Concrete Construction and Materials.

b. 211.1, Standard Practice for Selecting Proportions for Normal, Heavyweight and Mass

Concrete.

c. 212.3R, Chemical Admixtures for Concrete.

d. 304R, Guide for Measuring, Mixing, Transporting, and Placing Concrete.

e. 304.2R, Placing Concrete by Pumping Methods.

f. 305.1, Hot Weather Concreting.

g. 306.1, Cold Weather Concreting.

h. 318, Building Code Requirements for Structural Concrete.

i. 347, Guide to Formwork for Concrete.

j. CT-13, Concrete Terminology.

2. ASTM International (ASTM):

a. A185, Standard Specification for Steel Welded Wire Reinforcement, Plain, for

Concrete.

b. A615, Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete

Reinforcement.

c. A1064, Standard Specification for Steel Wire and Welded Wire Replacement, Plain and

Deformed, for Concrete.

d. C31, Standard Practice for Making and Curing Concrete Test Specimens in the Field.

e. C33, Standard Specification for Concrete Aggregates.

f. C39, Standard Test Method for Compressive Strength of Cylindrical Concrete

Specimens.

g. C94/C94M, Standard Specification for Ready-Mixed Concrete.

h. C138, Standard Method of Test for Density (Unit Weight), Yield, and Air Content

(Gravimetric) of Concrete.

i. C143, Standard Test Method for Slump of Hydraulic Cement Concrete.

j. C150, Standard Specification for Portland Cement.

k. C172, Standard Practice for Sampling Freshly Mixed Concrete.

l. C173, Standard Test Method for Air Content of Freshly Mixed Concrete by the

Volumetric Method.

m. C231, Standard Test Method for Air Content of Freshly Mixed Concrete by the

Pressure Method.

n. C260, Standard Specification for Air-Entraining Admixtures for Concrete.

o. C309, Standard Specification for Liquid Membrane-Forming Compounds for Curing

Concrete.

p. C494, Standard Specification for Chemical Admixtures for Concrete.

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

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r. C1293, Standard Test Method for Determination of Length Change of Concrete Due to

Alkali-Silica Reaction.

s. C1315, Standard Specification for Liquid Membrane-Forming Compounds Having

Special Properties for Curing and Sealing Concrete.

t. D882, Standard Test Method for Tensile Properties of Thin Plastic Sheeting.

u. D994, Standard Specification for Preformed Expansion Joint Filler for Concrete

(Bituminous Type).

v. D1056, Standard Specification for Flexible Cellular Materials-Sponge or Expanded

Rubber.

w. D1751, Standard Specification for Preformed Expansion Joint Filler for Concrete

Paving and Structural Construction (Nonextruding and Resilient Bituminous Types).

x. E96, Standard Test Methods for Water Vapor Transmission of Materials.

y. E329, Standard Specification for Agencies Engaged in Construction Inspection and/or

Testing.

3. Corps of Engineers (COE):

a. CRD-C621, Standard Specification for Packaged, Dry, Hydraulic-Cement Grout

(Nonshrink).

4. National Ready Mixed Concrete Association (NRMCA).

5. National Sanitation Foundation (NSF):

a. 61, Drinking Water System Components - Health Effects.

B. Quality Control:

1. Concrete testing agency:

a. Contractor to employ and pay for services of a testing laboratory to:

1) Perform materials evaluation.

2) Design concrete mixes.

b. Concrete testing agency to meet requirements of ASTM E329.

2. Do not begin concrete production until proposed concrete mix design has been approved by

Contracting Officer.

a. Approval of concrete mix design by Contracting Officer does not relieve Contractor of his responsibility to provide concrete that meets the requirements of this Specification.

3. Adjust concrete mix designs when material characteristics, job conditions, weather, strength test results or other circumstances warrant.

a. Do not use revised concrete mixes until submitted to and approved by Contracting

Officer.

C. Qualifications:

1. Ready mixed concrete batch plant certified by NRMCA.

1.3 DEFINITIONS

A. Per ACI CT-13 except as modified herein:

1. Concrete fill: Non-structural concrete.

2. Concrete Testing Agency: Testing agency employed to perform materials evaluation, design of concrete mixes or testing of concrete placed during construction.

3. Exposed concrete: Exposed to view after construction is complete.

4. Indicated: Indicated by Contract Documents.

5. Nonexposed concrete: Not exposed to view after construction is complete.

6. Required: Required by Contract Documents.

7. Specified strength: Specified compressive strength at 28 days.

8. Submitted: Submitted to Contracting Officer.

1.4 SUBMITTALS

A. Shop Drawings:

1. See Specification Section 01 33 23 for requirements for the mechanics and administration of the submittal process.

2. Concrete mix designs proposed for use.

a. Concrete mix design submittal to include the following information:

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1) Sieve analysis and source of fine and coarse aggregates.

2) Test for aggregate organic impurities.

3) Test for deleterious aggregate per ASTM C1293.

4) Proportioning of all materials.

5) Type of cement with mill certificate for cement.

6) Type of fly ash with certificate of conformance to specification requirements.

7) Slump.

8) Air content.

9) Brand, type, ASTM designation, and quantity of each admixture proposed for use.

10) 28-day cylinder compressive test results of trial mixes per ACI 318 and as indicated herein.

3. Product technical data including:

a. Acknowledgement that products submitted meet requirements of standards referenced.

b. Manufacturer's installation instructions.

c. Manufacturers and types:

1) Joint fillers.

2) Curing agents.

3) Bonding and patching mortar.

4) Construction joint bonding adhesive.

5) Nonshrink grout with cure/seal compound.

4. Reinforcing steel:

a. Show grade, sizes, number, configuration, spacing, location and all fabrication and placement details.

b. In sufficient detail to permit installation of reinforcing without having to make reference to Contract Drawings.

c. Obtain approval of Shop Drawings by Contracting Officer before fabrication.

d. Mill certificates.

5. Scaled (minimum 1/8 IN per foot) drawings showing proposed locations of construction joints, control joints, expansion joints (as applicable) and joint dimensions.

6. Strength test results of in place concrete including slump, air content and concrete temperature.

7. Certifications:

a. Certification of standard deviation value in psi for ready mix plant supplying the concrete.

b. Certification that the material and sources submitted in the mix design will be used in the concrete for this project.

8. Test reports:

a. Cement mill reports for all cement to be supplied.

1.5 DELIVERY, STORAGE, AND HANDLING

A. Storage of Material:

1. Cement and pozzolan:

a. Store in moistureproof, weathertight enclosures.

b. Do not use if caked or lumpy.

2. Aggregate:

a. Store to prevent segregation and contamination with other sizes or foreign materials.

b. Obtain samples for testing from aggregates at point of batching.

c. Do not use frozen or partially frozen aggregates.

d. Do not use bottom 6 IN of stockpiles in contact with ground.

e. Allow sand to drain until moisture content is uniform prior to use.

3. Admixtures:

a. Protect from contamination, evaporation, freezing, or damage.

b. Maintain within temperature range recommended by manufacturer.

c. Completely mix solutions and suspensions prior to use.

4. Reinforcing steel: Support and store all rebars above ground.

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B. Delivery:

1. Concrete:

a. Prepare a delivery ticket for each load for ready-mixed concrete.

b. Truck operator shall hand ticket to Contracting Officer at the time of delivery.

c. Ticket to show:

1) Mix identification mark.

2) Quantity delivered.

3) Amount of each material in batch.

4) Outdoor temp in the shade.

5) Time at which cement was added.

6) Numerical sequence of the delivery.

7) Amount of water added.

2. Reinforcing steel:

a. Ship to jobsite with attached plastic or metal tags with permanent mark numbers.

b. Mark numbers to match Shop Drawing mark number.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Subject to compliance with the Contract Documents, the following products and manufacturers are acceptable:

1. Nonshrink, nonmetallic grout:

a. Sika "SikaGrout 212."

b. Euclid Chemial "NS Grout."

c. BASF Admixtures, Inc. "Masterflow 713."

2. Expansion joint fillers:

a. Permaglaze Co.

b. Rubatex Corp.

c. Williams Products, Inc.

3. Form coating:

a. Richmond "Rich Cote."

b. Industrial Lubricants "Nox-Crete Form Coating."

c. Euclid Chemical "Kurez DR VOX."

4. Bonding agent:

a. Euclid Chemical Co.

b. BASF Admixtures, Inc.

c. L&M Construction Chemicals Inc.

B. Submit request for substitution in accordance with Specification Section 01 33 23.

2.2 MATERIALS

A. Portland Cement: Conform to ASTM C150 Type I/II.

B. Fly Ash:

1. ASTM C618, Class F or Class C.

2. Nonstaining.

a. Hardened concrete containing fly ash to be uniform light gray color.

3. Maximum loss on ignition: 4 PCT.

4. Compatible with other concrete ingredients.

C. Admixtures:

1. Air entraining admixtures: ASTM C260.

2. Water reducing, retarding, and accelerating admixtures:

a. ASTM C494 Type A through E.

b. Conform to provisions of ACI 212.3R.

c. Do not use retarding or accelerating admixtures unless specifically approved in writing by Contracting Officer and at no cost to Owner.

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d. Follow manufacturer's instructions.

e. Use chloride free admixtures only.

3. Maximum total water soluble chloride ion content contributed from all ingredients of concrete including water, aggregates, cementitious materials and admixtures by weight percent of cement:

a. 0.10 allconcrete.

4. Do not use calcium chloride.

5. Pozzolanic admixtures: ASTM C618.

6. Provide admixtures of same type, manufacturer and quantity as used in establishing required concrete proportions in the mix design.

D. Water: Potable, clean, free of oils, acids and organic matter.

E. Aggregates:

1. Normal weight concrete: ASTM C33, except as modified below.

2. Fine aggregate:

a. Clean natural sand.

b. No manufactured or artificial sand.

3. Coarse aggregate:

a. Crushed rock, natural gravel, or other inert granular material.

b. Maximum amount of clay or shale particles: 1 PCT.

4. Gradation of coarse aggregate:

a. All concrete: Size #57 or #67.

5. Use only washed aggregates.

F. Concrete Grout:

1. Nonshrink, nonmetallic grout:

a. Nonmetallic, noncorrosive, nonstaining, premixed with only water to be added.

b. Grout to produce a positive but controlled expansion.

c. Mass expansion not to be created by gas liberation.

d. Minimum compressive strength of nonshrink grout at 28 days: 6500 PSI.

e. In accordance with COE CRD-C621.

G. Reinforcing Steel:

1. Reinforcing bars: ASTM A615, Grade 60.

2. Welded wire reinforcement:

a. ASTM A185 or ASTM A1064.

b. Minimum yield strength: 60,000 PSI.

H. Forms:

1. Prefabricated or job built.

2. Wood forms:

a. 5/8 or 3/4 IN 5-ply structural plywood of concrete form grade.

b. Built-in-place or prefabricated type panel.

3. Metal forms:

a. Metal forms may be used except for aluminum in contact with concrete.

b. Forms to be tight to prevent leakage, free of rust and straight without dents to provide members of uniform thickness.

4. Chamfer strips: Clear white pine, surface against concrete planed.

I. Form Ties:

1. Commercially fabricated for use in form construction.

a. Field fabricated ties are unacceptable.

2. Constructed so that ends or end fasteners can be removed without causing spalling at surfaces of the concrete.

3. 3/4 IN minimum to 1 IN maximum diameter cones on both ends.

4. Embedded portion of ties to be not less than 1-1/2 IN from face of concrete after ends have been removed.

5. Cone size:

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a. 3/4 IN minimum to 2 1/2 IN maximum diameter cones on both ends.

b. Depth of cone not to exceed the concrete reinforcing cover.

6. Form release: Nonstaining and shall not prevent bonding of future finishes to concrete surface.

J. Chairs, Runners, Bolsters, Spacers, and Hangers:

1. Stainless steel, epoxy coated, or plastic coated metal.

a. Plastic coated: Rebar support tips in contact with the forms only.

K. Membrane Curing Compound:

1. ASTM C309, Type 1D, Class A or B.

2. Fugitive dye shall dissipate over time and exposure.

3. Curing compound shall not prevent bonding of any future coverings, coatings or finishes.

L. Bonding Agent:

1. High solids acrylic latex base liquid for interior or exterior application as a bonding agent to improve adhesion and mechanical properties of concrete patching mortars.

2. Euclid Chemical Co. "Flex-Con."

3. BASF Admixtures, Inc. "Acryl-Set."

4. L&M Construction Chemicals "Everbond."

M. Expansion Joint Filler:

1. In contact with water or sewage:

a. Closed cell neoprene.

b. ASTM D1056, Class SC (oil resistant and medium swell) of 2 to 5 PSI compression deflection (Grade SCE41).

2. Exterior driveways, curbs and sidewalks:

a. Asphalt expansion joint filler.

b. ASTM D994.

3. Other use:

a. Fiber expansion joint filler.

b. ASTM D1751.

2.3 CONCRETE MIXES

A. General:

1. All concrete to be ready mixed concrete conforming to ASTM C94/C94M.

2. Provide concrete of specified quality capable of being placed without segregation and, when cured, of developing all properties required.

3. All concrete to be normal weight concrete.

4. Provide pozzolan content for all cast-in-place construction.

B. Strength:

1. Provide specified strength and type of concrete for each use in structure(s) as follows:

TYPE WEIGHT

SPECIFIED

STRENGTH*

All concrete Normal weight 4000 PSI

* Minimum 28-day compressive strength.

C. Air Entrainment:

1. Provide air entrainment in all concrete resulting in a total air content percent by volume as follows:

MAX AGGREGATE SIZE TOTAL AIR CONTENT PERCENT

1 IN or 3/4 IN 6 ±1-1/2

<3/4 IN 6-1/2 ±1-1/2

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2. Air content to be measured in accordance with ASTM C231, ASTM C173, or ASTM C138.

D. Slump - 4 IN maximum, 1 IN minimum:

1. Measured at point of discharge of the concrete into the concrete construction member.

2. 8 IN maximum after addition of superplasticizer (if used).

3. Concrete of lower than minimum slump may be used provided it can be properly placed and consolidated.

4. Pumped concrete:

a. Provide additional water at batch plant to allow for slump loss due to pumping.

b. Provide only enough additional water so that slump of concrete at discharge end of pump hose does not exceed maximum slump specified and the maximum specified water-cement ratio is not exceeded.

5. Slump may be adjusted in the field through the use of water reducers.

a. Coordinate dosage and mixing requirements with concrete supplier.

6. Determine slump per ASTM C143.

E. Selection of Proportions:

1. General:

a. Proportion ingredients to:

1) Produce proper workability, durability, strength, and other required properties.

2) Prevent segregation and collection of excessive free water on surface.

2. Minimum cement contents and maximum water cement ratios for concrete to be as follows:

SPECIFIED

STRENGTH

MINIMUM CEMENT, MAXIMUM

AGGREGATE SIZE MAXIMUM WATER

CEMENT RATIO BY

WEIGHT 1/2 IN 3/4 IN 1 IN

4000 564 564 564 0.45

3. Fly ash:

a. For cast-in-pace concrete only, a maximum of 25 PCT by weight of Portland cement content per cubic yard may be replaced with fly ash at rate of 1 LB fly ash for 1 LB of cement.

b. Provide a minimum of 15 PCT by weight of Portland cement content per cubic yard replaced at rate of 1 LB fly ash for 1 LB of cement.

c. When fly ash is used, the water to cementitious materials ratio shall not exceed the maximum value specified herein.

4. Concrete mix proportioning methods for normal weight concrete:

a. Proportion mixture to provide desired characteristics using one of methods described below:

1) Method 1 (Trial Mix):

a) Per ACI 318, Chapter 5, except as modified herein.

b) Air content within range specified above.

c) Record and report temperature of trial mixes.

d) Proportion trial mixes per ACI 211.1.

2) Method 2 (Field Experience):

a) Per ACI 318, Chapter 5, except as modified herein:

b) Field test records must be acceptable to Contracting Officer to use this method.

c) Test records shall represent materials, proportions and conditions similar to those specified.

5. Required average strength to exceed the specified 28-day compressive strength by the amount determined or calculated in accordance with the requirements of Chapter 5 of ACI

318 using the standard deviation of the proposed concrete production facility.

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PART 3 - EXECUTION

3.1 FORMING AND PLACING CONCRETE

A. Formwork:

1. Contractor is responsible for design and erection of formwork.

2. Construct formwork so that concrete members and structures are of correct size, shape, alignment, elevation and position.

a. Allowable tolerances: As recommended in ACI 347.

3. Provide slabs and beams of minimum indicated depth when sloping foundation base slabs or elevated floor slabs to drains.

a. For slabs on grade, slope top of subgrade to provide floor slabs of minimum uniform indicated depth.

b. Do not place floor drains through beams.

4. Openings:

a. Provide openings in formwork to accommodate work of other trades.

b. Accurately place and securely support items built into forms.

5. Chamfer strips: Place 3/4 IN chamfer strips in forms to produce 3/4 IN wide beveled edges on permanently exposed corners of members.

6. Clean and adjust forms prior to concrete placement.

7. Tighten forms to prevent mortar leakage.

8. Coat form surfaces with form release agents prior to placing reinforcing bars in forms.

B. Reinforcement:

1. Position, support and secure reinforcement against displacement.

2. Locate and support with chairs, runners, bolsters, spacers and hangers, as required.

3. Set wire ties so ends do not touch forms and are directed into concrete, not toward exposed concrete surfaces.

4. Lap splice lengths: ACI 318 Class B top bar tension splices unless indicated otherwise on the Drawings.

5. Extend reinforcement to within 2 IN of concrete perimeter edges.

a. If perimeter edge is earth formed, extend reinforcement to within 3 IN of the edge.

6. Minimum concrete protective covering for reinforcement: As shown on Drawings.

7. Do not weld reinforcing bars.

8. Welded wire reinforcement:

a. Install welded wire reinforcement in maximum practical sizes.

b. Splice sides and ends with a splice lap length measured between outermost cross wires of each fabric sheet not less than:

1) One spacing of cross wires plus 2 IN.

2) 1.5 x development length.

3) 6 IN.

c. Development length: ACI 318 basic development length for the specified fabric yield strength.

C. Construction, Expansion, and Contraction Joints:

1. Locate joints as indicated on Contract Drawings or as shown on approved Shop Drawings.

a. Where construction joint spacing shown on Drawings exceeds the joint spacing indicated in Paragraph below, submit proposed construction joint location in conformance with this Specification Section.

2. Unplanned construction joints will not be allowed.

3. Locate construction joints in floor slabs and foundation base slabs so that concrete placements are approximately square and do not exceed 2500 SQFT.

4. Install construction joints perpendicular to main reinforcement with all reinforcement continued across construction joints.

5. At least 48HRS shall elapse between placing of adjoining concrete construction.

6. Thoroughly clean and remove all laitance and loose and foreign particles from construction joints.

7. Before new concrete is placed, dampen concrete surfaces.

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D. Embedments:

1. Set and build in anchorage devices and other embedded items required for other work that is attached to, or supported by concrete.

2. See Specification Section 03 15 19 - Anchorage to Concrete.

3. Use setting diagrams, templates and instructions for locating and setting.

E. Placing Concrete:

1. Place concrete in compliance with ACI 304R and ACI 304.2R.

2. Place in a continuous operation within planned joints or sections.

3. Begin placement when work of other trades affecting concrete is completed.

4. Place concrete by methods which prevent aggregate segregation.

5. Do not allow concrete to free fall more than 4 FT.

6. Where free fall of concrete will exceed 4 FT, place concrete by means of tremie pipe or chute.

F. Consolidation: Consolidate all concrete using mechanical vibrators supplemented with hand rodding and tamping, so that concrete is worked around reinforcement and embedded items into all parts of forms.

G. Protection:

1. Protect concrete from physical damage or reduced strength due to weather extremes.

2. In cold weather comply with ACI 306.1 except as modified herein.

a. Do not place concrete on frozen ground or in contact with forms or reinforcing bars coated with frost, ice or snow.

b. Do not place heated concrete that is warmer than 80 DEGF.

c. If freezing temperatures are expected during curing, maintain the concrete temperature at or above 50 DEGF for seven days or 70 DEGF for 3 days.

d. Do not allow concrete to cool suddenly.

3. In hot weather comply with ACI 305.1 except as modified herein.

a. At air temperature of 90 DEGF and above, keep concrete as cool as possible during placement and curing.

b. Do not allow concrete temperature to exceed 90 DEGF at placement.

c. Prevent plastic shrinkage cracking due to rapid evaporation of moisture.

d. Do not place concrete when the actual or anticipated evaporation rate equals or exceeds

0.2 LBS/SF/HR as determined from ACI 305.1, Figure 2.1.5.

H. Curing:

1. Begin curing concrete as soon as free water has disappeared from exposed surfaces.

2. Cure concrete by use of moisture retaining cover, burlap kept continuously wet or by membrane curing compound.

3. Provide protection as required to prevent damage to concrete and to prevent moisture loss from concrete during curing period.

4. Provide curing for minimum of 7 days.

5. Form materials left in place may be considered as curing materials for surfaces in contact with the form materials except in periods of hot weather.

6. In hot weather follow curing procedures outlined in ACI 305.1.

7. In cold weather follow curing procedures outlined in ACI 306.1.

8. Curing vertical surfaces with a curing compound:

a. Cover vertical surfaces with a minimum of two coats of the curing compound.

b. Allow the preceding coat to completely dry prior to applying the next coat.

c. Apply the first coat of curing compound immediately after form removal.

d. Vertical surface at the time of receiving the first coat shall be damp with no free water on the surface.

e. A vertical surface is defined as any surface steeper than 1 vertical to 4 horizontal.

I. Form Removal:

1. Remove forms after concrete has hardened sufficiently to resist damage from removal operations or lack of support.

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2. Where no reshoring is planned, leave forms and shoring used to support concrete until it has reached its specified 28-day compressive strength.

3.2 CONCRETE FINISHES

A. Tolerances:

1. Class A: 1/8 IN in 10 FT.

2. Class B: 1/4 IN in 10 FT.

B. Surfaces Exposed to View:

1. Provide a smooth finish for exposed concrete surfaces and surfaces that are:

a. To be covered with a coating or covering material applied directly to concrete.

b. Scheduled for grout cleaned finish.

2. Remove fins and projections, and patch voids, air pockets, and honeycomb areas with cement grout.

3. Cementitious concrete coating:

a. Form facing material shall produce a smooth, hard, uniform texture.

1) Use forms specified for surfaces exposed to view.

b. Prepare the surface in accordance with manufactures printed installation instructions.

c. Brush on coating to entire surface.

1) As a mixing liquid for the coating, use bonding agent and water mixture as recommended by the manufacture.

2) Apply two (2) coats at 2 LB/SQYD per coat.

d. When second coat is set, float to a uniform texture with a sponge coat.

e. Provide this finish at the following locations:

1) Walls, columns, exposed to view.

C. Surfaces Not Exposed to View:

1. Patch voids, air pockets and honeycomb areas with cement grout.

2. Fill tie holes with nonshrink, nonmetallic grout.

D. Slab Float Finish:

1. After concrete has been placed, consolidated, struck off, and leveled, do no further work until ready for floating.

2. Do not use water to aid in finishing.

3. Begin floating when water sheen has disappeared and surface has stiffened sufficiently to permit operation.

4. During or after first floating, check planeness of entire surface with a 10 FT straightedge applied at not less than two different angles.

5. Cut down all high spots and fill all low spots during this procedure to produce a surface within Class B tolerance throughout.

6. Refloat slab immediately to a uniform sandy texture.

E. Troweled Finish:

1. Float finish surface.

2. Next power trowel, and finally hand trowel.

3. Do not use water to aid in finishing.

4. Produce a smooth surface which is relatively free of defects with first hand troweling.

5. Perform additional trowelings by hand after surface has hardened sufficiently.

6. Final trowel when a ringing sound is produced as trowel is moved over surface.

7. Thoroughly consolidate surface by hand troweling.

8. Leave finished surface essentially free of trowel marks, uniform in texture and appearance and plane to a Class A tolerance.

9. On surfaces intended to support floor coverings remove any defects of sufficient magnitude that would show through floor covering by grinding.

F. Broom Finish: Immediately after concrete has received a float finish as specified, give it a transverse scored texture by drawing a broom across surface.

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3.3 GROUT

A. Preparation:

1. Nonshrinking, nonmetallic grout:

a. Clean concrete surface to receive grout.

b. Saturate concrete with water for 24 HRS prior to grouting.

B. Application:

1. Nonshrinking, nonmetallic grout:

a. Mix in a mechanical mixer.

b. Use no more water than necessary to produce flowable grout.

c. Place in accordance with manufacturer's instructions.

d. Completely fill all spaces and cavities below the bottom of baseplates.

e. Provide forms where baseplates and bedplates do not confine grout.

f. Where exposed to view, finish grout edges smooth.

g. Except where a slope is indicated on Drawings, finish edges flush at the baseplate, bedplate, member, or piece of equipment.

h. Protect against rapid moisture loss by covering with wet rags or polyethylene sheets.

i. Wet cure grout for seven days, minimum.

3.4 FIELD QUALITY CONTROL

A. Contractor will employ and pay for services of a concrete testing laboratory to perform testing of concrete placed during construction.

B. Tests During Construction:

1. Strength test:

a. For each strength test, mold and cure cylinders from each sample in accordance with

ASTM C31.

1) Cylinder size: Per ASTM C31.

a) 4 IN cylinders may not be used for concrete mixes with concrete aggregate size larger than 1 IN.

2) Quantity:

a) 6 IN DIA by 12 IN high: Four cylinders.

b) 4 IN DIA by 8 IN high: Six cylinders.

b. Field cure one (1) cylinder for the seven day test.

1) Laboratory cure the remaining.

c. Test cylinders in accordance with ASTM C39.

1) 6 IN DIA cylinders:

a) Test two cylinders at 28 days for strength test result and the one field cured sample at seven days for information.

b) Hold remaining cylinder in reserve.

2) 4 IN DIA cylinders:

a) Test three cylinders at 28 days for strength test result and the one field cured cylinder at seven days for information.

b) Hold remaining cylinders in reserve.

d. Strength test result:

1) Average of strengths of two 6 IN DIA cylinders or three 4 IN DIA cylinders from the same sample tested at 28 days.

2) If one cylinder in a test manifests evidence of improper sampling, molding, handling, curing, or testing, discard and test reserve cylinder(s); average strength of remaining cylinders shall be considered strength test result.

3) Should all cylinders in any test show any of above defects, discard entire test.

e. Frequency of tests:

a) One strength test to be taken not less than once a day, nor less than once for each 60 CUYD or fraction thereof placed in any one day.

b) Once for each 5000 SQFT of slab or wall surface area placed each day.

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c) If total volume of concrete on Project is such that frequency of testing required in above paragraph will provide less than five strength tests for each concrete mix, tests shall then be made from at least five randomly selected batches or from each batch if fewer than five batches are provided.

2. Slump test:

a. Per ASTM C143.

b. Determined for each strength test sample.

c. Additional slump tests may be taken.

3. Air content:

a. Per ASTM C231, ASTM C173, and ASTM C138.

b. Determined for each strength test sample.

4. Temperature: Determined for each strength test sample.

C. Evaluation of Tests:

1. Strength test results:

a. Average of 28-day strength of two cylinders from each sample.

1) If one cylinder manifests evidence of improper sampling, molding, handling, curing or testing, strength of remaining cylinder will be test result.

2) If both cylinders show any of above defects, test will be discarded.

D. Acceptance of Concrete:

1. Strength level of each type of concrete shall be considered satisfactory if both of the following requirements are met:

a. Average of all sets of three consecutive strength tests equals or exceeds the required specified 28-day compressive strength.

b. No individual strength test falls below the required specified 28-day compressive strength by more than 500 PSI.

2. If tests fail to indicate satisfactory strength level, perform additional tests and/or corrective measures as directed by Contracting Officer.

a. Perform additional tests and/or corrective measures at no additional cost to Owner.

E. Concrete tolerances per ACI 117.

3.5 SCHEDULES

A. Form Types:

1. Surfaces exposed to view:

a. Prefabricated or job-built wood forms.

b. Laid out in a regular and uniform pattern with long dimensions vertical and joints aligned.

c. Produce finished surfaces free from offsets, ridges, waves, and concave or convex areas.

d. Construct forms sufficiently tight to prevent leakage of mortar.

2. Surfaces normally submerged or not normally exposed to view: Wood or steel forms sufficiently tight to prevent leakage of mortar.

3. Other types of forms may be used:

a. For surfaces not restricted to plywood or lined forms.

b. As backing for form lining.

B. Grout:

1. Nonshrinking, nonmetallic grout: General use.

C. Concrete:

1. Normal weight concrete: All concrete.

D. Concrete Finishes:

1. Slab finishes:

a. Use following finishes as applicable, unless otherwise indicated:

1) Floated finish: Surfaces intended to receive roofing, concrete topping, lean concrete, concrete fill and waterproofing.

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2) Troweled finish: Interior floor slabs, exposed roof slabs and base slabs of structures, equipment bases, and column bases.

3) Broom finish: Sidewalks, docks, concrete stairs, and ramps.

END OF SECTION

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ANCHORAGE TO CONCRETE

SECTION 03 15 19

PART 1 - GENERAL

A. Keep the SUMMARY Article brief and stipulate Specification requirements in PART 2 and 3, not in this Article.

1.2 SUMMARY

1. Section Includes:

2. Requirements for all cast-in-place anchor bolts, anchor rods, reinforcing adhesive anchorage, and post-installed concrete anchors required for the Project but not specified elsewhere in the Contract Documents.

3. Design of all concrete anchors not indicated on the Drawings including, but not limited to, installation of anchors into concrete for the following structural and nonstructural components:

a. Structural members and accessories.

b. Metal, wood, and plastic fabrications.

c. Architectural components.

d. Mechanical and electrical equipment and components.

e. Plumbing, piping, and HVAC work.

f. All other components requiring attachment to concrete.

B. Related Specification Sections include but are not necessarily limited to:

1. Division 1 - Specification

2. Section 03 09 00 Concrete

1.3 QUALITY ASSURANCE

A. Referenced Standards:

1. American Concrete Institute (ACI):

a. 318, Building Code Requirements for Structural Concrete and Commentary.

2. American Concrete Institute/Concrete Reinforcing Steel Institute (ACI-CRSI):

a. Adhesive Anchor Installation Certification Program: Adhesive Anchor Installer.

3. American Institute of Steel Construction (AISC):

a. 303, Code of Standard Practice for Steel Buildings and Bridges.

4. ASTM International (ASTM):

a. A36, Standard Specification for Carbon Structural Steel.

b. A108, Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished.

c. A123, Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel

Products.

d. A153, Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware.

e. A307, Standard Specification for Carbon Steel Bolts and Studs, 60,000 PSI Tensile

Strength.

f. A496, Standard Specification for Steel Wire, Deformed, for Concrete Reinforcement.

g. A563, Standard Specification for Carbon and Alloy Steel Nuts.

h. A780, Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip

Galvanized Coatings.

i. F436, Standard Specification for Hardened Steel Washers.

j. F593, Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs.

k. F594, Standard Specification for Stainless Steel Nuts.

l. F1554, Standard Specification for Anchor Bolts, Steel, 36, 55, and 105-ksi Yield

Strength.

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m. F2329, Standard Specification for Zinc Coating, Hot-Dip, Requirements for

Application to Carbon and Alloy Steel Bolts, Screws, Washers, Nuts, and Special

Threaded Fasteners

5. ICC Evaluation Service (ICC-ES):

a. AC193, Acceptance Criteria for Mechanical Anchors in Concrete Elements.

b. AC308, Acceptance Criteria for Post-Installed Adhesive Anchors in Concrete

Elements.

6. Building code:

a. International Code Council (ICC):

1) International Building Code and associated standards, 2015 Edition including all amendments, referred to herein as Building Code.

B. Qualifications:

1. Anchor designer for Contractor-designed post-installed anchors and cast in place anchorage shall be a professional structural engineer licensed in the State that the Project is located in.

2. Installer for post-installed anchors shall be trained by the manufacturer or certified by a training program approved by the Contracting Officer.

C. Post-installed anchors and related materials shall be listed by the following agencies:

1. ICC-ES.

2. Engineer approved equivalent.

1.4 DEFINITIONS

A. Adhesive Anchors:

1. Post-installed anchors developing their strength primarily from chemical bond between the concrete and the anchor.

2. Includes anchors using acrylics, epoxy and other similar adhesives.

B. Anchor Bolt: Any cast-in-place anchorage that is made of a headed (i.e. bolt) material.

C. Anchor Rod: Any cast-in-place or post-installed anchorage made from unheaded, threaded, rod or deformed bar material.

D. Concrete Anchor: Generic term for either an anchor bolt or an anchor rod.

E. Galvanizing: Hot-dip galvanizing per ASTM A123, ASTM A153 or ASTM F2329 with minimum coating of 2.0 OZ of zinc per square foot of metal (average of specimens) unless noted otherwise or dictated by standard.

F. Hardware: As defined in ASTM A153.

G. Installer or Applicator:

1. Installer or applicator is the person actually installing or applying the product in the field at the Project site.

2. Installer and applicator are synonymous.

H. MPII: Manufacturer’s printed installation instructions.

I. Mechanical Anchors:

1. Post-installed anchors developing their strength from attachment other than thru adhesives or chemical bond to concrete.

2. Includes expansion anchors, expansion sleeve, screw anchors, undercut anchors, specialty inserts and other similar types of anchorages.

3. Drop-in anchors and other similar anchors are not allowed.

J. Post-Installed Anchor: Any adhesive or mechanical anchor installed into previously placed and adequately cured concrete.

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1.5 SUBMITTALS

A. Shop Drawings:

1. See Specification Section 01 33 23 for requirements for the mechanics and administration of the submittal process.

2. Product technical data including:

a. Acknowledgement that submitted products meet requirements of referenced standards.

b. Manufacturer material data sheet for each anchor.

1) Clearly indicate which products on the data sheet are proposed for use on the

Project.

c. Manufacturer's printed installation instructions.

d. Current ICC-ES report for each post-installed anchor system indicating the following:

1) Certification that anchors meet all requirements indicated in this Specification.

2) Performance data showing that anchor is approved for use in cracked concrete.

3) Seismic design categories for which anchor system has been approved.

4) Required installation procedures.

5) Special inspection requirements for installation.

e. Anchorage layout drawings and details:

1) Indicate anchor diameter, embedment, length, anchor type, material and finish.

2) Drawings showing location, configuration, spacing and edge distance.

f. Contractor Designed Post-Installed Anchors:

1) Show diameter and embedment depth of each anchor.

2) Indicate compliance with ACI 318, Chapter 17 Design tension and shear loads used for anchor design.

3) Engineering design calculations:

a) Indicate design load to each anchor.

b) When the design load is not indicated on Drawings, include calculations to develop anchor forces based on Design Criteria listed herein.

c) Sealed and signed by contractor’s professional structural engineer.

d) Calculations will be submitted for information purposes only.

4) Type of post-installed anchor system used.

a) Provide manufacturer's ICC-ES report for the following:

(1) Mechanical anchorage per ICC-ES AC193.

(2) Adhesive anchorage per ICC-ES AC308.

B. Samples:

1. Representative samples of concrete anchors may be requested by Contracting Officer.

Review will be for type and finish only. Compliance with all other requirements is exclusively the responsibility of the Contractor.

C. Informational Submittals:

1. See Specification Section 01 33 23 for requirements for the mechanics and administration of the submittal process.

2. Certification of qualifications for each installer of post-installed anchors.

a. Indicate successful completion or certification for each type of approved post-installed anchor as required by the Contract Documents.

b. Provide one of the following for each type of anchor, as required by this specification section:

1) Letter from manufacturer documenting successful training completion.

2) Certification of completion for Contracting Officer approved program.

1.6 DELIVERY, STORAGE, AND HANDLING

A. Deliver products to job site in manufacturer’s or distributor’s packaging undamaged and complete with installation instructions.

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B. Store above ground on skids or other supports to keep items free of dirt and other foreign debris and to protect against corrosion.

C. Protect and handle materials in accordance with manufacturer’s recommendations to prevent damage or deterioration.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Cast-in-place Concrete Anchors:

1. Building, nonbuilding structures, and equipment:

a. ASTM F1554, Grade 36 or Grade 55 with weldability supplement S1 for galvanized threaded rods.

b. ASTM A307, Grade A for galvanized headed bolts.

2. All other cast-in-place concrete anchors:

a. Stainless steel with matching nut and washer.

b. Submerged application: ASTM F593, Type 316.

c. Non-submerged application: ASTM F593, Type 304 or Type 316.

B. Post-Installed Mechanical and Adhesive Concrete Anchors:

1. Stainless steel with matching nut and washer.

2. Submerged application: ASTM F593, Type 316.

3. Non-submerged application: ASTM F593, Type 304 or Type 316.

4. Zinc coated carbon steel anchors with matching nut and washer.

C. Reinforcement: See Section 03 09 00.

D. Headed Studs: ASTM A108 with a minimum yield strength of 50,000 PSI and a minimum tensile strength of 60,000 PSI.

E. Deformed Bar Anchors: ASTM A496 with minimum yield strength of 70,000 PSI and a minimum tensile strength of 80,000 PSI.

F. Washers:

1. ASTM F436 unless noted otherwise.

2. If stainless steel anchorage is being used for cast-in-place anchorage, furnish washers of the same material and alloy as in the accompanying anchorage.

3. Plate washers: Minimum 3/4 IN thick fabricated ASTM A36 square plates as required.

4. Follow manufacturer’s requirements for all post-installed anchorage.

G. Nuts:

1. ASTM A563 for all cast-in-place anchorage.

2. If stainless steel anchorage is being used for cast-in-place anchorage, nuts shall meet ASTM

F594 and be the matching material and alloy as in the accompanying anchorage.

3. Follow manufacturer’s requirements if using post-installed anchorage.

H. Galvanizing Repair Paint:

1. High zinc dust content paint for regalvanizing welds and abrasions.

2. ASTM A780.

3. Zinc content: Minimum 92 PCT in dry film.

4. ZRC "ZRC Cold Galvanizing" or Clearco "High Performance Zinc Spray."

I. Dissimilar Materials Protection: Provide protection for dissimilar metals.

2.2 CONTRACTOR DESIGNED ANCHORAGE

A. Manufacturers:

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1. Post-installed anchor systems for the listed manufacturers will be considered only if a current ICC-ES evaluation report is submitted in accordance with the Submittals section 01

33 23 of this Specification Section and if the anchor system is approved by the Contracting

Officer.

a. Hilti.

b. Dewalt.

c. Simpson Strong-Tie.

2. Submit request for substitution in accordance with Specification Section 01 33 23.

B. Design the anchorage when any of the following occur:

1. Design load for concrete anchorage is shown on the Drawings.

2. When specifically required by the Contract Documents.

3. When an anchorage is required but not specified in the Drawings.

4. When anchorage is shown on Drawings other than Structural Drawings.

C. Anchorage Design Loads:

1. Determine all of the design loads, including wind and seismic loads, per the Building Code.

a. Anchorage of equipment and non-structural components: Use the actual dead and operating loads provided by the manufacturer.

D. When Contract Drawings, other than the Structural Drawings, indicate an anchor diameter or length, the Contractor design shall incorporate these as “minimums.”

E. Cast-in-Place Concrete Anchors:

1. Provide the material, nominal diameter, embedment length, spacing, edge distance and design capacity to resist the calculated load based on the requirements given in the Building

Code including ACI 318, Chapter 17.

2. Design assuming cracked concrete.

F. Post-installed Concrete Anchors:

1. Provide the manufacturer’s system name/type, nominal diameter, embedment depth, spacing, minimum edge distance, cover, and design capacity to resist the specified or calculated load based on requirements given in the Building Code, ACI 318 Chapter 17 and current ICC-ES report, for the anchor to be used.

2. Design assuming cracked concrete.

2.3 ENGINEER DESIGNED ANCHORAGE

A. When the size, length and details of anchorages are shown on Contract Structural Drawings, Contractor design of anchorage is not required unless otherwise indicated.

B. Manufacturers:

1. Additional newer post-installed anchor systems for the listed manufacturers will be considered only if a current evaluation agency report is submitted in accordance with the

SUBMITTALS Article in PART 1 of this Specification Section, the anchor system is certified by ICC-ES for cracked concrete conditions, and if approved by the Contracting

Officer.

2. Mechanical Anchors:

a. Hilti:

1) Kwik Bolt TZ (ICC-ES ESR-1917).

b. Dewalt:

1) Power-Stud+ SD1 (ICC-ES ESR-2818).

c. Simpson Strong-Tie:

1) Strong-Bolt 2 (ICC-ES ESR-3037).

3. Adhesive Concrete Anchors:

a. Hilti:

1) HIT RE 500 V3 (ICC ESR-3814).

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2) HIT-HY 200 (ICC-ES ESR-3187).

b. Dewalt:

1) PURE110+ (ICC-ES ESR-3298).

c. Simpson Strong-Tie: SET-XP (ICC-ES ESR-2508).

4. Submit request for substitution in accordance with Specification Section 01 33 23.

a. Substitution request to indicate the proposed anchor has the at least the same tension and shear strength as the specified anchor installed as indicated in the Contract

Drawings.

b. Calculations to be stamped by a Professional Engineer registered in the state that the

Project is located in.

PART 3 - EXECUTION

3.1 GENERAL

A. Cast-in-Place Anchorage:

1. Use where anchor rods or bolts are indicated on the Drawings, unless another anchor type is approved by the Contracting Officer

2. Provide concrete anchorage as shown on the Drawings or as required to secure components to concrete.

B. Adhesive Anchorage:

1. Use only where specifically indicated on the Drawings or when approved for use by the

Contracting Officer

2. May be used where subjected to vibration or where buried or submerged.

3. Do not use in overhead applications or sustained tension loading conditions such as utility hangers.

4. Contact Contracting Officer for clarification when anchors will not be installed in compliance with manufacturer's printed installation requirements.

C. Mechanical Anchorage:

1. Use only where specifically indicated on the Drawings or when approved for use by the

Contracting Officer

2. Do not use where subjected to vibration.

3. May be used in overhead applications.

4. Contact Contracting Officer for clarification when anchors will not be installed in compliance with manufacturer's printed installation requirements.

D. Do not use powder actuated fasteners and other types of bolts and fasteners not specified herein for structural applications unless approved by the Contracting Officer or specified in Contract

Documents.

3.2 PREPARATION

A. Provide adequate time to allow for proper installation and inspection prior to placing concrete for cast-in-place concrete anchorage.

B. Prior to installation, inspect and verify areas and conditions under which concrete anchorage is to be installed.

1. Do not proceed with work until unsatisfactory conditions have been corrected in a manner acceptable to the Contracting Officer.

C. Special Inspection is required in accordance with the Building Code for all concrete anchorage.

1. Notify the Special Inspector that an inspection is required prior to concrete placement (or during post-installed anchorage installation).

2. Refer to the Division 1 specification 01-40-00 for special inspection requirements.

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D. Post-installed anchor manufacturer’s representative shall demonstrate and observe the proper installation procedures for the post-installed anchors at no additional expense to the Owner.

1. Follow such procedures to assure acceptable installation.

2. Adhesive anchors must be installed in concrete aged a minimum of 21 days

3.3 INSTALLATION

A. Tie cast-in-place anchorage in position to embedded reinforcing steel using wire.

1. Tack welding of anchorage is prohibited.

2. Coat the projected portion of carbon steel anchors and nut threads with a heavy coat of clean grease after concrete has cured.

3. Anchorage location tolerance shall be in accordance with AISC 303.

4. Provide steel or durable wood templates for all column and equipment anchorage.

a. Templates to be placed above top of concrete and not impede proper concrete placement and consolidation.

B. Unless noted or specified otherwise:

1. Connect aluminum and steel members to concrete and masonry using stainless steel cast-in-place anchorage unless shown otherwise.

a. Provide dissimilar materials protection per Specification Section 09 96 00.

2. Provide washers for all anchorage.

3. Where exposed, extend threaded anchorage a maximum of 3/4 IN and a minimum of 1/2 IN above the top of the fully engaged nut.

a. If anchorage is cut off to the required maximum height, threads must be dressed to allow nuts to be removed without damage to the nuts.

C. Do the following after nuts are snug-tightened down:

1. If using post-installed anchorage, follow MPII.

2. Upset threads of anchorage to prevent nuts from backing off.

a. Provide double nut or lock nut in lieu of upset threads for items that may…