A06_Specifications_-_Pre-Cast_Concrete_Abutment.pdf

CHOH 241453

Seneca Pedestrian Bridge

SECTION 03 42 13.00 10 Page 2

DIVISION 03 - CONCRETE

SECTION 03 42 13.00 10

PRECAST CONCRETE BRIDGE ABUTMENTS

04/19

PART 1 GENERAL

REFERENCES

1.1 SUBMITTALS

1.2 QUALITY ASSURANCE

1.2.1 NPCA and ACPA Plant Certification

1.2.2 Qualifications, Quality Control and Inspection

1.2.2.1 Qualifications

1.2.2.2 Quality Control Procedures

1.2.2.2.1 Slump

1.2.2.2.2 Temperature

1.2.2.2.3 Compressive Strength

1.2.2.2.4 Air Content

1.2.2.2.5 Unit Weight

1.2.2.3 Inspection

1.2.2.4 Test Reports

1.2.2.4.1 Material Certifications or Laboratory Test Reports

1.2.2.4.2 Mix Test

1.2.2.4.3 Self-Consolidating Concrete

1.2.2.4.4 In-Plant QA/QC Inspection Reports

1.3 DELIVERY, STORAGE, AND HANDLING

1.3.1 Delivery

1.3.2 Storage

1.3.3 Handling

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

2.1.1 Custom-Made Precast Units

2.1.2 Joints and Sealants

2.1.3 Concrete Mix Design

2.1.3.1 Concrete Mix Proportions

2.1.3.2 Concrete Strength

2.1.3.3 Water-to-Cement Ratio

2.1.3.4 Air Content

2.2 MATERIALS

2.2.1 Pigments

2.2.2 Reinforcement

2.2.3 Inserts, Embedded Metal, & Bearing Accessories

2.2.4 Grout

PART 3 EXECUTION

3.1 FABRICATION AND PLACEMENT

3.1.1 Forms

3.1.2 Reinforcement

SECTION 03 42 13.00 10 Page 2

3.1.3 Embedded Items / Bearing Accessories

3.2 CONCRETE

3.2.1 Concrete Mixing

3.2.2 Concrete Placing

3.2.2.1 Cold Weather Concreting

3.2.2.2 Hot Weather Concreting

3.2.3 Concrete Curing

3.2.3.1 Curing by Moisture Retention

3.2.3.2 Curing with Heat and Moisture

3.2.4 Surface Finish

3.2.4.1 Formed Non-Architectural Surfaces

3.2.4.2 Unformed Surfaces

3.2.5 Stripping Products from Forms

3.2.6 Patching and Repair

3.2.6.1 Repairing Minor Defects

3.2.6.2 Repairing Honeycombed Areas

3.2.6.3 Repairing Major Defects

3.2.7 Shipping Products

3.3 INSTALLATION

3.3.1 Site Access

3.3.2 General Requirements

3.4 FIELD QUALITY CONTROL

3.4.1 Site Tests

-- End of Section Table of Contents --

SECTION 03 42 13.00 10 Page 12

PART 1 GENERAL

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN CONCRETE INSTITUTE (ACI)

ACI 211.1 (1991; R 2009) Standard Practice for Selecting Proportions for Normal, Heavyweight and Mass Concrete

ACI 211.2 (1998; R 2004) Standard Practice for Selecting Proportions for Structural Lightweight Concrete

ACI 305R (2010) Guide to Hot Weather Concreting

ACI 306.1 (1990; R 2002) Standard Specification for Cold Weather Concreting

ACI 318 (2014; Errata 1-2 2014; Errata 3-5 2015;

Errata 6 2016; Errata 7-9 2017) Building Code Requirements for Structural Concrete (ACI 318-

14) and Commentary (ACI 318R-14)

ACI 318M (2014; ERTA 2015) Building Code Requirements for Structural Concrete & Commentary

AMERICAN CONCRETE PIPE ASSOCIATION (ACPA)

ACPA QPC (202016) QCast Plant Certification Manual

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2015; Errata 1 2015; Errata 2 2016) Structural Welding Code - Steel

AWS D1.4/D1.4M (2011) Structural Welding Code - Reinforcing Steel

ASTM INTERNATIONAL (ASTM)

ASTM A153/A153M (2016) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware

ASTM A36/A36M (2014) Standard Specification for Carbon

SECTION 03 42 13.00 10 Page 12

Structural Steel

ASTM A615/A615M (2016) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

ASTM A706/A706M (2016) Standard Specification for Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement

ASTM A767/A767M (2016) Standard Specification for Zinc-Coated (Galvanized) Steel Bars for Concrete Reinforcement

ASTM A775/A775M (2017) Standard Specification for Epoxy- Coated Steel Reinforcing Bars

ASTM C1064/C1064M (2017) Standard Test Method for Temperature of Freshly Mixed Hydraulic-Cement Concrete

ASTM C1107/C1107M (2017) Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Nonshrink)

ASTM C138/C138M (2017a) Standard Test Method for Density (Unit Weight), Yield, and Air Content (Gravimetric) of Concrete

ASTM C143/C143M (2015) Standard Test Method for Slump of Hydraulic-Cement Concrete

ASTM C171 (2016) Standard Specification for Sheet Materials for Curing Concrete

ASTM C173/C173M (2016) Standard Test Method for Air Content of Freshly Mixed Concrete by the Volumetric Method

ASTM C192/C192M (2016a) Standard Practice for Making and Curing Concrete Test Specimens in the Laboratory

ASTM C231/C231M (2017a) Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method

ASTM C309 (2011) Standard Specification for Liquid Membrane-Forming Compounds for Curing Concrete

ASTM C31/C31M (2018b) Standard Practice for Making and Curing Concrete Test Specimens in the Field

SECTION 03 42 13.00 10 Page 12

ASTM C39/C39M (2018) Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

ASTM C858 (2010; E 2012) Standard Specification for Underground Precast Concrete Utility Structures

ASTM C920 (2018) Standard Specification for Elastomeric Joint Sealants

CSA GROUP (CSA)

CSA A23.4 (2016; Errata 2016) Precast Concrete - Materials and Construction

NATIONAL PRECAST CONCRETE ASSOCIATION (NPCA)

NPCA QC Manual (2017) Quality Control Manual for Precast and Prestressed Concrete Plants

1.1 SUBMITTALS

All submittals are the responsibility of the precast concrete producer. Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following:

SD-01 Preconstruction Submittals

Quality Control Procedures

SD-02 Shop Drawings

Custom-Made Precast Units; G

SD-03 Product Data Embedded Items & Accessories

SD-05 Design Data

Design Calculations; G Concrete Mix Proportions

SD-06 Test Reports

Test Reports

SD-07 Certificates

SECTION 03 42 13.00 10 Page 12

Quality Control Procedures

1.2 QUALITY ASSURANCE

Demonstrate adherence to the standards set forth in NPCA QC Manual or ACPA QPC. Meet requirements written in the subparagraphs below.

1.2.1 NPCA and ACPA Plant Certification

The precast concrete producer must be certified by the National Precast Concrete Association's or the American Concrete Pipe Association's Plant Certification Program prior to and during production of the products for this project.

1.2.2 Qualifications, Quality Control and Inspection

1.2.2.1 Qualifications

Select a precast concrete producer that has been in the business of producing precast concrete units similar to those specified for a minimum of 3 years. The precast concrete producer must maintain a permanent quality control department or retain an independent testing agency on a continuing basis.

1.2.2.2 Quality Control Procedures

Submit quality control procedures established by the precast manufacturer in accordance with NPCA QC Manual and ACPA QPC. Show that the following QC tests are performed as required and in accordance with the ASTM standards indicated.

1.2.2.2.1 Slump

Perform a slump test for each 150 cu yd of concrete produced, or once a day, whichever comes first. Perform slump tests in accordance with ASTM C143.

1.2.2.2.2 Temperature

Measure the temperature of fresh concrete when slump or air content tests are made and when compressive test specimens are made in accordance with ASTM C1064.

1.2.2.2.3 Compressive Strength

Make at least four compressive strength specimens for each 150 cubic yards of concrete of each mix in accordance with the following Standards: ASTM C31, ASTM C192, ASTM C39.

1.2.2.2.4 Air Content

Perform tests for air content on air-entrained, wet-cast concrete for each 150 cu yd of concrete, but not less often than once each day when air-entrained concrete is

SECTION 03 42 13.00 10 Page 12 used. Determine the air content in accordance with either ASTM C231 or ASTM C173 for normal weight aggregates and ASTM C173 for lightweight aggregates.

1.2.2.2.5 Unit Weight

Perform tests for unit weight a minimum of once per week to verify the yield of batch mixes. Perform unit weight tests for each 100 cu yd of lightweight concrete in accordance with ASTM C138.

1.3.2.3 Inspection

The Contracting Officer may place an inspector in the plant when the units covered by this specification are being manufactured. The precast concrete producer must give notice 14 days prior to the time the units will be available for plant inspection. Neither the exercise nor waiver of inspection at the plant will affect the Government's right to enforce contractual provisions after units are transported or erected.

1.3.2.4 Test Reports

Submit the following:

1.3.2.4.1 Material Certifications or Laboratory Test Reports

Include mill tests and all other test data, for portland cement, blended cement, pozzolans, ground granulated blast furnace slag, silica fume, aggregate, admixtures, and curing compound proposed for use on this project.

1.3.2.4.2 Mix Test

Submit reports showing that the mix has been successfully tested to produce concrete with the properties specified and will be suitable for the job conditions. Such tests may include compressive strength, flexural strength, plastic or hardened air content, freeze thaw durability, abrasion and absorption. Clearly detail in the specifications special tests for precast concrete or cast-in items.

1.3.2.4.3 Self-Consolidating Concrete

Submit sufficient documentation, when the use of self-consolidating concrete (SCC) is proposed, showing a minimum of 30-days production track records demonstrating that SCC is appropriate for casting of the product.

1.3.2.4.4 In-Plant QA/QC Inspection Reports

Submit inspection reports upon the request of the Contracting Officer.

1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 Delivery

SECTION 03 42 13.00 10 Page 12

Deliver precast units to the site in accordance with the delivery schedule to avoid excessive build-up of units in storage at the site. Upon delivery to the jobsite, all precast concrete units will be inspected by the Contracting Officer for quality and final acceptance.

1.4.2 Storage

Store units off the ground or in a manner that minimizes potential damage.

1.4.3 Handling

Handle, transport, and store products in a manner to minimize damage. Lifting devices or holes must be consistent with industry standards. Perform lifting with methods or devices intended for this purpose as indicated on shop drawings.

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

Furnish precast concrete units designed and fabricated by an experienced and acceptable precast concrete manufacturer who has been, for at least three years, regularly and continuously engaged in the manufacture of precast concrete work similar to that indicated on the drawings. Coordinate precast work with the work of other trades. Below grade structures must comply with ASTM C858.

2.1.1 Custom-Made Precast Units

Submit design calculations for custom-made precast units, prepared and sealed by a registered professional engineer in the State of Maryland, for approval prior to fabrication.

Design precast concrete units to withstand indicated design load conditions in accordance with applicable industry design standards ACI 318, AASHTO LRFD Bridge Design specifications, and other applicable codes. Design must also consider stresses induced during handling, shipping and installation as to avoid product cracking or other handling damage.

Include in the calculations the analysis of units for lifting stresses and the sizing of lifting devices. Submit drawings furnished by the precast concrete producer for approval by the Contracting Officer. Show on these drawings complete design, installation, and construction information in such detail as to enable the Contracting Officer to determine the adequacy of the proposed units for the intended purpose. Include details of steel reinforcement size and placement as well as supporting design calculations, if appropriate. Produce precast concrete units in accordance with the approved drawings.

2.1.2 Joints and Sealants

Provide joints and sealants between adjacent units of the type and configuration indicated on shop drawings meeting specified design and performance requirements.

2.1.3 Concrete Mix Design

2.1.3.1 Concrete Mix Proportions

SECTION 03 42 13.00 10 Page 12

Base selection of proportions for concrete on the methodology presented in ACI 211.1 for normal weight concrete and ACI 211.2 for lightweight concrete. Develop the concrete proportions using the same type and brand of cement, the same type and brand of pozzolan, the same type and gradation of aggregates, and the same type and brand of admixture that will be used in the manufacture of precast concrete units for the project. Do not use calcium chloride in precast concrete containing reinforcing steel or other embedded metal items. At a minimum of thirty days prior to precast concrete unit manufacturing, the precast concrete producer will submit a mix design and proportions for each strength and type of concrete that will be used. Furnish a complete list of materials, including quantity, type, brand and applicable data sheets for all mix design constituents as well as applicable reference specifications. The use of self-consolidating concrete is permitted, provided that mix design proportions and constituents meet the requirements of this specification.

2.1.3.2 Concrete Strength

Provide precast concrete units with a minimum 28-day compressive strength (f'c) of 4000 psi.

2.1.3.3 Water-to-Cement Ratio

Furnish concrete containing entrained air and with a water-cementitious ratio of 0.45 or less.

2.1.3.4 Air Content

The air content of concrete that will be exposed to freezing conditions must be within the limits given below.

AIR CONTENT PERCENT

NOMINAL MAXIMUM

AGGREGATE SIZE

EXPOSURE

CLASS F1

EXPOSURE

CLASSES F2

and F3 10 mm3/8 inch 6.0 7.5 13 mm1/2 inch 5.5 7.0 19 mm3/4 inch 5.0 6.0 25 mm1.0 inch 4.5 6.0 38 mm1.5 inch 4.5 5.5

Note: For specified compressive strengths greater than 34.5 MPa 5000 psi, air content may be reduced 1 percent

2.2 MATERIALS

2.2.1 Pigments

Non-fading and lime-resistant

2.2.2 Reinforcement

SECTION 03 42 13.00 10 Page 12

a. Deformed Billet-steel: Epoxy Coated in accordance with ASTM A775, Grade 60. Cut and bend steel in accordance with ASTM A706.

2.2.3 Inserts, Embedded Metal, and Bearing Accessories

All items embedded in concrete must be of the type required for the intended task, and meet the following standards.

a. Structural Steel Plates, Angles, etc.: ASTM A36/A36M

b. Hot-dipped Galvanized: ASTM A153/A153M

c. Proprietary Items: In accordance with manufacturers published literature

2.2.4 Grout

Nonshrink Grout must conform to ASTM C1107/C1107M. Cementitious grout must be a mixture of portland cement, sand, and water. Proportion one part cement to approximately

2.5 parts sand, with the amount of water based on placement method. Provide air entrainment for grout exposed to the weather.

PART 3 EXECUTION

3.1 FABRICATION AND PLACEMENT

Perform fabrication in accordance with NPCA QC Manual or ACPA QPC unless specified otherwise.

3.1.1 Forms

Use forms, for manufacturing precast concrete products, of the type and design consistent with industry standards and practices. They should be capable of consistently providing uniform products and dimensions. Construct forms so that the forces and vibrations to which the forms will be subjected can cause no product damage. Clean forms of concrete build-up after each use. Apply form release agents according to the manufacturers recommendations and do not allow to build up on the form casting surfaces.

3.1.2 Reinforcement

Follow applicable ASTM Standard or ACI 318 for placement and splicing. Fabricate cages of reinforcement either by tying the bars, wires or welded wire reinforcement into rigid assemblies or by welding, where permissible, in accordance with AWS D1.4. Position reinforcing as specified by the design and so that the concrete cover conforms to requirements. Provide concrete cover in accordance with ACI 318. Take positive means to assure that the reinforcement does not move significantly during the casting operations.

3.1.3 Embedded Items / Bearing Accessories

Position embedded items as required by the bridge abutment design. Perform welding in

SECTION 03 42 13.00 10 Page 12 accordance with AWS D1.1 when necessary. Hold rigidly in place inserts, plates, weldments, lifting devices and other items to be embedded in precast concrete products so that they do not move significantly during casting operations. Submit product data sheets and proper installation instruction for anchors, lifting inserts and other devices.

Clearly indicate the products dimensions and safe working load. All anchoring hardware and elastomeric bearing pads shall be designed, provided, & installed by the contractor.

Elastomeric joint sealants shall be provided, when necessary, in accordance with ASTM C920.

3.2 CONCRETE

3.2.1 Concrete Mixing

Mixing operations must produce batch-to-batch uniformity of strength, consistency, and appearance.

3.2.2 Concrete Placing

Deposit concrete into forms as near to its final location as practical. Keep the free fall of the concrete to a minimum. Consolidate concrete in such a manner that segregation of the concrete is minimized and honeycombed areas are kept to a minimum. Use vibrators to consolidate concrete with frequencies and amplitudes sufficient to produce well consolidated concrete.

3.2.2.1 Cold Weather Concreting

Perform cold weather concreting in accordance with ACI 306.1.

a. Provide adequate equipment for heating concrete materials and protecting concrete during freezing or near-freezing weather.

b. All concrete materials, reinforcement, forms, fillers, and ground with which concrete is to come in contact must be free from frost.

c. Do not use frozen materials or materials containing ice.

d. In cold weather the temperature of concrete at the time of placing must not be below 45 degrees F. Discard concrete that freezes before its compressive strength reaches 500 psi.

3.2.2.2 Hot Weather Concreting

Follow recommendations for hot weather concreting in ACI 305R. During hot weather, give proper attention to constituents, production methods, handling, placing, protection, and curing to prevent excessive concrete temperatures or water evaporation that could impair required strength or serviceability of the member or structure. The temperature of concrete at the time of placing must not exceed 90 degrees F.

3.2.3 Concrete Curing

SECTION 03 42 13.00 10 Page 12

Commence curing immediately following the initial set and completion of surface finishing.

3.2.3.1 Curing by Moisture Retention

Prevent moisture evaporation from exposed surfaces until adequate strength for stripping is reached by one of the following methods:

a. Cover with polyethylene sheets a minimum of 6 mils thick in accordance with

ASTM C171.

b. Cover with burlap or other absorptive material and keep continually moist.

c. Use a membrane-curing compound, conforming to ASTM C309 and applied at a rate not less than 200 square ft/gallon, or in accordance with manufacturers' recommendations.

3.2.3.2 Curing with Heat and Moisture

Do not subject concrete to steam or hot air until after the concrete has attained its initial set.

Apply steam, if used, within a suitable enclosure, which permits free circulation of the steam in accordance with CSA A23.4. If hot air is used for curing, take precautions to prevent moisture loss from the concrete. The temperature of the concrete must not be permitted to exceed 150 degrees F. These requirements do not apply to products cured with steam under pressure in an autoclave. Cure surfaces a minimum of 3 days. Forms should be considered effective in preventing evaporation from the contact surfaces. If air temperature is below 50 degrees F the curing period must be extended.

3.2.4 Surface Finish

Finish unformed surfaces of wet-cast precast concrete products as specified. If no finishing procedure is specified, finish such surfaces using a strike-off to level the concrete with the top of the form. Chamfer all exposed edges of concrete ¾ inch. Stain all exposed faces brown (samples to be provided to Contracting Officer for selection from manufacturer’s full range of colors).

3.2.4.1 Formed Non-Architectural Surfaces

Cast surfaces against approved forms following industry practices in cleaning forms, designing concrete mixes, placing and curing concrete. Normal color variations, form joint marks, small surface holes caused by air bubbles, and minor chips and spalls will be accepted but no major imperfections, honeycombs or other major defects will be permitted.

3.2.4.2 Unformed Surfaces

Finish unformed surfaces with a vibrating screed, or by hand with a float. Normal color variations, minor indentations, minor chips and spalls will be accepted. Major imperfections, honeycombs, or other major defects are not permitted.

SECTION 03 42 13.00 10 Page 12

3.2.5 Stripping Products from Forms

Do not remove products from the forms until the concrete reaches the compressive strength for stripping required by the design. If no such requirement exists, products may be removed from the forms after the final set of concrete provided that stripping damage is minimal.

3.2.6 Patching and Repair

No repair is required to formed surfaces that are relatively free of air voids and honeycombed areas, unless the surfaces are required by the design to be finished.

3.2.6.1 Repairing Minor Defects

Defects that will not impair the functional use or expected life of a precast concrete product may be repaired by any method that does not impair the product.

3.2.6.2 Repairing Honeycombed Areas

When honeycombed areas are to be repaired, remove all loose material and cut back the areas into essentially horizontal or vertical planes to a depth at which coarse aggregate particles break under chipping rather than being dislodged. Use proprietary repair materials in accordance with the manufacturer's instructions. If a proprietary repair material is not used, saturate the area with water. Immediately prior to repair, the area should be damp, but free of excess water. Apply a cement-sand grout or an approved bonding agent to the chipped surfaces, followed immediately by consolidating an appropriate repair material into the cavity.

3.2.6.3 Repairing Major Defects

Evaluate, by qualified personnel, defects in precast concrete products which impair the functional use or the expected life of products to determine if repairs are feasible and, if so, to establish the repair procedure.

3.2.7 Shipping Products

Do not ship products until they are at least five days old, unless it can be shown that the concrete strength has reached at least 75 percent of the specified 28-day strength, or that damage will not result, impairing the performance of the product.

3.3 INSTALLATION

3.3.1 Site Access

It is the Contractor's responsibility to provide adequate access to the site to facilitate hauling, storage and proper handling of the precast concrete products.

3.3.2 General Requirements

SECTION 03 42 13.00 10 Page 12

a. Install precast concrete products to the lines and grades shown in the contract documents or otherwise specified.

b. Lift products by suitable lifting devices at points provided by the precast concrete producer.

c. Install products in accordance with the precast concrete producer's instructions.

d. Field modifications to the product will relieve the precast producer of liability even if such modifications result in the failure of the product.

3.4 FIELD QUALITY CONTROL

3.4.1 Site Tests

Visual inspection will be accomplished on-site to ensure that no damage has occurred during shipping and delivery. Grades shall be checked and confirmed by the contractor, with documentation provided to the contracting officer, prior to final bridge placement.

-- End of Section --