A0003_Att_4_(Revised)_03_30_00___Cast-In-Place_Concrete_0003.pdf

Hyrum Dam Spillway Modifications Hyrum Project, Utah

Cast-In-Place Concrete

03 30 00 - 1

SECTION 03 30 00

CAST-IN-PLACE CONCRETE

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Cast-In-Place Concrete:

1. Measurement: Volume of concrete measured to structure neat lines shown on drawings.

a. Where concrete is placed on or against excavated surfaces, measurement will be made to lines for which payment for excavation is made.

b. Measurement of other concrete will be made to structure neat lines shown on drawings.

2. Payment: Unit price offered in Price Schedule A.

a. Includes:

1) Labor and materials for concrete.

2) Concrete forming for Cast-In Place Concrete.

B. Reinforced Structural Mass Concrete (RSMC):

1. Measurement: Volume of concrete measured to structure neatlines shown on drawings.

a. Where concrete is placed on or against excavated surfaces, measurement will be made to lines for which payment for excavation is made.

b. Measurement of other concrete will be made to structure neatlines shown on drawings.

c. Volume of openings, recesses, embedded pipes, and metalwork larger than

100 square inches in cross section will be deducted.

2. Payment: Unit price offered in Price Schedule A.

a. Includes:

1) Labor and materials for concrete.

2) Concrete forming for RSMC.

C. Spillway Test Section:

1. Payment: Lump-Sum price offered in Price Schedule A.

1) Labor and materials for concrete.

2) Includes concrete forming Spillway Test Section.

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D. Concrete for Mud Mat:

1. Measurement: Volume of concrete measured to structure neatlines shown on drawings.

2. Payment: Unit price offered in the Price Schedule.

a. Includes:

1) Labor and materials for concrete.

2) Includes forming for Mud Mat.

E.

1.02 ACRONYMS

A. NRMCA: National Ready Mixed Concrete Association

1.03 DEFINITIONS

A.

B. Shrinkage Reducing Admixture Concrete (SRA Concrete): Concrete with use of Shrinkage Reducing Admixture (SRA) to reduce material shrinkage due to drying.

Applicable concrete mix(es) in Table 03 30 00A - Concrete Mixes are identified as SRA Concrete in the Notes column.

C. Reinforced Structural Mass Concrete (RSMC): Placement greater than 3 feet in least direction. Specified requirements for RSMC lessen potentially detrimental thermal stresses from heat generated during curing.

D. Supplementary Cementitious Materials (SCM): Cementitious materials other than portland cement.

1.04 REFERENCE STANDARDS

A. American Concrete Institute (ACI)

1. ACI 201.2R-16 Guide to Durable Concrete

2. ACI 301-20 Structural Concrete

3. ACI 304R-00(2009) Guide for Measuring, Mixing, Transporting, and Placing Concrete

4. ACI 305.1-14(2020) Hot Weather Concreting

5. ACI 306.1-90(2002) Cold Weather Concreting

6. ACI 318-14 Building Code Requirements for Structural

Concrete

B. ASTM International (ASTM)

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1. ASTM C31/C31M-22 Making and Curing Concrete Test Specimens in the Field

2. ASTM C33/C33M-18 Concrete Aggregates

3. ASTM C39/C39M-21 Compressive Strength of Cylindrical

Concrete Specimens

4. ASTM C42/C42M-20 Obtaining and Testing Drilled Cores and

Sawed Beams of Concrete

5. ASTM C94/C94M-22a Ready-Mixed Concrete

6. ASTM C114-22 Chemical Analysis of Hydraulic Cement

7. ASTM C117-17 Materials Finer than 75-µm (No. 200) Sieve in Mineral Aggregates by Washing

8. ASTM C136/136M-19 Sieve Analysis of Fine and Coarse

Aggregates

9. ASTM C138/C138M-17a Density (Unit Weight), Yield, and Air

Content (Gravimetric) of Concrete

10. ASTM C143/C143M-20 Slump of Hydraulic-Cement Concrete

11. ASTM C150/C150M-22 Portland Cement

12. ASTM C157/C157M-17 Length Change of Hardened Hydraulic-

Cement Mortar and Concrete

13. ASTM C171-20 Sheet Materials for Curing Concrete

14. ASTM C231/C231M-22 Air Content of Freshly Mixed Concrete by the Pressure Method

15. ASTM C260/C260M-10a(2016) Air-Entraining Admixtures for Concrete

16. ASTM C309-19 Liquid Membrane-Forming Compounds for

Curing Concrete

17. ASTM C494/C494M-19e1 Chemical Admixtures for Concrete

18. ASTM C566-19 Total Evaporable Moisture Content of

Aggregates by Drying

19. ASTM C595/C595M-21 Blended Hydraulic Cements

20. ASTM C618-22e1 Coal Fly Ash and Raw or Calcined Natural

Pozzolan for Use in Concrete

21. ASTM C920-18 Elastomeric Joint Sealants

22. ASTM C989/C989M-22 Slag Cement for Use in Concrete and

Mortars

23. ASTM C1017/C1017M-13e1 Chemical Admixtures for Use in Producing

Flowing Concrete

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24. ASTM C1064/C1064M-17 Temperature of Freshly Mixed Hydraulic- Cement Concrete

25. ASTM C1260-22 Potential Alkali Reactivity of Aggregates (Mortar-Bar Method)

26. ASTM C1293-20a Determination of Length of Change of Concrete Due to Alkali-Silica Reaction

27. ASTM C1567-22 Determining the Potential Alkali-Silica Reactivity of Combination of Cementitious Materials and Aggregate (Accelerated Mortar-Bar Method)

28. ASTM C1602/C1602M-22 Mixing Water Used in the Production of Hydraulic Cement Concrete

29. ASTM D1751-18 Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types)

C. Bureau of Reclamation (USBR)

1. USBR M-47 Standard Specifications for Repair and

Maintenance of Concrete, August 2015 (Part 2 of “Guide to Concrete Repair” https://www.usbr.gov/tsc/techreferences/ma nds/mands-pdfs/Guide2ConcreteRepair2015_Final.pdf

2. USBR Concrete Manual Concrete Manual, Eighth Edition, Revised Reprint, 1981

D. U.S. Army Corps of Engineers (COE)

1. COE CRD-C 55-92 Within-Batch Uniformity of Freshly Mixed

Concrete

2. COE CRD-C 662-10 Determining the Potential Alkali-Silica

Reactivity of Combinations of Cementitious Materials, Lithium Nitrate Admixture and Aggregate (Accelerated Mortar-Bar Method)

E. International Concrete Repair Institute (ICRI)

1. ICRI 310.2-13 Selecting and Specifying Concrete Surface

Preparation for Sealers, Coatings, and Polymer Overlays and Concrete Repair https://www.usbr.gov/tsc/techreferences/mands/mands-pdfs/Guide2ConcreteRepair2015_Final.pdf https://www.usbr.gov/tsc/techreferences/mands/mands-pdfs/Guide2ConcreteRepair2015_Final.pdf https://www.usbr.gov/tsc/techreferences/mands/mands-pdfs/Guide2ConcreteRepair2015_Final.pdf

03 30 00 - 5

1.05 SUBMITTALS

A. Submit the following in accordance with Section 01 33 00 - Submittals.

B. RSN 03 30 00-1, Approval Data:

1. Mix Design: For each concrete mix.

a. Mixture proportions.

b. Material sources.

1) Name and manufacturer of each cementitious material.

2) Name of aggregate source(s).

3) Product name and manufacturer of admixtures to be used in mix.

a) Contain no purposefully added chlorides.

b) Chloride ion limits in accordance with ACI 201.2R.

c) Government reserves the right to require submission of samples of concrete materials for testing before or during use in concrete.

2. Physical properties:

a. Compressive strength: Test data shall meet the requirements of ACI 301, paragraph 4.2.3.4.

1) Field test data: Performed within past 24 months.

2) Trial mixtures:

a) Incorporate admixtures that will be used in production mixes into trial mixes.

b) Results from trial batches made within past 6 months.

c) Trial mix test results, three six-inch diameter cylinders each at 7, and 28, and 56 days.

d) Average compressive strength of trial batch cylinders at specified design age.

3) Shrinkage test results for SRA Concrete mix.

b. Resubmit mix design for change in material source or type.

3. Name and manufacturer of curing compounds, and joint filler.

a. Include application instructions for curing compound.

4. Certifications and test reports:

a. Sealed by Professional Engineer.

b. Less than 12 months old.

c. Certifications and test reports:

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1) Aggregate producer for:

a) ASTM C33 physical properties.

b) ASR testing reports for each aggregate source.

c) Less than 12 months old.

2) Mixing water: ASTM C1602.

d. Submittal of certifications and test reports shall not relieve Contractor of responsibility for furnishing materials meeting specified requirements.

C. RSN 03 30 00-2, Concrete Placement Drawings:

1. Drawings for individual concrete placements. More than one placement may be shown on a drawing.

a. An individual concrete placement is defined as a portion of concrete work placed in one continuous operation between specified lines or joints.

b. List contract drawing(s) from which details for placement were obtained.

c. Show locations, elevations, dimensions, blockouts, openings, recesses, waterstops, and finishes.

d. Show details of items embedded in or associated with placement except reinforcing steel. Include methods for securing against potential floatation of embedded items.

e. Reference related reinforcement drawing(s) associated with placement.

2. Include separate drawing(s) showing placement sequence.

3. A separate placement drawing must be submitted for each SJ, should the contractor elect to utilize the SJ options. See Section 01 14 12 – Work Restrictions and Limitations.

4. Identify proposed changes to joint locations.

5. Identify proposed additional joint locations.

D. RSN 03 30 00-3, Concrete Placement Schedule:

1. Complete, detailed concrete placement schedule showing plan for individual placements including placement of reinforcement and embedded items.

2. Detail as necessary to show location, sequence, and date of concrete placements scheduled for each item of concrete work.

3. If Contractor constructs an SJ, indicate their sequence on concrete placement schedule.

4. Show submittal schedule for placement and reinforcement drawings.

E. RSN 03 30 00-4, Plan for On-site Batch Plant(s):

1. Location, plan, and schematic drawing of on-site batch plant.

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a. Schematic drawing shall show:

1) Location of the principal components of the construction plant, and all offices and associated storage and Government and Contractor testing facilities.

2) General features of aggregate transporting; storage and reclaiming facilities; water storage; aggregate rinsing and unwatering plant;

coarse aggregate rescreening plant; concrete batching and mixing plant; batch water refrigeration and heating equipment; and concrete conveying and placing plan.

2. Peak capacity and anticipated daily production rate including aggregate transporting; volume of aggregate and cementitious material storage; concrete batching, mixing, transporting and placing in cubic yards per hour.

3. Description of methods for handling and storing aggregates and cementitious materials.

4. Description of methods to pre-cool aggregates in hot weather.

5. Describe facilities for sampling representative mix constituents and batched concrete at the on-site batch plant.

6. Resumes for on-site batch plant operator(s).

F. RSN 03 30 00-5, RSMC Temperature Control Plan:

1. Design temperature control plan using finite element type software capable of running thermal analysis to evaluate internal concrete temperature with ambient, construction, and foundational restraint influences. Stamp by Professional Engineer licensed in the United States.

2. Show location, sequence, and date of concrete placements scheduled for each RSMC designated structure.

a. Anticipated maximum temperature of concrete in each placement and methods used to calculate maximum temperature.

b. Methods used to control temperature, including anticipated duration and proposed termination criteria.

c. If internal cooling is used, include detailed cooling plan with at least the following.

1) Type, size, location, spacing, and diameter of cooling pipes; water cooling equipment; and flow.

2) Proposed method for abandoning cooling pipes including materials to be used to fill lines.

d. Identify how sequencing of adjacent RSMC placements will be determined.

3. Include name and manufacturer of temperature monitoring device, placement locations and temperature monitoring plan.

03 30 00 - 8

G. RSN 03 30 00-6, RSMC Temperature Readings.

1. Provide daily information to COR for review and written final report.

H. RSN 03 30 00-7, Certifications:

1. NRMCA Certification of Production Facilities. NRMCA certification shall be current and include automatic digital recording of cementitious materials, aggregate, water, and chemical admixtures. NRMCA certification shall be maintained throughout duration of project.

2. ACI Aggregate Testing Technician certifications.

3. ACI Concrete Flatwork Finisher certification(s).

4. ACI Concrete Field Testing Technician certifications.

5. ACI Concrete Strength Testing Technician certifications.

I. RSN 03 30 00-8, Pre-placement Inspection Placement Cards:

1. Prior to each placement, submit to COR, a placement card signed by authorized personnel, certifying that formwork, dimensions, reinforcing steel, embedments, RSMC temperature control (if specified) conform to project documents.

J. RSN 03 30 00-9, Test Reports:

1. Aggregate test results as required by Table 03 30 00B - Contractor Batch Plant

Quality Testing within 24 hours of completion of testing.

2. Concrete test reports as required by Table 03 30 00E- Contractor Field Quality

Testing within 24 hours of completion of testing.

K. RSN 03 30 00-10, Permission to use optional SJ

1. Contractor must request permission to use SJ before submitting any required SJ-related submittals.

1.06 QUALIFICATIONS

A. Ready Mix Plant: Currently certified by NRMCA. NRMCA certification shall include automatic digital recording of cementitious materials, aggregate, water, and chemical admixtures. Certification shall remain current for the duration of the project.

B. ACI Aggregate Testing Technician: Currently certified ACI Aggregate Testing Technician - Level 1.

C. ACI Concrete Flatwork Finisher: Currently certified as ACI Concrete Flatwork Finisher.

D. ACI Concrete Field Testing Technician: Currently certified ACI Concrete Field Testing Technician - Grade I.

E. ACI Strength Testing Technician: Currently certified ACI Strength Testing Technician.

03 30 00 - 9

F. On-site Batch Plant Operator: Minimum 5 years of experience operating a mobile batch plant.

1.07 DELIVERY, STORAGE, AND HANDLING

A. Furnish legible and digitized batch ticket with each batch of concrete in accordance with ASTM C94. Deliver ticket to COR at jobsite during batch delivery.

B. Sponge Rubber Joint Filler Storage:

1. Store in protected area at temperature of 70 degrees F (21 degrees C) or less.

2. Do not expose to direct sun.

1.08 PRE-PLACMENT MEETING

A. At least 14 days before each of the placements below, meet with COR for pre-placement meeting.

1. first concrete placement for the spillway test section,

2. first inlet placement,

3. first crest slab placement,

4. first ogee placement,

5. first crest wall placement,

6. first upper transition placement,

7. first chute placement,

8. first lower transition placement,

9. if Contactor chooses to utilize the SJ, any SJ placement,

10. first stilling basin placement.

B. Coordinate time and place of pre-placement meeting with COR at least 14 days before meeting.

C. Contractor attendees shall be at least the following:

1. Contractor onsite supervisor.

2. Concrete forming, placing, and finishing onsite supervisor(s); Contractor or subcontractor(s) employee as applicable.

3. Technical specialist from ready-mix supplier.

4. Concrete pump subcontractor onsite supervisor, if applicable.

5. Testing agency onsite supervisor(s).

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PART 2 PRODUCTS

2.01 CEMENTITIOUS MATERIALS

A. Portland Cement:

1. ASTM C150, Type II.

a. Meet equivalent alkalies (Na2O + 0.658K2O) of 0.60% maximum.

1) Low-alkali limitation for portland cement may be waived when tests of concrete aggregate source show that low-alkali cement is not required for ASR mitigation. See Concrete Aggregate Materials article (2.03).

b. Meet false-set requirements of ASTM C150 - Table 4.

B. Blended Hydraulic Cement: ASTM C595, Type IP, IS, IL or IT

1. Contain maximum 0.60% equivalent alkalies. Alkali content shall be reported.

C. SCM:

1. Pozzolan:

a. ASTM C618, Class F or N.

1) Except:

a) Sulfur trioxide, maximum: 4.0 percent.

b) Loss on ignition, maximum: 2.5 percent.

2) In addition:

a) Calcium oxide, maximum: 8.0 percent.

b) Pozzolan will have an "R" factor less than 2.5. Pozzolan with this "R" factor will not decrease sulfate resistance of concrete.

i. R: (C-5)/F.

ii. C: Calcium oxide content of pozzolan in percent determined in accordance with ASTM C114.

iii. F: Ferric oxide content of pozzolan in percent determined in accordance with ASTM C114.

2. Slag Cement:

a. ASTM C989, Grade 100 or 120.

2.02 WATER

A. ASTM C1602, including optional requirements of Table 2.

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2.03 AGGREGATE MATERIALS

A. Fine Aggregate: ASTM C33.

1. Percent Material Passing No. 200 Sieve: Less than 3 percent.

B. Coarse Aggregate: ASTM C33, Class 4S, Size No. specified in Table 03 30 00A - Concrete Mixes.

C. Stockpiles:

1. Prior to placing spillway concrete, stockpile on site a minimum of one-half the fine aggregate and one-half the coarse aggregate needed to complete spillway construction.

2. If a concrete pad is not used under the stockpiles, it is acceptable to use a 6-inch minimum base of stockpiled material extending below the grade at which the loader bucket will operate. The base will not be counted as stockpiled material for production.

3. Protect aggregate stockpiles containing free water from freezing.

a. Screen out frozen materials prior to use to remove frozen particles.

b. Fine aggregate containing particles frozen together will be rejected.

D. Alkali Silica Reaction (ASR).

1. Test fine and coarse aggregates in accordance with ASTM C1260 for potential deleterious alkali-silica reaction.

a. For ASTM C1260, and other tests when required, continue readings for 28 days after the zero readings.

b. Acceptance criteria specified below are based on 28-day readings after the zero readings.

c. Expansion is no greater than 0.10 percent:

1) Aggregates are acceptable.

d. Expansion is greater than 0.10 percent:

1) Test aggregates according to ASTM C1567 using proposed components (e.g. coarse aggregate, fine aggregate, cementitious materials, and Alkali Silica Reaction (ASR) inhibiting admixtures) in proportions proposed for mixture design.

a) For mixes using lithium admixtures use test procedure COE

CRD-C 662.

b) Expansion of proposed mixture design test specimens, tested in accordance with ASTM C1567 does not exceed

0.10 percent:

i. Aggregates are acceptable.

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c) Expansion of proposed mixture design test specimens is greater than 0.10 percent:

i. Aggregates are not acceptable unless adjustments to mixture design can reduce expansion to less than

0.10 percent, or testing by ASTM C1293 indicates aggregates will not experience deleterious expansion.

2. ASTM C1293 test results may be substituted for ASTM C1260 test results:

a. Less than 3 years old.

b. Average ASTM C1293 concrete prism expansion less than 0.04 percent at one year: Aggregates acceptable.

c. Average ASTM C1293 concrete prism expansion greater than 0.04 percent at one year: Aggregates not acceptable.

3. Appropriate for use in accordance with ASTM C295.

2.04 ADMIXTURES

A. Air-entraining Admixture: ASTM C260.

B. Chemical Admixtures:

1. Do not use chemical admixtures which contain more than 0.1-percent chloride, by weight.

2. Admixtures shall be compatible with each other.

3. Allowable Chemical Admixtures:

a. ASTM C494, Type A, D, F, G, or S.

b. ASTM C1017, Type I or II.

c. ASTM C494, Type C and E, provided they do not contain chlorides.

C. Specialized Chemical Admixtures:

1. When the batch plant has not previously used a specialized chemical admixture, the admixture manufacturer shall provide an on-site representative to assist with mix design and to train batch plant personnel in dispensing and mixing operations.

2. Do not use specialized chemical admixtures which contain more than 0.1-percent chloride, by weight.

3. Shrinkage Reducing Admixture (SRA):

a. Shrinkage reducing admixture conforming to ASTM C494, Type S.

b. Provides a length change not exceeding 0.036 percent when tested in accordance with ASTM C157.

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4. Alkali Silica Reaction (ASR) Inhibiting Admixture:

a. Lithium Nitrate Admixture for ASR mitigation of reactive aggregates having the following characteristics:

1) Meets NSF/ANSI 61.

2) Nominal 30 percent aqueous solution of Lithium Nitrate:

a) Density: 10 pounds/gallon (1.2 kg/L).

b) Approximate chemical constituents (percent by mass):

i. LiNo3 (Lithium Nitrate): 30 plus or minus 0.5.

ii. SO4-2 (Sulfate Ion), maximum: 0.1.

iii. Cl- (Chloride Ion), maximum: 0.2.

iv. NA+ (Sodium Ion), maximum: 0.1.

v. K+ (Potassium Ion), maximum: 0.1.

b. Coordinate with manufacturer regarding Lithium Nitrate dosage.

c. Do not use Lithium Nitrate Admixture for concrete in continuous or nearly continuous contact with water.

5. Extended Set Control Admixture:

a. MasterSet Delvo hydration controlling admixture manufactured by Master Builders Solutions. www.master-builders-solutions.com; or equal, with the following essential characteristics:

1) Meets ASTM C494, Type B.

2) Retards setting.

3) Does not reduce concrete strength.

b. Use within manufacturer’s time limits.

c. Dispense admixture in presence of COR. Include admixture on the batch ticket.

d. Admixture quantity required to stabilize concrete shall be pre-determined using jobsite materials. Initial concrete setting time shall be monitored and adjusted during the project by a qualified concrete technician.

2.05 CURING MATERIALS

A. Water: ASTM C1602, including optional requirements of Table 2.

B. Curing Compound: ASTM C309, Type 1 or 1-D, Class B:

1. Capable of meeting moisture retention at manufacturer’s application rate.

2. Meet Federal, state, and local regulations for VOCs.

http://www.master-builders-solutions.com/

03 30 00 - 14

C. Sheet Materials:

1. Polyethylene Film: ASTM C171, clear.

2.06 ACCESSORIES

A. Sponge rubber joint filler:

1. ASTM D1752, Type I, except:

a. Test specimen compression load: 50 to 150 lb/in2.

2. Joint filler adhesive: Non-bituminous adhesive recommended by filler manufacturer.

B. Elastomeric Sealant: ASTM C920, polyurethane, Use M, Grade NS, Class 25.

C. Temperature Monitoring Devices for Monitoring RSMC Placements:

1. Measuring Device: Thermocouple, thermistor, or Resistant Temperature Device

(RTD).

a. Operating range: 14 degrees F to 185 degrees F.

b. Accuracy: 1.8 degrees F (1 degree C) or better.

2. Recording Device:

a. Record temperature as a function of time.

b. Records temperature at least once per hour and the max/min over a 24-hour period can be obtained.

c. Records data in digital format.

D. Evaporation Control:

1. MasterKure® ER 50 manufactured by Master Builders Solutions, Incorporated, www.master-builders-solutions.com; or equal having the following essential characteristics:

a. Monomolecular film forming compound applied to exposed concrete slab surfaces for temporary protection from rapid moisture loss.

b. For application after finishing and prior to applying curing compound.

c. For use when the evaporation rate is high.

2. Do not use as a finishing aid or work into surface.

2.07 MIX

A. The Contractor shall design and adjust concrete mix.

1. The Government reserves the right to adjust mix proportions when adjustment is indicated by results of materials testing.

http://www.master-builders-solutions/

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a. When required, adjustment of mix proportions by the Government will be in accordance with USBR Concrete Manual.

B. Cementitious Materials Options:

1. Specified portland cement plus specified pozzolan by percent weight specified in

Table 03 30 00A - Concrete Mixes.

2. Specified portland cement plus specified slag cement by percent weight specified in Table 03 30 00A - Concrete Mixes.

3. Blended Hydraulic: ASTM C595 provided, specified portland cement with percent of specified pozzolan or specified slag cement specified in Table 03 30 00A - Concrete Mixes.

C. Design concrete mixes in accordance with Table 03 30 00A - Concrete Mixes. General concrete mix shall be used for concrete unless otherwise specified.

1. Net water-cementitious materials ratio (w/c) is maximum, by weight.

Cementitious material weight is cement plus SCM.

2. Slump at Point of Placement: In accordance with ASTM C143.

3. Air Entrainment: Percent air by volume of concrete as discharged at point of placement, in accordance with ASTM C231.

Table 03 30 00A - Concrete Mixes

Mix No Feature f’c (pounds per square inch)

Max w/c* NMSA**

Percent

SCM***

A: Class F Pozzolan

B: Slag Cement C: Silica Fume

Slump or

Slump flow

Air Content Notes

1 General & Exterior

Structural Concrete:

Other concrete not specified

4500 at 28 days

0.45 No. 57 or

A or B: 20 plus or minus 5

2 to 4 4.5 to 7.5 1, 2

2 High Slump Structural Concrete

4500 at 28 days

0.45 No. 57 or

A or B: 20 plus or minus 5

4 to 7 4.5 to 7.5 1, 2

3 Interior Slabs (Not RSMC)

4500 at 28 days

0.45 No. 57 or

A or B: 20 plus or minus 5

2 to 4 n/a 1, 2

4 RSMC 4500 at 56 days

0.45 No. 467 A: 35 plus or

minus 10 or B: 50 to 80

1 to 3 4 to 6 1,3,4

5 RSMC:

Crest

Structure Slabs

4500 at 56 days

0.45 No. 467 A: 35 plus or

minus 10 or B: 50 to 80

1 to 3 4 to 6 1,3,4

03 30 00 - 16

Table 03 30 00A - Concrete Mixes

Mix No Feature f’c (pounds per square inch)

Max w/c* NMSA**

Percent

SCM***

A: Class F Pozzolan

B: Slag Cement C: Silica Fume

Slump or

Slump flow

Air Content Notes

6 Grout for Rip Rap

4000 at 28 days

0.50 No. 8 A: 20 plus or

minus 5

B: 30 plus or minus 10

5 to 9 4.5 to 7.5 1, 2

*Maximum water/cementitious materials ratio.

**Nominal Maximum Size Aggregate.

*** SCM as percent of total cementitious material, by weight.

NOTES:

1 Ternary blended cementitious materials which meet the specifications may be submitted for approval.

2 Concrete with ASTM C1017, Type I or II plasticizing admixtures, ASTM C494 Type F high-range water-reducing admixtures, or Type G high-range water-reducing and retarding admixtures:

i. - Admixture shall be incorporated into trial batch or historical data.

ii. - Use slump appropriate for placing conditions.

3 RSMC requires temperature control measures.

4 SRA required. Shrinkage test results shall be submitted with mix design. Test mix in accordance with

ASTM C157.

D. Prepare design mixes for each type and strength of concrete by either laboratory trial batch or field performance methods as specified in ACI 301. For the trial batch method, mix shall be proportioned and stamped by a professional engineer.

E. Concrete Trial Mixes:

1. Average Compressive Strength of Trial Batch Cylinders at Design Age: Design strength plus 1,200 lbs/in2 for concrete between 3,000 and 5,000 psi or field data meeting the over design requirements of ACI 318.

2. Admixtures to be used in mix shall be incorporated into mix design submitted for approval.

3. Air Content: Within 1-percent of top of specified range.

4. Slump: Within 1 inch of top of specified range.

5. When SRA Required:

a. Mortar and concrete tested in accordance with ASTM C157 except:

length change shall not exceed 0.036 percent after 7 days of moist curing followed by 28 days of air drying.

2.08 BATCHING, MIXING, AND TRANSPORTING

A. Batch plant shall be currently NRMCA certified with automatic digital recording of cementitious materials, aggregate, water, and chemical admixtures.

03 30 00 - 17

B. Contractor’s On-Site Batch plant:

1. Currently NRMCA certified with automatic digital recording of cementitious materials, aggregate, water, and chemical admixtures.

2. Batch plant shall be located on-site in accordance with RSN 03 30 00-5. Location shall be approved by the COR prior to setup and production.

3. Equipment performance requirements:

a. Batching and mixing rated capacity:

1) Minimum 200 cubic yards per hour.

2) If the Contractor's batching, mixing, and delivery equipment fails to meet the required placing rate, the Contractor shall make any necessary improvements, including but not limited to adding additional mixing or batching equipment to meet the required capacities.

b. Provide, maintain, and operate batching equipment to accurately measure and control the prescribed amounts of the various materials entering the mixers.

c. Maintain in a clean and freely operating condition.

d. Mixer blades shall be replaced when worn down more than 10 percent of original manufacture.

4. Material Storage

a. Provide separate bins or compartment for each size group of aggregate and each cementitious material.

b. Water Storage: Provide sufficient water storage for batching concrete, washing aggregate, and concrete curing.

5. Finish screening:

a. Use potable water for wash water.

b. Locate finish screens so that screen vibration is not transmitted to batching bins or scales and does not affect accuracy of weighing equipment.

c. Do not allow wash water to enter batching bins or weighing hoppers.

d. Finish screen coarse aggregate on multideck vibrating screens capable of simultaneously removing undersized and oversized aggregate from each of the nominal aggregate sizes.

e. If aggregate moisture content varies during intermittent batching, use a dewatering screen after finish screens to remove excess free moisture.

f. Do not overload screens.

g. Finish screen:

1) Finished product shall meet specified gradation.

03 30 00 - 18

2) Avoid segregation and breakage.

3) Feed coarse aggregate to finish screens in a combination or alternation of nominal sizes which will not cause noticeable accumulation of poorly graded coarse aggregate in any batching bin.

4) Minus 3/16-inch material passing through the finish screens shall be wasted or routed back through a sand classifier for uniform blending with the sand being processed.

h. Just prior to batching, wash coarse aggregate by pressure spraying using adequate water nozzles and vibrating screens to remove foreign materials and coatings from aggregate.

i. Water from finish screening shall be drained in such a manner as to prevent wash water from entering the batching bins and weighing hoppers.

j. Washing and finish screening equipment shall be subject to approval by the COR.

C. Manufacture and deliver in accordance with ASTM C94 and ACI C304R.

1. Prepare batch ticket in accordance with ASTM C94 for every batch of concrete.

D. Cold Weather: When air temperature has fallen to or is expected to fall below 40 degrees F, prepare ingredients and mix in accordance with ACI 306.1.

1. Do not use frozen materials or materials containing ice or snow.

2. Uniformly heat water and aggregates before mixing to obtain a concrete mixture temperature of not less than 50 degrees.

E. Hot Weather: When precautions are necessary, prepare ingredients and mix in accordance with ACI 305.1.

1. Cool ingredients before mixing to maintain specified maximum concrete temperature at time of placement.

2. Mixing water may be chilled or chopped ice may be used to control temperature, provided water equivalent of ice is calculated to total amount of mixing water.

Ice replacing batch water shall be melted prior to discharge.

3. Using liquid nitrogen to cool concrete is Contractor’s option with approval from

COR.

F. Prevent appreciable segregation of ingredients.

G. Place concrete within 90 minutes from introduction of cement to water or aggregates.

1. For placing times exceeding 90 minutes, extended set control admixtures may be used when approved by COR.

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2.09 CONCRETE TEMPERATURE

A. Concrete Temperature at Placing:

1. Concrete other than RSMC: 50 to 90 degrees F (10 to 32 degrees C).

2. RSMC: 50 to 70 degrees F (10 to 21 degrees C).

a. Unless superseded by approved Temperature Control Plan.

2.10 CONTRACTOR QUALITY TESTING

A. Contractor shall perform sampling, testing, and reporting as required in Table 03 30 00B

- Batch Plant Testing.

1. Independent testing agency shall meet requirements specified in Section 01 46 20

– Testing Agency Services.

2. Personnel conducting tests under this section: Qualified as ACI Aggregate

Testing Technician, Level 1; or equal.

B. Perform tests at least as often as the frequencies specified in Table 03 30 00B - Batch Plant Testing.

C. Notify COR immediately of test results showing failure of materials to meet specifications. Provide test results to COR within 24 hours. Submit reports of test results as specified.

D. If on-site batch plant is used, Contractor shall perform Mixer Uniformity Testing in the presence of the COR.

1. Mixer Uniformity Testing:

a. Stationary Mixers:

1) Adjust batch size, mixing time, charging sequence, and other factors identified by the contractor to provide concrete that meets the uniformity limits specified.

2) Tests shall be performed on three batches of concrete.

3) The concrete shall meet the limits of any five of the six uniformity requirements.

4) Concrete proportions used for the evaluation shall contain the largest size aggregate on the project.

5) Testing shall consist of performing all six tests per Table 03 30

00B – Mixer Uniformity Tests on three batches of concrete.

6) The range for testing shall be the average of the ranges of the three batches.

7) If more than one mixer is used and all are identical in terms of make, type, and capacity, condition, speed of rotation, etc., the

03 30 00 - 20 results of the tests on one of the mixers shall apply to the others, subject to approval.

Table 03 30 00B- Mixer Uniformity Tests

Parameter Tests Allowable Maximum Range for Average of 3 Batches

Unit weight of air-free mortar, lb/cu ft 2.0 Air content, percent 1.0 Slump, inches 1.0 Coarse Aggregate, percent 6.0 Compressive strength at 7 days, percent 7.5 Water Content, percent 1.5

Table 03 30 00C- Mixer Uniformity Frequency

Tests Of Test Standard Standard Title Requirement Testing Frequency

Mixer Uniformity Testing

COE CRD-C 55 Within-Batch Uniformity of Freshly Mixed Concrete

Verify uniformity of distribution of constituents with a batch of freshly mixed hydraulic-cement concrete.

At batch plant commissioning or when a major change in mixer equipment occurs.

2.11 GOVERNMENT CONTRACT QUALITY ASSURANCE - SOURCE

A. In addition to specified Contractor Quality Testing, the Government may also perform the tests listed in Table 03 30 00B - Batch Plant Testing.

2.12 BATCH PLANT TESTING

Table 03 30 00B- Batch Plant Testing

TESTS OF TEST

STANDARD

STANDARD TITLE REQUIREMENT TESTING FREQUENCY

Aggregate Gradation

ASTM C136 Sieve Analysis of Fine and Coarse Aggregates

Fine and Coarse Aggregate meets sizing requirements per

ASTM C33.

At beginning of placing each mix.

At change in mix design.

At least every 500 yd3 of placing a mix.

Aggregate Fines content

ASTM C117 Materials Finer than 75-μm (No. 200) Sieve in Mineral Aggregates by Washing

Fine aggregate meet specified allowable fines content (material passing No. 200 sieve)

At beginning of placing each mix.

At change in mix design.

At least every 500 yd3 of placing a mix.

03 30 00 - 21

Table 03 30 00B- Batch Plant Testing

TESTS OF TEST

STANDARD

STANDARD TITLE REQUIREMENT TESTING FREQUENCY

Aggregate moisture content

ASTM C566 Total Evaporable Moisture Content of Aggregate by Drying

Verify that moisture meter at batch plant is accurate with the material batched.

At beginning of placing each mix.

At change in mix design.

At least every 500 yd3 of placing a mix.

PART 3 EXECUTION

3.01 PREPARATION

A. Remove standing water, mud, and debris from foundation surfaces to be covered by concrete.

B. Prepare rock surfaces free from oil, objectionable coatings, and loose, semidetached, and unsound fragments. Immediately before placement of concrete, wash rock surfaces with an air-water jet and dry to a uniform surface-dry condition.

C. Prepare earth foundations free from frost or ice.

D. Thoroughly moisten surfaces of absorptive foundations to be covered with concrete so that moisture will not be drawn from fresh concrete. Keep subgrade moisture uniform without puddles or dry areas.

E. Clean, roughen, and surface dry surfaces of construction joints to be covered with fresh concrete.

1. Remove laitance, loose or defective concrete, coatings, sand, curing compound, and other foreign material.

2. Sandblast, steel shotblast, or high-pressure water jet surfaces, or use other method approved by COR to create a surface equivalent to or larger than CSP 5 in accordance with ICRI 310.2.

3. Wash surface thoroughly, and surface dry immediately before placement of adjoining concrete.

3.02 TEMPERATURE CONTROL OF RSMC

A. Design RSMC Temperature Control Plan for:

1. Maximum temperature of 155 degrees F in concrete during curing and protection.

2. Maximum temperature differential of 35 degrees F between the center of the thickest section and the outside face furthest from the center.

03 30 00 - 22

3. Installation and monitoring of at least 2 monitoring devices for every 150 cubic yards of concrete placed in one placement period (day) or each individual placement at each of the following locations:

a. At the center of the thickest sections.

b. Along the coolest anticipated concrete face(s) at a depth of 1-1/2 inches from the surface as approved by the COR.

4. Monitor ambient temperature near placement location for RSMC Temperature

Control Plan specified duration.

B. Install temperature monitoring devices prior to placement according to approved RSMC Temperature Control Plan.

C. Continually record temperature readings until temperature differentials are within limits outlined in approved RSMC Temperature Control Plan or concrete core temperature is within 35 degrees F of daily low temperature. Temperature information in digital format shall be available to COR daily.

D. Maintain specified temperature differential between temperature monitoring devices at the center of the thickest section and the outside face.

1. Insulate concrete with blankets or other approved insulation as necessary.

2. Do not discontinue temperature monitoring or remove insulation until temperature at the outside face is within 35 degrees F of the lowest ambient temperature in a 24-hour period.

3. Internally cool concrete as necessary in accordance with approved temperature control plan.

4. Evaluate temperature records daily and adjust temperature control methods as necessary.

E. If internal concrete temperatures or concrete temperature differentials exceed specified limits, revise RSMC Temperature Control Plan and resubmit for approval prior to further placements.

3.03 CONCRETE TEST SLAB AND WALLS (FURTHERMORE REFERENCED AS

THE “SPILLWAY TEST SECTION”

A. Provide COR at least 28-day advance notice of placing concrete. Provide COR at least 5-day advance notice of demolition concrete.

B. Contractor is responsible for demolition and disposal of Spillway Test Section upon authorization to do so from the COR.

C. Batch concrete in presence of COR.

D. Construct test slab in presence of COR.

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E. Admixtures added on site shall be in the presence of and as approved by COR.

F. Acceptance:

1. The Contractor shall not commence construction of spillway prior to acceptance of the test slab by the COR.

2. The COR will determine when the contractor has demonstrated successful completion of the test slab. Acceptance will be dependent on the quality of the test slab construction, including concrete field testing, curing, and final finish.

3. Acceptance of the test slab does not imply acceptance of floor slab placements.

Each floor slab shall meet the requirements of the specifications and be accepted by the COR.

G. Location: As determined by the COR. Must be on a slope equal to or greater than the slab slope at station 10+57.50.

H. The spillway test section will be detailed similar to the crest section between stations 3+25.00 and 3+35.00. Size: Test slab size and geometry shall be 20.0 feet in the stream direction (including one properly detailed joint in the center modeled after the joint at station 3+29.50) and 40.0 feet perpendicular to the spillway alignment (including one properly detailed joint in the center modeled after the joint at Station 3+29.50) and 6.25 feet thick, as approved by the COR. The slab shall be constructed on a minimum 3-inch-thick mudmat that matches or exceeds the extents of the spillway test section. The walls of the test slab shall match the batter of station 3+25 and a minimum height 3 feet. To ensure that the bottom thickness of the spillway wall is sufficient, batter must be calculated using full height of the wall at station 3+25. The walls will be placed such that the heel between the bottom exterior face of the wall and the edge of the test slab is equal to that of station 3+25. Wall joint will be detailed to match the joint at station 3+29.50.

I. Drainage: A drainage system is to be constructed with the same dimensions, layout, and detailing as shown between stations 3+90.00 and 4+10.00. The drainage system must include two cleanouts, one for drains parallel to spillway alignment and one for drains perpendicular to spillway alignment.

J. Cutoff Wall: A cut off wall will be constructed perpendicular to the stream direction with the same dimensions, reinforcement, and detailing as shown for the cut off wall located at station 3+73.00. This cutoff wall must have perforations for drainage system to pass though cut off wall.

K. Reinforcement: Reinforcement in test slab shall be the same size, function, spacing, and configuration as required in the design drawings for the crest section spillway floor slab and walls between stations 3+25.00 and 3+35.00 (including joint at station 3+29.50).

Provide 3 inches clear cover to the bottom layer and 3 inches clear cover to the top layer.

Vertical wall reinforcement shall protrude through the top face of the test slab at edges to match the wall reinforcement through the construction joint between the spillway crest floor slab and walls.

03 30 00 - 24

L. Protruding wall reinforcement shall be two bundled #11 bars at 6 inches on-center in each face of the walls with 3 inches clear cover to the outside layer and 3 inches clear cover to the inside layer. no splicing of the vertical bars is allowed. Horizontal wall reinforcement shall be #11 at 9 inches on-center. Out-of-plane reinforcement is to be #4 at 6 inches on-center horizontally and 12” on-center vertically and is to be of the same shape required between stations 3+50 and 3+70. Protruding vertical reinforcement shall angle such that 3-inch clear cover is maintained on all appropriate faces and extend a minimum of one foot higher than the minimum wall height.

M. Finish: Finish test panel in accordance with Table 03 30 00G for “Floors: service spillway”.

N. Concrete Mix:

1. Concrete test slab shall be constructed of mass concrete meeting the requirement of mass concrete in these specifications including cooling strategies.

2. Concrete test slab shall use the approved mass concrete mix.

3. Concrete test slab shall come from the same batch plant and use the same material sources as the approved mass concrete mix.

4. Test slab concrete shall be field tested in accordance with Table 03 30 00E.

3.04 PLACING

A. Notify COR at least 24 hours before placing concrete.

B. Do not place concrete without approval of COR.

C. Place concrete in presence of COR or designated representative.

D. Placing of concrete shall be performed under direct supervision of a Craftsman certified as ACI Concrete Flatwork Finisher.

E. Allow at least 7 days between adjacent placements, or as approved by COR.

1. For RSMC, COR may require more than 7 days between adjacent placements based on temperature control plan or actual temperature data of RSMC.

F. Furnish legible and digitized batch ticket with each batch of concrete in accordance with ASTM C94. Ticket shall include additions made to the load after batching (water, air adjustment, admixtures). Deliver ticket to COR at jobsite during batch delivery.

G. Do not use aluminum pipes or chutes for placing or pumping concrete.

H. Adding water to concrete batch at the site will be allowed only once and only when approved by the COR.

1. Additional water shall be added before concrete is discharged.

2. Do not exceed specified water to cement ratio.

03 30 00 - 25

3. After water is added, concrete shall be mixed for at least 30 revolutions of the mixer drum at mixing speed.

4. Record added water on the batch ticket to nearest gallon.

I. Adding air entraining admixtures to concrete batch at the site will be allowed only once when approved by the COR.

1. After air entraining admixture is added, concrete shall be mixed for a minimum of

30 revolutions of the mixer drum at mixing speed.

2. Take slump and air content after air-entraining admixture addition and additional revolutions.

3. Record added air entraining admixture on the batch ticket to nearest ounce.

J. Do not use concrete which has become so stiff that concrete cannot be properly placed.

K. Place formed concrete in continuous, approximately horizontal layers. Do not exceed 20 inches in depth of layers.

L. Vibrate concrete until concrete has been consolidated to maximum practical density, is free from pockets of coarse aggregate, and closes snugly against surfaces of forms and embedded materials. Do not use vibrators to move concrete within forms.

M. Hot Weather:

1. Place concrete in accordance with ACI 305.1.

2. Protect reinforcing steel so that steel temperature does not exceed ambient air temperature immediately before placing concrete.

3. Fog spray forms, reinforcing steel, and subgrade just before placing concrete.

Keep subgrade moisture uniform without puddles or dry areas.

N. Cold Weather:

1. Place concrete in accordance with ACI 306.1.

2. Do not place concrete on frozen subgrade or subgrade containing frozen materials.

3.05 FINISHING

A. Notify COR before finishing concrete.

B. Finish concrete in presence of Government inspector unless inspection is waived in each specific case.

C. Finishing of concrete shall be performed under direct supervision of a Craftsman certified as ACI Concrete Flatwork Finisher.

03 30 00 - 26

1. A minimum of one certified ACI Concrete Flatwork Finisher is required at each finishing operation.

D. Finish surfaces as specified in Table 03 30 00F- Formed Surfaces and Table 03 30 00G- Unformed Surfaces.

E. Where finishes are not specified for a particular surface, finish concrete as specified for similar work.

F. Formed Surfaces:

1. Finish class is designated by symbols F1, F2, and F3.

2. Finish F1:

a. Applies to formed surfaces to be covered by fill material, grout, or concrete, and construction joint surfaces as specified in Table 03 30 00F - Formed Surfaces.

b. Protect form tie rod ends on surfaces in contact with fill material from moisture where they will be below the water table or waterline.

1) Recess tie rod ends and fill recess with dry pack or other material approved by COR.

c. Cut off flush with formed surface form tie rod ends on surfaces in contact with concrete or fill material and above maximum water table or waterline elevation.

3. Finish F2:

a. Applies to exposed formed surfaces not permanently concealed by fill material, grout, or concrete, and not required to receive finish F3, and to contraction joint surfaces and expansion joint surfaces as specified in Table 03 30 00F- Formed Surfaces.

1) Recess tie rod ends and fill recess with dry pack or other material approved by COR.

4. Finish F3:

a. Applies to formed surfaces with special appearance requirements, such as surfaces exposed to view, as specified in Table 03 30 00F - Formed Surfaces.

b. After required patching and correction of imperfections has been completed, sack rub surface as follows:

1) Thoroughly wet surface and sack rub while surface is still damp.

2) Use mortar consisting of 1 part cement; 2 parts, by volume, of sand passing a No. 16 screen; and enough water so that mortar has consistency of thick cream. Blend standard cement with white cement as necessary to obtain a color which will match surrounding concrete surface.

03 30 00 - 27

3) Thoroughly rub mortar over area with clean burlap or a sponge rubber float to fill pits, bugholes, and other defects.

4) While mortar in pits is still plastic, rub surface with a dry mix of above proportions and material to remove excess plastic material and place enough dry material in the pits to stiffen and solidify mortar so that filling will be flush with surface. Remove material remaining on surface except material within pits.

5) Continue curing surface as specified.

G. Unformed Surfaces:

1. Do not use dry portland cement or additional water during finishing.

2. Do not use "jitterbugs" or other tools to force coarse aggregate away from surface.

3. Finish class is designated by symbols U1, U2, U3, or broom finish.

4. Finish U1 (Screeded Finish):

a. Applies to unformed surfaces to be covered by fill material, grout, or concrete as specified in Table 03 30 00G - Unformed Surfaces.

b. Use as first stage of finish U2 and U3.

c. After concrete is placed and consolidated, strike off and level concrete to produce even uniform surface.

5. Finish U2 (Floated Finish):

a. Applies to unformed surfaces not permanently concealed by fill material, grout, or concrete, and not required to receive finish U3, as specified in Table 03 30 00G - Unformed Surfaces.

b. Begin floating as soon as screeded surface has sufficiently stiffened and bleed water sheen has disappeared.

c. Use hand- or power-driven equipment.

d. Finish surface with minimum floating necessary to produce a surface that is free of screed marks and is uniform in texture.

e. Use as second stage of finish U3. Floating shall bring a small amount of mortar without excess water to the surface, so as to permit effective troweling.

6. Finish U3 (troweled finish):

a. Applies to unformed surfaces where appearance and porosity is considered by Government to be of special importance as specified in Table 03 30 00G - Unformed Surfaces.

b. Begin steel troweling after bleed water has disappeared and floated surface has sufficiently hardened to prevent an excess of fine material from being drawn to surface.

03 30 00 - 28

c. Trowel with firm pressure to flatten sandy texture of floated surface.

d. Trowel to a dense uniform surface free from blemishes and trowel marks.

Do not excessively trowel surface.

7. Broomed Finish:

a. Apply light broom finish in direction with slope immediately after concrete receives U2 finish.

b. Edge transverse joints before brooming.

c. Produce a scored surface by brooming with a fiber-bristle brush in a direction transverse to that of the traffic with adjacent strokes slightly overlapping.

d. Finished surface shall have a uniform appearance and shall be free of abrupt corrugation exceeding 1/8 inch in depth.

e. Brooming shall eliminate the flat surface left by the surface face of the edger.

8. Slope interior surfaces for drainage where shown on drawings or as directed by COR. Slope surfaces exposed to the weather for drainage as directed by COR.

9. Slope narrow surfaces, such as tops of walls and curbs, approximately 3/8…