36C78618Q0402-003.pdf

06-01-14

(SHORT FORM) CAST-IN-PLACE CONCRETE

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SECTION 03 30 53

(SHORT-FORM) CAST-IN-PLACE CONCRETE

PART 1 - GENERAL

1.1 DESCRIPTION

A. This section specifies cast-in-place structural concrete and material and mixes for other concrete.

1.2 RELATED WORK

A. Concrete roads, walks, and similar exterior site work: Section 32 05 23, CEMENT AND CONCRETE

FOR EXTERIOR IMPROVEMENTS.

1.3 TOLERANCES

A. ACI 117.

B. Slab Finishes: ACI 117, F-number method in accordance with ASTM E1155.

1.4 REGULATORY REQUIREMENTS

A. ACI SP-66 - ACI Detailing Manual.

B. ACI 318 - Building Code Requirements for Reinforced Concrete.

1.5 REGULATORY REQUIREMENTS FOR RECYCLED CONTENT

A. Products and Materials with Post-Consumer Content and Recovered Materials Content:

1. Contractor is obligated by contract to satisfy Federal mandates for procurement of products and materials meeting recommendations for post-consumer content and recovered materials content; the list of designated product categories with recommendations has been compiled by the EPA - refer to http://www.epa.gov/wastes/conserve/tools/cpg/products/.

2. Materials or products specified by this section may be obligated to satisfy this Federal mandate and Comprehensive Procurement Guidelines program.

3. The EPA website also provides tools such as a Product Supplier Directory search engine and product resource guides.

1.6 SUBMITTALS

A. Submit to the COR and Midwest District Engineer:

B. Concrete Mix Design.

C. Manufacturer's Certificates: Air-entraining admixture, chemical admixtures, curing compounds.

http://www.epa.gov/wastes/conserve/tools/cpg/products/

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1.7 APPLICABLE PUBLICATIONS

A. Publications listed below form a part of this specification to extent referenced. Publications are referenced in text by the basic designation only. Comply with applicable provisions and recommendations of the following, except as otherwise shown or specified.

B. American Concrete Institute (ACI):

117-10 Tolerances for Concrete Construction and Materials and

Commentary

211.1-91(R2009) Selecting Proportions for Normal, Heavyweight, and Mass

Concrete

211.2-98(R2004) Selecting Proportions for Structural Lightweight Concrete

301-10 Structural Concrete

305R-10 Guide to Hot Weather Concreting

306R-10 Guide to Cold Weather Concreting

SP-66-04 ACI Detailing Manual

318/318M-11 Building Code Requirements for Structural Concrete and

Commentary

347R-04 Guide to Formwork for Concrete

C. American Society for Testing and Materials (ASTM):

A185/A185M-07 Steel Welded Wire Reinforcement, Plain, for Concrete

A615/A615M-12 Deformed and Plain Carbon Steel Bars for Concrete

Reinforcement

A996/A996M-09b Rail Steel and Axle Steel Deformed Bars for Concrete

Reinforcement

C31/C31M-12 Making and Curing Concrete Test Specimens in the Field

C33/C33M-13 Concrete Aggregates

C39/C39M-12a Compressive Strength of Cylindrical Concrete Specimens

C94/C94M-13 Ready Mixed Concrete

C143/C143M-12 Slump of Hydraulic Cement Concrete

C150/C150M-12 Portland Cement

C171-07 Sheet Materials for Curing Concrete

C172/C172M-10 Sampling Freshly Mixed Concrete

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C173/C173M-12 Air Content of Freshly Mixed Concrete by the Volumetric

Method

C192/C192M-12a Making and Curing Concrete Test Specimens in the Laboratory

C231/C231M-10 Air Content of Freshly Mixed Concrete by the Pressure Method

C260/C260M-10a Air-Entraining Admixtures for Concrete

C330/C330M-09 Lightweight Aggregates for Structural Concrete

C494/C494M-13 Chemical Admixtures for Concrete

C618-12a Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in

Concrete

D1751-04(R2008) Preformed Expansion Joint Filler for Concrete Paving and

Structural Construction (Nonextruding and Resilient Bituminous

Types)

E1155-96(2008) Determining FF Floor Flatness and FL Floor Levelness Numbers

PART 2 - PRODUCTS

2.1 FORMS

A. Wood, plywood, metal, or other materials, approved by RE/COR, of grade or type suitable to obtain type of finish specified.

B. Form releasing agents to be commercial formulations that will not bond with, stain or adversely affect concrete surfaces. Agents must not impair subsequent treatment of concrete surfaces depending upon bond or adhesion nor impede the wetting of surfaces to be cured with water or curing compounds. If special form liners are to be used, follow the recommendation of the form coating manufacturer. Submit manufacturer's recommendation on method and rate of application of form releasing agents.

2.2 MATERIALS

A. Portland Cement: ASTM C150, Type I or II.

B. Fly Ash: ASTM C618, Class C or F including supplementary optional requirements relating to reactive aggregates and alkalis, and loss on ignition (LOI) not to exceed 5 percent.

C. Coarse Aggregate: ASTM C33, Size 67. Size 467 may be used for footings and walls over 300 mm

(12 inches) thick. Provide Size 7 coarse aggregate for applied topping and metal pan stair fill.

D. Fine Aggregate: ASTM C33.

E. Lightweight Aggregate for Structural Concrete: ASTM C330, Table 1

F. Mixing Water: Fresh, clean, and potable.

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G. Air-Entraining Admixture: ASTM C260.

H. Chemical Admixtures: ASTM C494.

I. Vapor Barrier: ASTM E1745, 0.38 mm (15 mil).

J. Welded Wire Fabric: ASTM A185.

K. Expansion Joint Filler: ASTM D1751.

L. Sheet Materials for Curing Concrete: ASTM C171.

2.3 CONCRETE MIXES

A. Design of concrete mixes using materials specified as set forth under Option C of ASTM C94.

B. Compressive strength at 28 days: Minimum 30 MPa ( 4000 psi ).

C. Establish strength of concrete by testing prior to beginning concreting operation. Test consists of average of three cylinders made and cured in accordance with ASTM C192 and tested in accordance with ASTM C39.

D. Maximum slump for vibrated concrete is 100 mm (4 inches) tested in accordance with ASTM

C143.

E. Cement and water factor (See Table I):

TABLE I - CEMENT AND WATER FACTORS FOR CONCRETE

Concrete: Strength Non-Air-Entrained Air-Entrained

Min. 28 Day Comp. Str.

MPa (psi)

Min. Cement kg/m3 (lbs/c. yd)

Max. Water Cement Ratio

Min. Cement kg/m3 (lbs/c.

yd)

Max. Water

Cement Ratio

35 (5000)1,3 375 (630) 0.45 385 (650) 0.40

30 (4000)1,3 325 (550) 0.55 340 (570) 0.50

25 (3000)1,3 280 (470) 0.65 290 (490) 0.55

25 (3000)1,2 300 (500) * 310 (520) *

1. If trial mixes are used, the proposed mix design must achieve a compressive strength 8.3

MPa (1200 psi) in excess of f'c. For concrete strengths above 35 Mpa (5000 psi), the proposed mix design must achieve a compressive strength 9.7 MPa (1400 psi) in excess of f’c.

2. Lightweight Structural Concrete. Pump mixes may require higher cement values.

3. For concrete exposed to high sulfate content soils maximum water cement ratio is 0.44.

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* Determined by Laboratory in accordance with ACI 211.1 for normal concrete or ACI 211.2 for lightweight structural concrete.

F. Air-entrainment is required for all exterior concrete and as required for Section 32 05 23, CEMENT AND CONCRETE FOR EXTERIOR IMPROVEMENTS. Air content must conform with ACI

318 Table 4.4.1.

2.4 BATCHING AND MIXING

A. Store, batch, and mix materials as specified in ASTM C94.

1. Job-Mixed: Mix in a batch mixer in manner specified for stationary mixers in ASTM C94.

2. Ready-Mixed: Comply with ASTM C94, except use of non-agitating equipment for transporting concrete to the site will not be permitted. With each load of concrete delivered to project, ready-mixed concrete producer must furnish, in duplicate, certification as required by ASTM C94.

PART 3 - EXECUTION

3.1 FORMWORK

A. Installation conforms to ACI 347. Sufficiently tight to hold concrete without leakage, sufficiently braced to withstand vibration of concrete, and to carry, without appreciable deflection while remaining within allowable construction tolerances, all dead and live loads to which they may be subjected.

B. Treating and Wetting: Treat or wet contact forms as follows:

1. Coat plywood and board forms with non-staining form sealer. In hot weather cool forms by wetting with cool water just before concrete is placed.

2. Clean and coat removable metal forms with light form oil before reinforcement is placed. In hot weather, cool metal forms by thoroughly wetting with water just before placing concrete.

3. Use sealer on reused plywood forms as specified for new material.

C. Inserts, sleeves, and similar items: Flashing reglets, masonry ties, anchors, inserts, wires, hangers, sleeves, boxes for floor hinges and other items specified as furnished under this and other sections of specifications are required to be in their final position at time concrete is placed - properly located, accurately positioned, built into construction, and maintained securely in place.

D. Construction Tolerances:

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1. Set and maintain concrete formwork to assure erection of completed work within tolerances specified to accommodate installation or other rough and finish materials.

2. Properly brace the forms so the set concrete is correct within the allowable construction tolerances when the forms are removed.

3. Remedial work necessary for correcting installations that is in excess of allowable tolerances are the responsibility of the Contractor.

4. Any remediation work is subject to approval of the RE/COR in advance of the work.

5. Permissible surface irregularities for various classes of materials are defined as "finishes" in specification sections covering individual materials. They are to be distinguished from tolerances specified which are applicable to surface irregularities of structural elements.

3.2 REINFORCEMENT

A. Details of concrete reinforcement, unless otherwise shown, in accordance with ACI 318 and ACI

SP-66. Support and securely tie reinforcing steel to prevent displacement during placing of concrete.

3.3 PLACING CONCRETE

A. Remove water from excavations before concrete is placed. Remove hardened concrete, debris and other foreign materials from interior of forms, and from inside of mixing and conveying equipment. Obtain approval of RE/COR before placing concrete. Provide screeds at required elevations for concrete slabs.

B. Roughen and clean set concrete free from laitance, foreign matter, and loose particles, before placing new concrete on or against concrete which has set.

C. Convey concrete from mixer to final place of deposit by method which will prevent segregation or loss of ingredients. Do not deposit in work concrete that has attained its initial set or has contained its water or cement more than 1 1/2 hours. Do not allow concrete to drop freely more than 1500 mm (5 feet) in unexposed work nor more than 900 mm (3 feet) in exposed work. Place and consolidate concrete in horizontal layers not exceeding 300 mm (12 inches) in thickness. Consolidate concrete by spading, rodding, and mechanical vibrator. Do not secure vibrator to forms or reinforcement. Provide vibration continuously with placing of concrete.

D. Hot weather placing of concrete: Follow recommendations of ACI 305R to prevent problems in the manufacturing, placing, and curing of concrete that can adversely affect the properties and serviceability of the hardened concrete.

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E. Cold weather placing of concrete: Follow recommendations of ACI 306R, to prevent freezing of thin sections less than 300 mm (12 inches) and to permit concrete to gain strength properly, except that use of calcium chloride cannot be used without written approval from RE/COR.

3.4 PROTECTION AND CURING

A. Protect exposed surfaces of concrete from premature drying, wash by rain or running water, wind, mechanical injury, and excessively hot or cold temperature. Curing method is subject to approval by RE/COR.

3.5 FORM REMOVAL

A. Forms remain in place until concrete has a sufficient strength to carry its own weight and loads supported. Removal of forms at any time is the Contractor's sole responsibility.

3.6 SURFACE PREPARATION

A. Immediately remove loose materials, after forms have been removed and work has been examined and approved by RE/COR, and patch all stone pockets, surface honeycomb, or similar deficiencies with cement mortar made with 1 part portland cement and 2 to 3 parts sand.

3.7 FINISHES

A. Slab Finishes:

1. Floating: Allow water brought to surface by float used for rough finishing to evaporate before surface is again floated or troweled. Do not sprinkle dry cement on surface to absorb water.

2. Float Finish: Screen and float ramps, stair treads, and platforms, both interior and exterior, equipment pads, and slabs to receive non-cementitious materials, except as specified, to a smooth dense finish. Check for alignment using a straightedge or template after first floating and while surface is still soft. Correct high spots by cutting down with a trowel or similar tool and correct low spots by filling in with material of same composition as floor finish. Remove any surface projections on floated finish by rubbing or dry grinding. Refloat the slab to a uniform sandy texture.

3. Steel Trowel Finish: Applied toppings, concrete surfaces to receive resilient floor covering or carpet, future floor roof and all monolithic concrete floor slabs exposed in finished work and for which no other finish is shown or specified must be steel troweled. Delay final steel troweling to secure a smooth, dense surface as long as possible, generally when the surface can no longer be dented with finger. During final troweling, tilt steel trowel at a slight angle

03 30 53 - 8 and exert heavy pressure on trowel to compact cement paste and form a dense, smooth surface. Finished surface must be free of trowel marks, uniform in texture and appearance.

4. Broom Finish: Finish all exterior slabs, ramps, and stair treads with a bristle brush moistened with clear water after the surfaces have been floated.

5. Finished slab flatness (FF) and levelness (FL) values must comply with the following minimum requirements:

Slab On Grade & Shored Suspended Slabs Unshored Suspended Slabs

Specified overall value FF 25/FL 20 Specified overall value FF 25

Minimum local value FF 17/FL 15 Minimum local value FF 17

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