03 30 53 Cast-in-Place Concrete.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. Materials testing and inspection during construction: Section 01 45 29, TESTING LABORATORY SERVICES.

B. 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 SUSTAINABILITY REQUIREMENTS

A. Materials in this section may contribute towards contract compliance with sustainability requirements. See Section 01 81 11, SUSTAINABLE

DESIGN REQUIRMENTS, for project local/regional materials, recycled content, requirements.

B. Blended Cement: It is the intent of this specification to reduce CO2 emissions and other environmentally detrimental effects resulting from the production of Portland cement by requiring that all concrete mixes, in aggregate, utilize blended cement mixes to displace Portland cement typically included in conventional construction. Provide the following submittals:

1. Copies of concrete design mixes for all installed concrete.

2. Copies of typical regional baseline concrete design mixes for all compressive strengths used on the Project.

3. Quantities in cubic yards of each installed concrete mix.

C. Biobased Material: For products designated by the USDA’s BioPreferred® program, provide products that meet or exceed USDA recommendations for biobased content, subject to the products compliance with performance requirements in this Section. For more information regarding the

03 30 53 - 2 product categories covered by the BioPreferred® program, visit http://www.biopreferred.gov.

1.6 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.

B. Fulfillment of regulatory requirements does not relieve the Contractor of satisfying sustainability requirements stipulated by Section

01 81 11, SUSTAINABLE DESIGN REQUIREMENTS, as it relates to recycled content; additional product and material selections with recycled content may be required, as determined by Contractor’s Sustainability

Action Plan.

1.7 SUBMITTALS

A. Submit in accordance with Section 01 33 23, SHOP DRAWINGS, PRODUCT

DATA, AND SAMPLES.

B. Concrete Mix Design.

C. Shop Drawings:

1. Submit Steel Reinforcement Shop Drawings and Product Data to include all information necessary for fabrication and placement of reinforcement.

2. Indicate grades of reinforcing steel.

3. Clearly indicate the splice length for every size and type of bar used.

4. Indicate the type, size and location of all accessories required for the proper assembly, placement and support of the reinforcement.

5. Provide layout drawings of all floor slabs and formed concrete indicating control and expansion joints.

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

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

1.8 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

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

G. Air-Entraining Admixture: ASTM C260.

H. Chemical Admixtures: ASTM C494.

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

J. Reinforcing Steel: ASTM A615 or ASTM A996, deformed. See structural drawings for grade.

K. Welded Wire Fabric: ASTM A185.

L. Expansion Joint Filler: ASTM D1751.

M. Sheet Materials for Curing Concrete: ASTM C171.

N. Abrasive Aggregates: Aluminum oxide grains or emery grits.

O. Liquid Hardener and Dustproofer: Fluosilicate solution or magnesium fluosilicate or zinc fluosilicate. Magnesium and zinc may be used separately or in combination as recommended by manufacturer.

P. Liquid Densifier/Sealer: 100 percent active colorless aqueous siliconate solution.

Q. Grout, Non-Shrinking: Premixed ferrous or non-ferrous, mixed and applied in accordance with manufacturer's recommendations. Grout cannot show settlement or vertical drying shrinkage at 3 days or thereafter based on initial measurement made at time of placement. Grout must produce a compressive strength of minimum 18 MPa (2500 psi) at 3 days and minimum 35 MPa (5000 psi) at 28 days.

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 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

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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

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.

* 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.

3. Mixing structural lightweight concrete: Charge mixer with 2/3 of total mixing water and all of the aggregate. Mix ingredients for not less than 30 seconds in a stationary mixer or not less than 10 revolutions at mixing speed in a truck mixer. Add remaining mixing water and other ingredients and continue mixing. Above procedure may be modified as recommended by aggregate producer.

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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:

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

3. Engage a professional surveyor to survey the form work for the exposed portions of the foundations for the columbarium or memorial walls, including wall segments, piers and/or columns, prior to concrete being poured. If the forms are not correct, they must be corrected and resurveyed. When correct, provide a written certification from the surveyor, to the RE/COR, that the forms are set according to the plans, within the allowable tolerances for elevation, location, orientation, and dimensions called for on the plans.

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

5. Upon removal of the forms, the professional surveyor must survey the placed concrete and provide information to the RE/COR where the work

03 30 53 - 8 is not in conformance with the design drawings, within the allowable construction tolerances. The work cannot progress until the exposed concrete for the foundations are brought into compliance.

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

Contractor.

7. Erected work that exceeds specified tolerance limits must be remedied or removed and replaced, at no additional cost to the

Government.

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

9. 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 VAPOR BARRIER

A. Except where membrane waterproofing is required, place interior concrete slabs on a continuous vapor barrier.

B. Place 100 mm (4 inches) of fine granular fill over the vapor barrier to act as a blotter for concrete slab.

C. Lap joints 150 mm (6 inches) and seal with a compatible pressure-sensitive tape.

D. Patch punctures and tears.

3.4 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.

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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.

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.

3.5 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.

3.6 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.

3.7 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.

B. For exposed surfaces of concrete for the columbarium and memorial walls and walls in their complexes, follow the procedures identified in

Paragraph FINISHES for Exterior Exposed Areas (finished).

C. For columbarium and memorial walls and their complexes, immediately after forms are removed, take steps to prepare and smooth the exposed portions of the concrete. Remove the form marks, including joint marks, fins, burrs and similar projections to produce a smooth surface.

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Complete the surface finish to result in a uniform textured surface with homogeneous color, unless surface is to be otherwise treated.

Work must be as approved during the review of the mock-up.

3.8 FINISHES

A. Vertical and Overhead Surface Finishes:

1. Unfinished Areas: Vertical and overhead concrete surfaces exposed in unfinished areas, above suspended ceilings in manholes, and other unfinished areas exposed or concealed will not require additional finishing.

2. Interior and Exterior Exposed Areas (to be painted): Fins, burrs and similar projections on surface must be knocked off flush by mechanical means approved by RE/COR and rubbed lightly with a fine abrasive stone or hone. Use an ample amount of water during rubbing without working up a lather of mortar or changing texture of concrete.

3. Interior and Exterior Exposed Areas (finished): Provide grout finish of uniform color and smooth finish treated as follows:

a. After concrete has hardened and laitance, fins and burrs have been removed, scrub concrete with wire brushes. Clean stained concrete surfaces by use of a hone or stone.

b. Apply grout composed of 1 part Portland cement and 1 part clean, fine sand (smaller than 600 micro-m (No. 30) sieve). Work grout into surface of concrete with cork floats or fiber brushes until all pits and honeycomb are filled.

c. After grout has hardened, but still plastic, remove surplus grout with a sponge rubber float and by rubbing with clean burlap.

d. In hot, dry weather use a fog spray to keep grout wet during setting period. Complete finish for any area in same day. Confine limits of finished areas to natural breaks in wall surface. Do not leave grout on concrete surface overnight.

B. Slab Finishes:

1. Scratch Finish: Slab surfaces to receive a bonded applied cementitious application must be thoroughly raked or wire broomed after partial setting (within 2 hours after placing) to roughen surface and ensure a permanent bond between base slab and applied cementitious materials.

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2. 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.

3. 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.

4. 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 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.

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

6. 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

3.9 SURFACE TREATMENTS

A. Mix and apply surface treatments in accordance with manufacturer's printed instructions.

B. Liquid Densifier/Sealer: Use on all exposed concrete floors and concrete floors to receive carpeting except those specified to receive non-slip finish.

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C. Non-Slip Finish: Except where safety nosing and tread coverings are shown, apply non-slip abrasive aggregate to treads and platforms of all concrete steps and stairs, and to surfaces of exterior concrete ramps and platforms. Broadcast aggregate uniformly over concrete surface.

Trowel concrete surface to smooth dense finish. After curing, rub the treated surface with abrasive brick and water sufficiently to slightly expose abrasive aggregate.

3.10 APPLIED TOPPING

A. Separate concrete topping with thickness and strength shown with only enough water to insure a stiff, workable, plastic mix.

B. Continuously place applied topping until entire section is complete, struck off with straightedge, compact by rolling or tamping, float and steel trowel to a hard smooth finish.

3.11 RESURFACING FLOORS

A. Remove existing flooring, in areas to receive resurfacing, to expose existing structural slab and to extend not less than 25 mm (1 inch) below new finished floor level. Prepare exposed structural slab surface by roughening, broom cleaning, wetting, and grouting. Apply topping as specified.

3.12 RETAINING WALLS

A. Provide concrete for retaining walls as shown and air-entrained.

B. Install and construct expansion and contraction joints, waterstops, weep holes, reinforcement and railing sleeves as shown.

C. Finish exposed surfaces to match adjacent concrete surfaces, new or existing.

D. Place porous backfill as shown.

3.13 PRECAST CONCRETE ITEMS

A. Cast precast concrete items, not specified elsewhere, using 25 MPa

(3000 psi) air-entrained concrete to shapes and dimensions shown.

Finish surfaces to match corresponding adjacent concrete surfaces.

Reinforce with steel as necessary for safe handling and erection.

- - - E N D - - -

C. Biobased Material: For products designated by the USDA’s BioPreferred® program, provide products that meet or exceed USDA recommendations for biobased content, subject to the products compliance with performance requirements in this Section. For ...

B. Fulfillment of regulatory requirements does not relieve the Contractor of satisfying sustainability requirements stipulated by Section 01 81 11, SUSTAINABLE DESIGN REQUIREMENTS, as it relates to recycled content; additional product and material sel...

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