Amendment -02 05500-081209 Spec.pdf

Modernization of the South Building US Department of Agriculture Contract No. 53-3142-4-6049

July 13, 2009 Bid Set 03310- 1 Cast-In-Place-Concrete

SECTION 03310

CAST-IN-PLACE CONCRETE

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. Description of Work: Work of this Section includes, but is not limited to, the following:

1. Concrete materials and additives.

2. Concrete mixing, placement and curing.

3. Reinforcing bars and welded wire mesh for cast-in-place concrete.

4. Concrete finishing.

5. Precast concrete fixed and removable vault covers.

1.3 RELATED WORK SPECIFIED ELSEWHERE

A. See Section 01120 CONSTRUCTION IAQ MANAGEMENT for managing indoor air quality during construction.

B. See Section 01045 CUTTING AND PATCHING and 02222 SELECTIVE DEMOLITION for removal of existing concrete and concrete infill.

C. See Section 01352 LEED REQUIREMENTS for sustainable design requirements and procedures, including submittal requirements.

D. See Section 01410 TESTING AND INSPECTION SERVICES for requirements for independent agency for quality control testing and inspection.

E. See Section 01572 CONSTRUCTION WASTE MANAGEMENT for managing construction waste.

F. See Section 03530 CONCRETE TOPPINGS for light-weight aggregate concrete topping for floors.

G. See Section 03540 CONCRETE UNDERLAYMENT for concrete patching materials.

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H. See Section 05500 METAL FABRICATIONS for galvanized metal framing for precast concrete removable vault covers.

1.4 SUBMITTALS

A. Product Data: Submit manufacturer's specifications and installation instructions for each product, including applicable temperature ranges.

B. Shop Drawings: Indicate sizes, spacings, locations and quantities of reinforcing steel, wire fabric, bending and cutting schedules, laps and splices.

C. Test Reports:

1. Mix reports:

a. Submit mix design and strength test reports for each type and class of concrete.

b. Submit written reports to Government of each proposed mix design at least 15 days prior to start of work.

2. Submit certified mill test reports for each lot of cement.

D. Certificates:

1. Reinforcing:

a. Submit mill test certificates of supplied reinforcing, indicating physical and chemical analysis.

b. Submit welder's certificates for welders employed on Work, verifying AWS qualifications within previous 12 months.

2. If curing compounds are used, instead of moist curing methods, on slabs to receive adhered membranes or coatings, submit joint certification, signed by membrane or coating manufacturer and concrete curing agent manufacturer, stating that concrete curing agents have been reviewed and that curing agents are compatible with membrane or coating and that they will not interfere with membrane or coating adhesion.

1.5 QUALITY ASSURANCE

A. Supplier Qualifications: Not less than 5 years documented, successful experience with work comparable to Work of this Project.

B. Reinforcing Fabricator Qualifications:

1. Not less than 5 years documented, successful experience with work comparable to

Work of this Project.

2. Shop Drawings shall be prepared by a detailer who has specialized in concrete reinforcement detailing for minimum of 5 years.

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1.6 PRE-INSTALLATION CONFERENCE

A. Prior to commencing Work, meet at site and review installation procedures and coordination with other Work.

1.7 DELIVERY, STORAGE AND HANDLING

A. Store and maintain reinforcing steel and bar supports to prevent rusting, contamination or bending.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Environmental Requirements:

1. Recycled Content: Give preference to products with maximum recycled content possible.

2. Regional Materials: Give preference to products that have been manufactured within

800 km (500 miles) of Project site from materials that have been extracted, harvested, or recovered, as well as manufactured, within 800 km (500 miles) of Project site.

B. Concrete Materials:

1. Portland Cement: ASTM C150, Type I. Air-entraining portland cement is prohibited.

2. Coarse aggregate:

a. Normal weight aggregate: ASTM C33, Class 1S.

b. Lightweight aggregate: ASTM C330.

3. Water: Clean, fresh and potable.

4. Admixtures:

a. Only use admixtures which have been tested and accepted in design mix.

b. Air entraining admixture: ASTM C260. Provide product certified by manufacturer to be compatible with other required admixtures.

c. Water-reducing admixture: ASTM C494, Type A. Provide product containing not more than 0.05% chloride ions.

d. High-range water-reducing admixture (super plasticizer): ASTM C494, Type F or

Type G.

1) Provide product containing not more than 0.05% chloride ions.

2) Additives with minimum half life of 2 hours, which can be added at batch plant are preferred; if Contractor elects to use field-mixed additives, mixing must be supervised by representative of concrete supplier.

e. Water-reducing, non-corrosive, non-chloride accelerator admixture: ASTM C494, Type C or E.

1) Provide product containing not more chloride ions than are present in municipal drinking water.

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2) Provide long-term non-corrosive test data from independent laboratory (or at least one year duration), using acceptable accelerated corrosion test method such as that using electrical potential measures, for admixture.

f. Water-reducing, retarding admixture: ASTM C494, Type D. Provide product containing not more than 0.05% chloride ions.

g. Prohibited admixtures: Calcium chloride, thiocyanates or admixtures containing more than 0.05% chloride ions are not permitted.

h. Mineral admixtures: ASTM C618 and ASTM C989.

C. Formwork:

1. Where possible, rent reusable formwork, or use FSC-certified wood formwork.

2. Plywood, metal, or other panel-type material providing continuous smooth surfaces, non-reactive with form release agent or water.

3. Furnish in largest practicable sizes to minimize number of joints.

4. Provide form material with sufficient thickness to withstand pressure of newly placed concrete without bow or deflection.

5. Provide bio-based releasing agent.

D. Reinforcing:

1. Galvanized bars: ASTM A767, Class II hot-dip galvanized after fabrication and bending.

2. Steel wire: ASTM A82, plain, cold-drawn, steel.

3. Welded wire fabric: Welded steel; ASTM A185 with minimum yield strength of

450MPa.

4. Fabricate reinforcing in accordance with ACI 315.

E. Curing Materials:

1. Sheet: Conform to ASTM C171. Provide polyethylene sheeting, waterproof paper or white burlap-polyethylene sheet.

2. Liquid membrane forming compound: Combination curing and sealing compound complying with ASTM C309, Type I, Class B. Sodium silicate compounds are not permitted.

2.2 ACCESSORIES

A. Vapor Retarder: Clear polyethylene sheet complying with ASTM D4397; minimum 6 mil thick.

B. Reinforcing Accessories:

1. Tie wire, minimum 1.5mm, annealed type.

2. Supports: Conform to CRSI Manual of Standard Practice, "Bar Support

Specifications."

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C. Bonding Compound:

1. Where possible, select low-VOC products.

2. Acrylic latex or styrene butadiene type.

3. Acceptable products and manufacturers:

a. SBR Latex or Flex-Con by Euclid Chemical Co.

b. Everbond by L&M Construction Chemicals, Inc.

c. Sonocrete by Sonneborn Building Products.

d. Acryl 60 by Thoro Corp.

D. Epoxy-Resin Grout: Two-component mineral-filled epoxy-polysulfide, complying with ASTM C881, type as applicable for epoxy grouting new reinforcing to existing concrete.

1. Where possible, select low-VOC products.

2.3 FABRICATION OF REINFORCING

A. Fabricate in accordance with ACI 315.

B. Reinforcing with any of the following defects is not acceptable:

1. Bar lengths, depths and/or bends exceeding specified fabrication tolerances.

2. Bends or kinks not indicated on Drawings.

3. Bars with reduced cross-section.

C. See Section 01352 LEED REQUIREMENTS for requirements regarding recycled content and local regional materials for fabricated steel reinforcing.

2.4 MIXES

A. Minimum Compressive Strength: 20.7 Mpa at 28 days unless otherwise indicated. Use minimum of 7 bags of cement per cubic meter of concrete. All concrete shall contain minimum of 75% portland cement.

B. Concrete Slump at Point of Placement: 100mm +/- 25mm.

C. Design Mixes:

1. Base concrete proportions for design mixes on field experience or trial batch method described in ACI 318, Chapter 5.

2. Use concrete of approved mix designs only.

3. Do not place any concrete until design mix for that class and type of concrete is approved in accordance with requirements of ACI 318.

2.5 MIXING

A. Ready-Mix Concrete:

1. Comply with ASTM C94.

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2. Before using trucks for batching, mixing and transporting concrete, thoroughly clean trucks and equipment of materials capable of contaminating concrete.

3. During hot weather, or under conditions contributing to rapid setting of concrete, a shorter mixing time than specified in ASTM C94 may be required.

4. When air temperature is between 29EC and 32EC, reduce mixing and delivery time from 1-1/2 hours to 75 minutes; when air temperature is above 32EC, reduce mixing and delivery time to 60 minutes.

5. Do not add water to or re-temper ready-mix concrete after batching.

B. Job-Site Mixing:

1. Use drum-type batch machine mixer, mixing not less than 1-1/2 minutes for one cubic meter or smaller capacity.

2. Increase mixing time at least 15 seconds for each additional cubic meter or fraction thereof.

2.6 PRECAST CONCRETE VAULT COVERS

A. Precast Concrete Vault Covers:

1. Type: Fixed and removable precast concrete vault cover units.

2. Design and reinforcement: As indicated on Structural Drawings.

3. Sizes and locations: As indicated on Structural Drawings.

4. Hand pull (removable units only): Flat recessed pull ring handle; unless indicated otherwise.

5. Accessories: As indicated.

6. Concrete finish: To match existing sidewalk area.

B. See Section 05500 METAL FABRICATIONS for galvanized metal framing for precast concrete vault covers.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine substrates, formwork and conditions under which Work is to be installed. Do not proceed with Work until unsatisfactory conditions are corrected.

B. Verify that anchors, plates, reinforcement and other items to be cast into concrete are accurately placed and held securely.

3.2 PREPARATION

A. Vapor Retarder:

1. For slabs-on-grade, place vapor retarder in as large sheets as practicable.

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2. Lap joints 150mm minimum, and seal with manufacturer's recommended mastic and pressure-sensitive tape. Lap over footings and seal to foundations.

3. Cut, fit and seal vapor retarder to pipes, conduit and other penetrations projecting through membrane, using small sheets of vapor retarder and pressure-sensitive tape.

4. Repair damage to vapor retarder using additional sheets of vapor retarder material; lap over damaged areas at least 150mm and seal with pressure-sensitive tape.

B. Install inserts required to bond adjacent construction to concrete.

C. Formwork:

1. Fabricate formwork to prevent leakage of cement paste during concrete placement.

Solidly butt joints and provide back-up material at joints. Minimize joints.

2. Fabricate forms for easy removal without hammering or prying against concrete surfaces.

3. Conform to requirements of ACI 301.

4. Do not damage concrete surfaces during form removal.

3.3 REINFORCEMENT

A. Placement:

1. Comply with CRSI recommended practice for "Placing Reinforcing Bars."

2. Support and tie reinforcing steel to prevent displacement by construction loads or placement of concrete.

3. Allow for minimum concrete covering of reinforcement indicated on Drawings.

B. Splices:

1. Lap splices: Tie securely with wire to prevent displacement of splices during placement of concrete.

2. Do not splice bars except at locations indicated on Drawings without approval of

Government.

3. Wherever possible, stagger splices of adjacent bars.

4. Wire mesh: Lap adjacent sheets at least 150mm and securely tie.

C. Dowels: Place required steel dowels and securely anchor them into position before concrete is placed.

3.4 CONCRETE PLACEMENT

A. Mix and place concrete according to ACI 301 and 304, as modified or supplemented herein.

B. Convey concrete from mixer to place of deposit by method that will prevent segregation or loss of material, and that will not require addition of water to produce desired slump at point of placement.

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C. Depositing:

1. Deposit concrete continuously or in layers of sufficient thickness that no concrete will be placed on concrete which has hardened enough to cause seams or planes of weakness.

2. Deposit concrete as nearly as practicable to its final location.

3. Do not allow free fall of concrete to exceed 1200mm.

4. Place concrete without displacing reinforcing and accessories.

D. Placing Concrete Slabs:

1. Deposit and consolidate concrete slabs in metal forms until placing of panel or section is completed.

2. Bring surfaces to correct level with screed.

3. Do not disturb slab surfaces when bleed water is present or prior to beginning finishing operations.

E. Curbs:

1. Form curbs in areas indicated.

2. Provide monolithic finish to interior curbs by stripping forms while concrete is still green and steel-troweling surfaces to a hard, dense finish with corners, intersections and terminations slightly rounded.

F. Steel Pan Stairs:

1. Provide concrete for steel pan stair treads, landings and associated items.

2. Cast-in nosings, inserts and accessories as indicated.

3. Screed and tamp concrete.

4. Provide steel trowel finish.

G. Filling Holes:

1. Fill holes and openings left in concrete for passage of Work by other trades, after

Work of other trades is in place.

2. Fill openings in concrete left from selective demolition operations. See Section 03540

CONCRETE UNDERLAYMENT.

3. Mix, place and cure concrete to blend with in-place construction.

H. Finishes:

1. Begin floating when surface water has disappeared or when concrete has stiffened sufficiently to permit operation of power-driven floats.

2. After floating, straighten slab to provide specified tolerance.

3. Power trowel:

a. Where slab receives resilient flooring or carpet, provide power trowel finish after floating, free of trowel marks, pockets or other defects and uniform in texture and appearance.

b. Grind smooth surface defects which would telegraph through applied finishes.

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3.5 CURING

A. General:

1. Start immediately after placing and finishing concrete.

2. Protect from premature drying, temperature extremes, temperature variations, rain, flowing water and mechanical injury.

3. Cure continuously, without allowing to dry, for minimum period required for hydration of cement and hardening of concrete.

4. Maintain temperature of concrete above 10EC for curing period.

5. Comply with requirements of ACI 301.

6. Use moist curing for surfaces to receive an adhered membrane or coating.

3.6 FIELD QUALITY CONTROL

A. Independent Agency Responsibilities:

1. Compression tests: Conform to ASTM C31 and C39.

a. Sample at point of deposit.

b. Make 1 set of 3 cylinders for every 50 cubic meters, or fraction thereof, of each type of concrete used each day, unless more cylinders are required by Building Department.

1) 1 - 7 day break; lab cure.

2) 2 - 28 day breaks; lab cure.

c. When frequency of testing will provide less than 3 strength tests for given class of concrete, conduct testing from at least 3 randomly selected batches or from each batch if fewer than 3 are used.

d. When total quantity of concrete is less than 50 cubic meters, strength test may be waived by Government upon written request from Contractor.

2. Air content: ASTM C173, volumetric method for lightweight or normal weight air-entrained concrete; ASTM C 231 pressure method for non-air-entrained normal weight concrete. Make one test for each set of compressive strength test specimens when air entrainment is used.

3. Slump: ASTM C143; one test for each concrete load at point of discharge; and one test for each set of compressive strength test specimens.

4. Provide weekly written reports.

B. Contractor's Responsibility:

1. Make arrangements for independent agency to perform tests and inspections.

2. Provide lockable curing boxes in secure location for concrete cylinders, complete with electric power and insulation, as required by Independent Agency.

3. See Section 01410 TESTING AND INSPECTION SERVICES for additional requirements.

C. Acceptance: Concrete will be considered acceptable if meeting criteria of ACI 301.

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3.7 PROTECTION

A. Protect concrete from construction traffic, weather or mechanical injury for 14 days after placing.

B. Protect concrete from staining.

END OF SECTION