Attachment B – Specifications

Table of Contents

Section Description Page

01030 Alternates-Alternatives 2

033600 Artificial Rockwork 3

033713 Shotcrete 11

041222 Architectural Stone 22

Section 01030

ALTERNATES/ALTERNATIVES

PART 1 - GENERAL

1.01 SUMMARY:

A. Section Includes: General requirements pertaining to:

1. The Work specified for accepted alternate bids, the materials and methods referenced in other sections to achieve specified work, and the coordination and modification of related work and surrounding construction to complete the project under each accepted bid.

B. Related Sections: Drawings and Contract

1.02 DESCRIPTION OF ALTERNATE BIDS:

A. Base Bid: Provide a total bid for line items 1-3.

B. Alternate Bid No. 1: Interpretive River and Pits, Cave Painting, and Staining.

1.03 ALTERNATE BID REQUIREMENTS:

A. Bidder must submit alternate bids. Bids submitted without alternate bid will be rejected as unresponsive.

B. Alternate bids, if awarded, will be considered as a basis for award. The low bid will be analyzed on the base bid and any combination of alternate bids. The Owner reserves the right to award the base bid and all alternates, that in the Owner's opinion, will provide the most cost-effective end product. The Owner's decision is final.

C. Provide alternate bid for the cost of the service requested in each alternate, either as an addition or as a reduction in the total bid.

D. The Owner may award any alternate bid or bids at the time of contract award. Any alternate bids awarded as part of the original contract will not extend the project completion time beyond that specified.

END OF SECTION 01030

SECTION 033600

ARTIFICIAL ROCKWORK

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections included in the Project Manual, apply to this Section.

1.2 SUMMARY

A. Furnish all materials, equipment, supplies, and manpower incidental to conduct all forming, fabrication of reinforcing material, shooting of concrete, sculpturing, staining, and other incidental Work. Features include, but are not limited to the following:

1. Low relief carving at building walls.

2. Rocks, rock walls, rock ledges

3. Building Columns

4. Staining and painting of artificial rockwork.

B. All work required to fully construct and finish completely the required shotcrete simulated structures shall be a part of this Contract, including related foundations, support structures, earthwork and subgrade preparation, excepting only items of this nature which may be specifically noted as furnished by the General Contractor.

1.3 DESCRIPTION

A. Artificial rockwork shall be constructed in the location and types as shown on the Drawings and as specified herein. The Work shall be constructed by a firm qualified according to criteria in Paragraph 1.5 below.

1.4 DEFINITIONS

A. Contractor: A company who specializes in a certain aspect of construction. For the purposes of this Section, a company whose primary business is the construction of naturalistic simulated rocks. (Themework Contractor – T.C.).

1.5 GENERAL REQUIREMENTS

A. It is intended that this Contract provide for all simulated rock formations a product which will perform and remain, under normal project site conditions of weather and wear, and free from the need of any structural repair or extensive maintenance for a period of at least twenty (20) years.

B. The artificial rock formations shall be an imitation of naturally occurring rock structures in color ranges as approved by the Owner and Architect. In general, the artificial rock work shall consist of a steel skeleton supporting structure covered with metal wire fabric and pneumatically applied, stained and painted, colored concrete walls and floors.

C. The material and method of application used for simulated rock must be able to simulate the appearance of natural rock, which may require shading of cracks and highlighting of some areas. The natural rock, or “live” rock, shall be supplied by others and incorporated into the simulated rock or secured to grade as detailed on the drawings.

D. The Contractor shall be responsible for the detailed design and appearance of the rock formations which shall be of the general style and geological character approved by the Owner and Architect and as indicated in the construction drawings and attached renderings.

E. The Contractor shall be responsible for the structural design of the system including attachment methods. If the weight of the system dictates special foundation or support structures, it shall be engineered and constructed by the Contractor as part of his original contract. The supporting structure shall be designed to support superimposed dead and live loads as indicated. The design shall be approved and certified by a qualified Professional Engineer, who is legally qualified to practice in the State or Iowa, and is experienced in providing engineering services of this type.

F. The design and construction of the rock forms shall be such that thermal expansion and contraction and any shrinkage of materials can be accommodated with concealed expansion or control joints to prevent uncontrolled cracking.

G. The end product in each case shall, in the opinion of the Architect and Owner, be realistic in form, texture, color variations and sheen and, in general, must have the appearance and character of natural environment.

1.6 GENERAL DATA

A. The work under this Contract shall be carefully coordinated with the work of other Contractors so that the installation of these elements does not impede progress of, or delay the completion of the facility. The General Contractor will provide the construction schedule, and this Contractor will perform his or her work to maintain the established pace and progress of the project.

B. All excavation, grading or earthwork, and the compaction and preparation of subgrade, as required to complete the work of this contract, shall be done by the General Contractor.

Demolition work as required for this contract work will be done by the General Contractor.

Themework contractor will coordinate their scope with the General Contractor as necessary.

C. This work must be fitted to the profiles of building structures and site conditions, and be securely anchored. All anchorage devices shall be concealed from public view.

D. This Contractor shall provide all required anchors and methods of attachment. If anchors must be built into the building construction, coordinate such work with the General Contractor for the building construction.

E. Protect adjacent or existing surfaces of existing buildings and work of other contracts from damage or discoloration due to operations under this Contract. Contractor shall mask off adjacent surfaces prior to shotcrete application, painting, or other potentially damaging work.

F. At the completion of the work, all waste and excess materials shall be removed from the premises and disposed of by this Contractor.

1.7 QUALITY ASSURANCE

A. Installers – Qualification Requirements:

1. The Owner reserves the right to accept or reject any and all qualification submittals and to waive any informality or irregularity in any submittal.

2. All qualification information shall be submitted prior award of the project.

3. A principal in the Company shall have experience in providing and constructing simulated rockwork.

4. The Company shall be required to submit color photographs of five different naturalistic looking rock installations or themed building components for each type indicated in the drawings.

5. A list of at least three previously completed similar or comparable projects and their dollar value shall be submitted.

B. Work Force:

1. The Contractor shall employ skilled or professional help, one or more as may be required, with the ability to sculpt the fresh shotcrete to simulate natural rock, plaster and other formations.

C. Codes and References:

1. American Concrete Institute Standard 506, “Recommended Practice for Shotcreting” shall be made a part of these Specifications.

1.8 SUBMITTALS

A. The successful Contractor shall provide, as part of this Contract, the following work:

1. Consult with the Owner and General Contractor to establish the relationship to, or effect upon, other branches of the Work as these support or relate to the successful execution of the simulated rockwork.

2. Furnish Drawings, specifications or other descriptive material or information as may be required to accomplish the Work.

3. Mock-Ups: After preliminary approval of the designs based on the above, this Contractor shall construct for approval, mock-ups of the following, at full scale, having an area of approximately 25 sq. ft. The mock-up shall demonstrate profiles, styles, textures, colors, and variations to be expected in the final work. If directed, provide additional mock-ups with changes necessary to meet the approval of the Owner and Architect. The mock-up may be constructed as part of the permanent installation provided it is acceptable to the Owner and Architect, but no other work shall proceed until final approval of the mock-up is obtained.

a. Typical Rock Wall Formation

4. Material Descriptions:

a. At the completion of the work, submit a written specification of the basic materials used, plus a final adjusted list of mixes showing the proportions of pigment, aggregate, etc. for the Owner’s use in future repair work.

1.9 PRODUCT HANDLING

A. Storage of material, parking of vehicles and the location of the equipment shall be only in designated areas. Coordinate locations with DNR District Engineer.

1.10 JOB CONDITIONS

A. No cold weather work (outside air temperature 45 deg F and falling) will be permitted for artificial rockwork construction unless written permission from the DNR District Engineer has been obtained and methods to maintain heat for curing have been submitted and approved.

PART 2 – PRODUCTS

2.1 MATERIALS

A. The rockwork method proposed by this Contractor shall equal or exceed the following live loads in addition to all dead loads:

1. Wind Load – 25 psf

2. Impact up to eight feet high – 1000 psf

3. Tension – 500 psf

B. All connections and anchoring devices shall meet above loads with a safety factor of 2.5.

2.2 CONCRETE

A. Concrete for the construction of additional footings, pads and walls not shown on the Drawings, but required for the Work shall comply with the requirements of Section 033000, +3,000 psi compressive strength at 28 days.

B. Shotcrete for artificial rockwork to be wet-mix

2.3 WATER

A. Potable, available on site at the discretion of the DNR District Engineer.

2.4 REINFORCING

A. Reinforcing Bars: ASTM A615/A615M, Grade 60, deformed.

B. Plain-Steel Wire: ASTM A1064/A1064M.

C. Welded Wire Reinforcement: ASTM A1064/A1064M, plain, fabricated from as-drawn steel wire furnished in flat sheet.

2.5 METAL LATH

A. Expanded-Metal Lath: ASTM C847, cold-rolled carbon-steel sheet with ASTM A653/A653M, G60, hot-dip galvanized-zinc coating.

1. Diamond-Mesh Lath: Flat or Self-furring, 3.4 lb/sq. yd.

2. Flat-Rib Lath: Rib depth of not more than 1/8 inch, 3.4 lb/sq. yd.

3. 3/8-Inch Rib Lath: 4 lb/sq. yd/

2.6 COLOR ADDITIVES

A. Colored Cement Mortar: Manufacturer: Davis Colors, or equal.

1. Concentrated pigments specially processed for mixing into concrete and complying with ASTM C979.

2. Color additives containing carbon black are acceptable.

B. Chemical Stains: Manufacturer: L.M. Scoffield Company, or equal.

C. 100% Acrylic Paints: Manufacturer: Benjamin Moore, Sherwin Williams – Exterior SOLO, or equal. Minimum of 5 different colors to create highlights, shadows, and staining of various shades.

D. It is the intention to imitate natural rock appearance and to provide shading of cracks and highlighting of rock formations. This shading and highlighting shall be accomplished by using mineral oxide color additives and acrylic paint, which are to be selected by the Contractor and approved by the Owner. The material shall be applied with various airless, brush or spray equipment as needed to achieve desired appearance and effect.

PART 3 - EXECUTION

3.1 GENERAL

A. Inspection:

1. Prior to any Work of this section, carefully inspect the installed Work of all other trades and verify that such Work is complete to the point where this installation may properly commence.

2. The plumbing and electrical Work will be conducted concurrently and the Contractor shall cooperate fully with the other Contractors to coordinate the Work involved in this section with the Work provided by others.

B. Conduct of the Work:

1. Contractor must be prepared to commence his work promptly and shall lay out and conduct his Work at all times so as not to interfere unnecessarily with operations of the Owner or of other Contractors, and shall work in harmony with such other Contractors to the best interest of the Work as a whole.

2. Contractor shall establish the actual alignment of shotcrete rock formations. Although the final layout shall be subject to approval of the Owner, the Contractor will be held responsible for any misalignment due to faulty measurement or incorrect interpretation of the Drawings.

3.2 SHOTCRETE APPLICATIONS EQUIPMENT

A. Dry-mix shotcrete shall be applied by equipment whereby the dry cement aggregate mixture is delivered by air pressure to the nozzle where water is then introduced.

B. The cement gun shall be equipped with a loader having the following minimum mechanical features:

1. Accurate proportioning devices by volume or weight.

2. Tumbling or screw type mixing to ensure thorough blending.

3. Variable speed controls.

4. Clutch control for its mix and elevating mechanism.

5. A loading hopper above the cement gun.

6. Mixing range shall be from a minimum of 1:3 to 1:7.

7. All material must be screened before entering hopper.

8. Measurement of material by the shovelful shall not be permitted.

3.3 ARTIFICIAL ROCKWORK CONSTRUCTION

A. Steel Reinforcement:

1. #4 reinforcing bars shall be placed 1’-0” on center both ways as the minimum acceptable amount of bar reinforcing, and shall be continuous around corners.

2. All bars are to be welded or tied where they contact or cross each other.

3. All overlaps shall be 18” in length. However, a lap of 4” will be allowed if one continuous fillet weld of 3” in length is used to tie or weld the bars together at the splice.

4. Reinforcing bars shall be placed and bent around circles, corners and angles. Bends are to be permanently shaped, not sprung into place. Particular attention shall be made to follow the outline of the stratified rock formations to eliminate excess non-reinforced shotcrete outcroppings.

5. Reinforcing bars placed over wire mesh, shall be supported by slab bar bolsters, high chairs, etc. Spacing shall be No. 3 bars as 12-inch o/c. Pieces of Truss Loop shall be placed on bar supports.

6. Rock outcroppings not part of the “main” cave structure, can be #3 bar, welded to the main structure as detailed in 3.3.A.3.

B. Back-up Construction:

1. Wire lath shall be bent to conform approximately to the welded steel reinforcing frame and shall be held away from the nearest bars a minimum distance of 2”. In order to facilitate the installation of wire lath the Contractor may increase the thickness of the shotcrete to do away with matching exactly the steel reinforcing outline.

2. Wire lath shall be fastened to the reinforcing bars by means of tie wires or anchor spacers. Ties or spacers shall be spaced not more than 10 inches on center in all directions.

3. Wire lath shall be lapped on all adjacent ends and sides, a sufficient amount to stop shotcrete.

C. Shotcrete (wet-mix)

1. Shotcrete simulated rock shall consist of the following types of construction:

a. Base coat with either a colored finish coat or masonry sand finish coat.

2. The finish coat mix by volume measurement shall consist of 4.0 parts fine aggregate to one part cement mortar. Sika Acryl 60 additive, or approved equal, shall be used to in the decorative finish coat application for crack resistance and adhesion.

3. The minimum thickness of wet-mix shotcrete shall be 6” or as shown on the Drawings.

Flash coat shall have a thickness of 3/8” to ½”.

4. It is expected that in many instances increased depths over the minimum allowable will be required to permit the creation of shadow lines and otherwise allow for sculpturing and shaping of exposed surfaces. Design may require additional shotcrete to produce the desired results. The cost of placing this additional depth shall deemed incidental.

5. Any construction joints in shotcrete shall be tapered off to a thin edge. Before shooting the adjacent section, the sloped portion shall be thoroughly cleaned with a compressed air and water blast. No square joints will be permitted. All construction joint locations must be so positioned as to conform to the natural rock appearance.

6. Wherever a flash coat is to be applied to a concrete surface, the concrete surface shall be a roughened texture.

D. Concrete Tests: Testing of composite samples of fresh concrete obtained in accordance with ASTM C 172/C 172M shall be performed in accordance with the following requirements:

1. Testing Frequency: Obtain one composite sample for each day's placement of each concrete mixture exceeding 5 cu. yd., but less than 25 cu. yd., plus one set for each additional 25 cu. yd. or fraction thereof.

a. When frequency of testing provides fewer than five compressive-strength tests for each concrete mixture, testing shall be conducted from at least five randomly selected batches or from each batch if fewer than five are used.

2. Slump: ASTM C143/C143M:

a. One test at point of placement for each composite sample, but not less than one test for each day's placement of each concrete mixture.

b. Perform additional tests when concrete consistency appears to change.

3. Air Content: ASTM C231/C231M pressure method, for normal-weight concrete.

a. One test for each composite sample, but not less than one test for each day's placement of each concrete mixture.

4. Concrete Temperature: ASTM C1064/C1064M:

a. One test hourly when air temperature is 40 deg F and below or 80 deg F and above, and one test for each composite sample.

5. Compression Test Specimens: ASTM C31/C31M:

a. Cast and laboratory cure two sets of two 6-inch by 12-inch cylinder specimens for each composite sample.

6. Compressive-Strength Tests: ASTM C39/C39M.

a. Test one set of two cured specimens at seven days and one set of two specimens at 28 days.

b. A compressive-strength test shall be the average compressive strength from a set of two specimens obtained from same composite sample and tested at age indicated.

7. Additional Tests:

a. Testing and inspecting agency shall make additional tests of concrete when test results indicate that slump, air entrainment, compressive strengths, or other requirements have not been met, as directed by Architect.

b. Testing and inspecting agency may conduct tests to determine adequacy of concrete by cored cylinders complying with ASTM C42/C42M or by other methods as directed by Architect.

1) Acceptance criteria for concrete strength shall be in accordance with

ACI 301 (ACI 301M), section 1.6.6.3.

8. Additional testing and inspecting, at Contractor's expense, will be performed to determine compliance of replaced or additional work with specified requirements.

9. Correct deficiencies in the Work that test reports and inspections indicate do not comply with the Contract Documents.

3.4 PHOTO REFERENCE

A. Photographs of representative natural features are included within the construction drawings for artistic guidelines on features, details, colors, etc. to be used in the creation of the artificial rockwork mockup.

END OF SECTION

SECTION 033713

SHOTCRETE

PART 1 – GENERAL

1.1 SECTION INCLUDES

A. Shotcrete applied by wet-mix process.

1.2 RELATED SECTIONS

1.3 REFERENCES

A. American Concrete Institute (ACI):

1. ACI 117R - Specifications for Tolerances for Concrete Construction and Materials.

2. ACI 301 - Specifications for Structural Concrete.

3. ACI 305R - Hot Weather Concreting.

4. ACI 306.1 - Specification for Cold Weather Concreting.

5. ACI 506R - Guide to Shotcrete.

6. ACI 506.2 - Specification for Shotcrete.

B. ASTM International (ASTM):

1. ASTM A 36 - Specification for Carbon Structural Steel.

2. ASTM A 82 - Specification for Steel Wire, Plain, for Concrete Reinforcement.

10. ASTM A 820 - Specification for Steel Fibers for Fiber Reinforced Concrete.

11. ASTM C 33 - Specification for Concrete Aggregates.

12. ASTM C 42 - Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete.

13. ASTM C 150 - Specification for Portland Cement.

14. ASTM C 171 - Specification for Sheet Materials for Curing Concrete.

15. ASTM C 173 - Test Method for Air Content of Freshly Mixed Concrete by the Volumetric Method.

24. ASTM C 1116 - Specification for Fiber-Reinforced Concrete and Shotcrete.

25. ASTM C 1141 - Specification for Admixtures for Shotcrete.

1.4 DEFINITIONS

A. Shotcrete: Mortar or concrete pneumatically projected onto a surface at high velocity.

B. Wet-Mix Shotcrete: Shotcrete with ingredients, including mixing water, mixed before introduction into delivery hose.

1.5 SUBMITTALS

A. Submit under provisions of Section 01300 - Submittal Procedures.

B. Product Data: Submit for manufactured materials and products including reinforcement and forming accessories, shotcrete materials and curing compounds.

C. Shop Drawings: Submit for details of fabricating, bending, and placing reinforcement. Include support and anchor details, number and location of splices, and special reinforcement required for openings through shotcrete structures.

D. Samples: Approximately 24 by 24 by 2 inches, to illustrate quality of finishes, colors, and textures of exposed surfaces of shotcrete.

E. Design Mixes: For each shotcrete mix.

F. Quality Assurance/Control Submittals:

1. Submit manufacturer's certificates that products meet or exceed specified requirements.

2. Submit test results prepared by a qualified independent testing laboratory.

1.6 QUALITY ASSURANCE

A. Manufacturer Qualifications: Firm specializing in manufacture of shotcrete materials, with minimum 5 years’ experience.

B. Quality Assurance/Control Testing: Test Reports prepared by a qualified independent laboratory indicating compliance with the following performance requirements:

1. ACI 301, Specifications for Structural Concrete.

2. ACI 506.2, Specification for Shotcrete.

C. Testing Agency Qualifications: An independent agency qualified according to ASTM C 1077 and ASTM E 329 for testing indicated.

D. Mockups: Before installing shotcrete, construct mockups for each finish required and for each design mix, shooting orientation, and nozzle operator to demonstrate aesthetic effects and set quality standard for installation.

1. Size: 4’-0” x 4’-0”.

2. Location: As directed by DNR District Engineer.

4. Approved mockups may become part of the completed Work if undamaged at time of Substantial Completion.

1.7 PROJECT CONDITIONS

A. Cold-Weather Shotcreting: Protect shotcrete work from physical damage or reduced strength caused by frost, freezing, or low temperatures according to ACI 306.1 and as follows:

1. Discontinue shotcreting when ambient temperature is 45 deg. F and falling. Uniformly heat water and pre-packaged materials before mixing to obtain a shotcrete shooting temperature of not less than 50 deg. F and not more than 90 deg. F.

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

3. Do not place shotcrete on frozen surfaces or surfaces containing frozen materials.

4. Do not use calcium chloride, salt, or other materials containing antifreeze agents.

B. Hot-Weather Shotcreting: Mix, place, and protect shotcrete according to ACI 506R when hot weather conditions and high temperatures would seriously impair quality and strength of shotcrete, and as follows:

1. Cool ingredients before mixing to maintain shotcrete temperature at time of placement below 100 deg. F for dry mixor90 deg. F for wet mix.

2. Reduce temperature of reinforcing steel and receiving surfaces below 100 deg. F before shotcreting.

PART 2 – PRODUCTS

2.2 REINFORCING MATERIALS

A. Reinforcing Bars: ASTM A 615, Grade 60 (Grade 420), deformed.

Supports: Bolsters, chairs, spacers, ties, and other devices for spacing, supporting, and fastening reinforcing steel in place according to CRSI's "Manual of Standard Practice".

2.3 SHOTCRETE MATERIAL MANUFACTURER

A. Acceptable Manufacturer: SPEC MIX®, Inc., which is located at: 1230 Eagan Industrial Road, Suite 160

– or approved equal

2.4 SHOTCRETE MATERIALS

A. SPECSHOT Shotcrete: Shotcrete is a pre-blended, high early strength, low permeability and low rebound cement based product containing Portland cement, aggregate, fly ash, silica fume, steel or synthetic fibers, and chemical admixtures, specifically designed for ground support shotcrete applications.

1. Applicable Standards: ASTM A820, ASTM C 33, ASTM C 150, ASTM C 260, ASTM C 494, ASTM C 618, ASTM C 1116, ASTM C 1141, ASTM C 1240, ACI 506.2.

B. SPECFINISH Shotcrete: is a pre-blended, high early strength, cement based product finish shotcrete containing Portland cement, aggregate, fly ash, silica fume, steel or synthetic fibers, and chemical admixtures specifically designed for finishing rockscapes, sculptures or other architectural shotcrete applications.

1. Coloring Agent: ASTM C 979, synthetic mineral-oxide pigments or colored, water-reducing admixtures, color stable, nonfading, and resistant to lime and other alkalis.

a. Color: As selected by Architect from manufacturer's full range

2. Applicable Standards: ASTM A 820, ASTM C 33, ASTM C 150, ASTM C 260, ASTM C 494, ASTM C 618, ASTM C 1116, ASTM C 1141, ASTM C 1240, ACI 506.2.

2.5 ACCESSORY MATERIALS

A. Water: Clean and free from deleterious acids, alkalis, and organic matter.

B. Concrete Admixture: Sika Acryl 60

2.6 CURING MATERIALS

A. Absorptive Cover: AASHTO M 182, Class 2, burlap cloth made from jute or kenaf, weighing approximately 9 oz./sq. yd. dry.

B. Moisture-Retaining Cover: ASTM C 171, polyethylene film or white burlap-polyethylene sheet.

C. Water: Clean and free from deleterious acids, alkalis, and organic matter.

D. Clear, [Waterborne] [Solvent-Borne], Membrane-Forming Curing Compound: ASTM C 309, Type 1, Class B.

2.7 SHOTCRETE MIXTURES

A. Prepare design mixes for each type and strength of shotcrete.

B. Design-Mix Adjustments: Subject to compliance with requirements, shotcrete design-mix adjustments may be proposed when characteristics of materials, Project conditions, weather, test results, or other circumstances warrant.

C. Mix pre-packaged shotcrete materials with water either in dry mix or wet mix process to provide shotcrete with the following properties:

1. Compressive Strength (28 Days): 4000 psi

2. If pre-packaged, air-entrained mixtures are selected, verify that normal-weight, wet-mix shotcrete has an air content before pumping of 8 percent with a tolerance of plus or minus 1 percent.

2.9 SHOTCRETE EQUIPMENT

A. Mixing Equipment: Capable of thoroughly mixing shotcrete materials in sufficient quantities to maintain continuous placement.

B. Wet-Mix Delivery Equipment: Capable of discharging aggregate-cement-water mixture accurately, uniformly, and continuously.

2.10 MIXING

A. Wet-Mix Process: Thoroughly mix clean water with pre-packaged shotcrete materials in batch mixer prior to use.

1. Verify with manufacturer quantity of water to be added to batch to achieve specified mix design.

PART 3 – EXECUTION

3.1 PREPARATION

A. Concrete or Masonry: Before applying shotcrete, remove unsound or loose materials and contaminants that may inhibit shotcrete bonding. Chip or scarify areas to be repaired to extent necessary to provide sound substrate. Cut edges square and 1/2 inch deep at perimeter of work, tapering remaining shoulder at 1:1 slope into cavity to eliminate square shoulders. Dampen surfaces before shotcreting.

1. Abrasive blast or hydroblast existing surfaces that do not require chipping to remove paint, oil, grease, or other contaminants and to provide roughened surface for proper shotcrete bonding.

B. Earth: Compact and trim to line and grade before placing shotcrete. Do not place shotcrete on frozen surfaces. Dampen surfaces before shotcreting.

C. Rock: Clean rock surfaces of loose materials, mud, and other foreign matter that might weaken shotcrete bonding.

D. Steel: Clean steel surfaces by abrasive blasting according to SSPC-SP 6/NACE No. 3, "Commercial Blast Cleaning."

3.3 STEEL REINFORCEMENT

A. General: Comply with CRSI's "Manual of Standard Practice" for fabricating, placing, and supporting reinforcement.

B. Clean reinforcement of loose rust and mill scale, earth, ice, and other materials that weaken shotcrete bonding.

C. Securely embed reinforcing anchors into existing substrates, located as required.

D. Accurately position, support, and rigidly secure reinforcement against displacement by formwork, construction, or shotcreting. Locate and support reinforcement by metal chairs, runners, bolsters, spacers, and hangers, as required.

E.

F.

Place reinforcement to obtain minimum coverage for shotcrete protection. Arrange, space, and securely tie bars and bar supports to hold reinforcement in position during shotcreting. Set wire ties with ends directed into shotcrete, not toward exposed shotcrete surfaces.

Install welded wire fabric in lengths as long as practicable. Lap adjoining pieces at least one full mesh and lace splices with wire. Offset laps of adjoining widths to prevent continuous laps in either direction.

3.4 JOINTS

A. Construction Joints: Locate and install construction joints tapered to a 1:1 slope where joint is not subject to compression loads and square where joint is perpendicular to main reinforcement. Continue reinforcement through construction joints, unless otherwise indicated.

B. Contraction Joints: Construct contraction joints in shotcrete using saw cuts 1/8-inch wide by 1/3 slab depth or joint-filler strips 1/4-inch wide by 1/3 shotcrete depth, unless otherwise indicated.

1. After shotcrete has cured, remove strip inserts and clean groove of loose debris.

2. Space joints at [15 feet o.c.] [centers indicated] <Insert spacing> horizontally and vertically.

3. Tool edges round on each side of strip inserts if floated or troweled finishes are required.

3.5 ALIGNMENT CONTROL

A. Ground Wires: Install ground wires to establish thickness and planes of shotcrete surfaces. Install ground wires at corners and offsets not established by forms. Pull ground wires taut and position adjustment devices to permit additional tightening.

3.6 EMBEDDED ITEMS

03 37 13-7

SPEC MIX, Inc. – Guide Specification

A. Place and secure anchorage devices and other embedded items required for adjoining work that is attached to or supported by shotcrete. Use setting drawings, templates, diagrams, instructions, and directions furnished with items to be embedded.

3.7 APPLICATION

A. Apply temporary protective coverings and protect adjacent surfaces against deposit of rebound and overspray or impact from nozzle stream.

B. Moisten substrate immediately before placing shotcrete.

1. Moisten wood forms immediately before placing shotcrete where form coatings are not used.

C. Apply shotcrete according to ACI 506.2.

D. Apply [dry-mix shotcrete materials within 45 minutes after pre-dampening] [and] [wet-mix shotcrete materials within 90 minutes after batching].

E.

F.

Deposit shotcrete continuously in multiple passes, to required thickness, without cold joints and laminations developing. Place shotcrete with nozzle held perpendicular to receiving surface. Begin shotcreting in corners and recesses.

1. Remove and dispose of rebound and overspray materials during shotcreting to maintain clean surfaces and to prevent rebound entrapment.

Maintain reinforcement in position during shotcreting. Place shotcrete to completely encase reinforcement and other embedded items. Maintain steel reinforcement free of overspray and prevent buildup against front face during shotcreting.

G. Do not place subsequent lifts until previous lift of shotcrete is capable of supporting new shotcrete.

H. Do not permit shotcrete to sag, slough, or dislodge.

I.

J.

Remove hardened overspray, rebound, and laitance from shotcrete surfaces to receive additional layers of shotcrete; dampen surfaces before shotcreting.

Do not disturb shotcrete surfaces before beginning finishing operations.

K. Remove ground wires or other alignment control devices after shotcrete placement.

L.

Installation Tolerances: Place shotcrete without exceeding installation tolerances permitted by

ACI 117R, increased by a factor of 2.

3.8 SURFACE FINISHES

A. General: Finish shotcrete according to descriptions in ACI 506R for the following finishes:

B. Natural Finish:

1. Gun Finish: Natural undisturbed finish.

2. Rod Finish: Rough-textured finish obtained by cutting or screeding exposed face of shotcrete to plane by rod or straightedge after initial set[, and wood-float finished] [, and steel-trowel finished].

3. Broom Finish: Rough-textured finish obtained by screeding exposed face of shotcrete to required plane by rod, cutting screed, or trowel, and brooming after initial set.

C. Flash-Coat Finish: After screeding and rodding surface, apply up to 1/4-inch coat of shotcrete using

ACI 506R, Gradation No. 1, fine-screened sand modified with maximum aggregate size not exceeding

No. 4 sieve to provide a finely textured finish.

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SPEC MIX, Inc. – Guide Specification

D. Flash-Coat and Final Finish: After screeding and rodding surface, apply up to 1/4-inch coat of shotcrete using ACI 506R, Gradation No. 1, fine-screened sand modified with maximum aggregate size not exceeding No. 4 sieve and apply [wood-float] [rubber-float] [brush-float] [steel-trowel] finish.

E.

F.

Finish-Coat Finish: After screeding and rodding surface, apply shotcrete finish coat, 1/4 to 1 inch thick, using ACI 506R, Gradation No. 1, fine-screened sand modified with maximum aggregate size not exceeding No. 4 sieve to provide a finish of uniform texture and appearance.

Finish-Coat and Final Finish: After screeding and rodding surface, apply shotcrete finish coat, 1/4 to 1 inch thick, using ACI 506R, Gradation No. 1, fine-screened sand modified with maximum aggregate size not exceeding No. 4 sieve and apply [wood-float] [rubber-float] [brush-float] [steel-trowel] finish.

3.9 CURING

A. Protect freshly placed shotcrete from premature drying and excessive cold or hot temperatures.

B. Start initial curing as soon as free water has disappeared from shotcrete surface after placing and finishing.

C. Curing Exposed Surfaces: Cure shotcrete by one of the following methods:

1. Moisture Curing: Keep surfaces continuously moist for at least seven days with water, continuous water-fog spray, water-saturated absorptive covers, or moisture-retaining covers. Lap and seal sides and ends of covers.

2. Curing Compound: Apply curing compound uniformly in continuous operation by power spray according to manufacturer's written instructions. Recoat areas subjected to heavy rainfall within three hours after initial application. Maintain continuity of coating and repair damage during curing period.

a. Apply curing compound to natural or gun-finished shotcrete at rate of 1 gal./100 sq. ft.

D. Curing Formed Surfaces: Cure formed shotcrete surfaces by moist curing with forms in place for full curing period or until forms are removed. If forms are removed, continue curing by methods specified above, as applicable.

3.10 FORM REMOVAL

A. Forms not supporting weight of shotcrete may be removed after curing at not less than 50 deg. F for consecutive hours after gunning, provided shotcrete is hard enough not to be damaged by form-removal operations and provided curing and protecting operations are maintained.

1. Leave forms supporting weight of shotcrete in place until shotcrete has attained design compressive strength. Determine compressive strength of in-place shotcrete by testing representative field-cured specimens of shotcrete.

2. Remove forms only if shores have been arranged to permit removal of forms without loosening or disturbing shores.

B. Clean and repair surfaces of forms to be reused in the Work. Split, frayed, delaminated, or otherwise damaged form facing materials are unacceptable for exposed surfaces. Apply new form coating compound as specified for new formwork.

3.11 FIELD QUALITY CONTROL

A. Testing Laboratory: Independent of the Owner, Architect and Contractor; the testing laboratory, in addition to meeting requirements of ASTM E-329, and must be an approved laboratory competent to perform concrete physical testing. All tests must be performed in strict accordance with the applicable

ASTM standard.

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SPEC MIX, Inc. – Guide Specification

B. Distribution of Results of Tests: Within 24 hours of results of tests, copies of the results shall be submitted to the Architect, Contractor and the supplier if applicable.

C. Shotcrete Testing:

1. Air Content: ASTM C 173, volumetric method or ASTM C 231, pressure method; 1 test for each compressive-strength test for each mix of air-entrained, wet-mix shotcrete measured before pumping.

2. Shotcrete Temperature: ASTM C 1064; 1 test hourly when air temperature is 40 deg. F and below and when 80 deg. F and above, and 1 test for each set of compressive-strength specimens.

3. In-Place Shotcrete: Take a set of 3 unreinforced cores for each mix and for each workday or for every

50 cu. yd. of shotcrete placed; whichever is less. Test cores for compressive strength according to

ACI 506.2 and ASTM C 42. Do not cut steel reinforcement.

a. Strength of shotcrete will be considered satisfactory when mean compressive strength of each set of 3 unreinforced cores equals or exceeds 85 percent of specified compressive strength, with no individual core less than 75 percent of specified compressive strength.

3.12 REPAIRS

A. Remove and replace shotcrete that is delaminated or exhibits laminations, voids, or sand/rock pockets exceeding limits for specified core grade of shotcrete.

1. Remove unsound or loose materials and contaminants that may inhibit bond of shotcrete repairs.

Chip or scarify areas to be repaired to extent necessary to provide sound substrate. Cut edges square and 1/2 inch deep at perimeter of work, tapering remaining shoulder at 1:1 slope into cavity to eliminate square shoulders. Dampen surfaces and apply new shotcrete.

B. Repair core holes from in-place testing according to repair provisions in ACI 301 and match adjacent finish, texture, and color.

3.13 CLEANING

A. Remove and dispose of rebound and overspray materials from final shotcrete surfaces and areas not intended for shotcrete placement.

SECTION 04122

ARCHITECTURAL STONE

General

Summary

References

American National Standards Institute (ANSI):

ANSI A118.4 Specifications for Latex-Portland Cement Mortar.

American Society for Testing and Materials (ASTM):

ASTM C 39 – Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens.

ASTM C 847 Standard Specification for Metal Lath.

ASTM C 1059 – Standard Specification for Latex Agents for Bonding Fresh To Hardened Concrete.

ASTM C1063 –Standard Specification for Installation of Lathing and Furring to Receive Interior and Exterior Portland Cement-Based Plaster

ASTM C1329 Standard specification for Portland cement

Other Standards:

Standard sample board consisting of small-scale pieces of veneer units showing full range of textures and colors.

Quality Assurance/Control Submittals:

Qualifications:

Proof of manufacturer qualifications.

Proof of installer qualifications.

Regulatory Requirements: Evaluation reports.

Veneer manufacturer’s installation instructions.

Installation instructions for other materials.

Closeout Submittals: Reference Section 01 78 00Closeout Submittals; submit following items:

Installer Qualifications: Experienced mason familiar with installation procedures and related local, state and federal codes masonry.

Field Sample: Prepare 4’-0” x 4’-0” sample at a location on the structure as selected by the Architect.

Use approved selection sample materials and colors.

Obtain Architect and DNR District Engineer’s approval.

Protect and retain sample as a basis for approval of completed manufactured stone work. Approved sample may be incorporated into completed work.

Delivery, Storage, and Handling

Reference Section 01 66 00Product Storage and Handling Requirements.

Follow manufacturer’s instructions.

Project/SITE Conditions

Environmental Requirements: When air temperature is 45 degrees F (4.5 degrees C) or below, work shall not be admitted. If stone has been applied and weather is dropping below 45 F, contractor shall ensure full cure and blanket or warm area to keep mortar or grout above 45 F.

Warranty

Manufacturer’s standard warranty coverage against defects in materials when installed in accordance with manufacturer’s installation instructions.

Products

Manufacturer

Eldorado Stone, LLC, or approved equal.

Product: Country Rubble - Polermo

Substitutions: Approved by Architect and DNR District Engineer.

Materials

Stone Veneer:

Reinforcing: ASTM C 847, 2.5lb/yd2 (1.4kg/m2) galvanized expanded metal lath, complying with code agency requirements for the type of substrate over which stone veneer is installed.

Mortar:

Cement: Portland cement complying with ASTM C 1329.

Lime: ASTM C 207.

Sand: ASTM C 144, natural or manufactured sand.

Water: Potable.

Pre-Packaged Latex-Portland Cement Mortar: ANSI A118.4.

Bonding Agent: Exterior integral bonding agent meeting ASTM C 932

MORTAR Mixes

Standard Installation (Grouted Joints):

Mix mortar in accordance with ASTM C 270, Polymer modified mortar complying with ANSI A118.4

Execution

Examination

Examine substrates upon which work will be installed.

Coordinate with responsible entity to perform corrective work on unsatisfactory substrates.

Commencement of work by installer is acceptance of substrate.

Preparation

Protection: Protect adjacent work from contact with mortar.

Surface Preparation: Prepare substrate in accordance with manufacturer’s installation instructions for the type of substrate being covered.

INSTALLATION

Install and clean stone in accordance with manufacturer’s installation instructions for Standard Installation (Grouted Joint) installation as specified above.

Remove protective coverings from adjacent work.

Cleaning Veneer Units: Wash with soft bristle brush and water/granulated detergent solution. Rinse immediately with clean water