Attachment N - UFGS 03 45 33 Precast Structural Concrete.pdf

SECTION 03 45 33 Page 1

SECTION TABLE OF CONTENTS

DIVISION 03 - CONCRETE

SECTION 03 45 33

PRECAST STRUCTURAL CONCRETE

05/16

Table of Contents

PART 1 GENERAL

1.1 REFERENCES

1.2 MODIFICATION TO REFERENCE

1.3 SUBMITTALS

1.4 QUALITY ASSURANCE

1.5 DELIVERY, STORAGE, AND HANDLING

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

2.2 MATERIALS

2.3 PRODUCTION QUALITY CONTROL PROCEDURES

2.4 TESTS, INSPECTIONS, AND VERIFICATIONS

PART 3 EXECUTION

3.1 EXAMINATION

3.2 ERECTION

3.3 BEARING SURFACES

3.4 ANCHORAGE

3.6 OPENINGS

3.7 GALVANIZING REPAIR

3.8 GROUTING

3.9 SEALANTS

3.10 PROTECTION AND CLEANING

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SECTION 03 45 33

PRECAST CONCRETE

05/16

PART 1 GENERAL.

1.1 REFERENCES.

The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only.

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS

(AASHTO)

AASHTO LRFDCONS (3rd Edition; 2010, 2011, 2012, 2014, 2015, and 2016 Int) Bridge Construction

Specifications

AASHTO M 251 (2006; R 2011) Standard Specification for

Plain and Laminated Elastomeric Bridge

Bearings

AASHTO T 259 (2002; R 2017) Standard Method of Test for

Resistance of Concrete to Chloride Ion

Penetration

AMERICAN CONCRETE INSTITUTE (ACI)

ACI 318 (2014; Errata 1-2 2014; Errata 3-5 2015;

Errata 6 2016; Errata 7-9 2017) Building

Code Requirements for Structural Concrete

(ACI 318-14) and Commentary (ACI 318R-14)

ACI 318M (2014; ERTA 2015) Building Code

Requirements for Structural Concrete &

Commentary

AMERICAN HARDBOARD ASSOCIATION (AHA)

AHA A135.4 (1995; R 2004) Basic Hardboard

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2020) Structural Welding Code - Steel

AWS D1.4/D1.4M (2011) Structural Welding Code -

Reinforcing Steel

ASTM INTERNATIONAL (ASTM)

ASTM A27/A27M (2020) Standard Specification for Steel

Castings, Carbon, for General Application

ASTM A36/A36M (2019) Standard Specification for Carbon

Structural Steel

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ASTM A47/A47M (1999; R 2018; E 2018) Standard

Specification for Ferritic Malleable Iron

Castings

ASTM A123/A123M (2017) Standard Specification for Zinc

(Hot-Dip Galvanized) Coatings on Iron and

Steel Products

ASTM A153/A153M (2016a) Standard Specification for Zinc

Coating (Hot-Dip) on Iron and Steel

Hardware

ASTM A307 (2014; E 2017) Standard Specification for

Carbon Steel Bolts, Studs, and Threaded

Rod 60 000 PSI Tensile Strength

ASTM A325 (2014) Standard Specification for

Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM A325M (2014) Standard Specification for

Structural Bolts, Steel, Heat Treated, 830

MPa Minimum Tensile Strength (Metric)

ASTM A416/A416M (2018) Standard Specification for

Low-Relaxation, Seven-Wire for

Prestressed Concrete

ASTM A421/A421M (2015) Standard Specification for Uncoated

Stress-Relieved Steel Wire for Prestressed

Concrete

ASTM A563 (2015) Standard Specification for Carbon and Alloy Steel Nuts

ASTM A563M (2007; R 2013) Standard Specification for

Carbon and Alloy Steel Nuts (Metric)

ASTM A615/A615M (2020) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete

Reinforcement

ASTM A706/A706M (2016) Standard Specification for

Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement

ASTM A722/A722M (2015) Standard Specification for Uncoated

High-Strength Steel Bar for Prestressing

ASTM A767/A767M (2016) Standard Specification for

Zinc-Coated (Galvanized) Steel Bars for

Concrete Reinforcement

ASTM A775/A775M (2017) Standard Specification for

Epoxy-Coated Steel Reinforcing Bars

ASTM A780/A780M (2009; R 2015) Standard Practice for

Repair of Damaged and Uncoated Areas of

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Hot-Dip Galvanized Coatings

ASTM A934/A934M (2016) Standard Specification for

Epoxy-Coated Prefabricated Steel

Reinforcing Bars

ASTM A996/A996M (2016) Standard Specification for

Rail-Steel and Axle-Steel Deformed Bars for Concrete Reinforcement

ASTM A1064/A1064M (2017) Standard Specification for

Carbon-Steel Wire and Welded Wire

Reinforcement, Plain and Deformed, for

ASTM C33/C33M (2018) Standard Specification for Concrete

Aggregates

ASTM C94/C94M (2020) Standard Specification for

Ready-Mixed Concrete

ASTM C150/C150M (2020) Standard Specification for Portland

Cement

ASTM C260/C260M (2010a; R 2016) Standard Specification for

Air-Entraining Admixtures for Concrete

ASTM C295/C295M (2019) Standard Guide for Petrographic

Examination of Aggregates for Concrete

ASTM C311/C311M (2018) Standard Test Methods for Sampling and Testing Fly Ash or Natural Pozzolans for Use in Portland-Cement Concrete

ASTM C330/C330M (2017a) Standard Specification for

Lightweight Aggregates for Structural

ASTM C494/C494M (2019) Standard Specification for Chemical

Admixtures for Concrete

ASTM C618 (2019) Standard Specification for Coal Fly

Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

ASTM C989/C989M (2018a) Standard Specification for Slag

Cement for Use in Concrete and Mortars

ASTM C1107/C1107M (2020) Standard Specification for Packaged

Dry, Hydraulic-Cement Grout (Nonshrink)

ASTM C1202 (2019) Standard Test Method for Electrical

Indication of Concrete's Ability to Resist

Chloride Ion Penetration

ASTM C1218/C1218M (2017) Standard Test Method for

Water-Soluble Chloride in Mortar and

Concrete

ASTM C1240 (2020) Standard Specification for Silica

Fume Used in Cementitious Mixtures

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ASTM C1260 (2014) Standard Test Method for Potential

Alkali Reactivity of Aggregates

(Mortar-Bar Method)

ASTM C1567 (2013) Standard Test Method for Potential

Alkali-Silica Reactivity of Combinations of Cementitious Materials and Aggregate

(Accelerated Mortar-Bar Method)

ASTM C1602/C1602M (2018) Standard Specification for Mixing

Water Used in Production of Hydraulic

Cement Concrete

ASTM D2240 (2015; E 2017) Standard Test Method for

Rubber Property - Durometer Hardness

ASTM D5759 (2012; R 2020) Characterization of Coal

Fly Ash and Clean Coal Combustion Fly Ash for Potential Uses

ASTM F436 (2011) Hardened Steel Washers

ASTM F436M (2011) Hardened Steel Washers (Metric)

ASTM F844 (2007a; R 2013) Washers, Steel, Plain

(Flat), Unhardened for General Use

PRECAST CONCRETE INSTITUTE (PCI)

PCI MNL-116 (1999) Manual for Quality Control for

Plants and Production of Structural

Precast Concrete Products, 4th Edition

PCI MNL-120 (2010) PCI Design Handbook - Precast and

Prestressed Concrete, 6th Edition

PCI MNL-124 (2011) Design for Fire Resistance of

Precast Prestressed Concrete, Third Edition

PCI MNL-135 (2000) Tolerance Manual for Precast and

Prestressed Concrete Consturction

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-C-882 (1989; Rev E) Cloth, Duck, Cotton or

Cotton-Polyester Blend, Synthetic Rubber, Impregnated, and Laminated, Oil Resistant

UNDERWRITERS LABORATORIES (UL)

UL Fire Resistance (2014) Fire Resistance Directory

1.2 MODIFICATION TO REFERENCE.

In the ACI publications, reference to the "Building Official," the

"Structural Engineer" and the "Architect/Engineer" must be interpreted to mean the Contracting Officer.

1.3 SUBMITTALS.

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Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the government officer that will review the submittal for the Government.

SD-01 Shop Drawings

Drawings of Precast Members; G, COR

SD-02 Closeout Submittals

Concrete Batch Ticket Information

Recycled Content for Silica Fume

1.4 QUALITY ASSURANCE.

1.4.1 Concrete Mix Design

ACI 318MACI 318. The minimum compressive strength of concrete at 28 days must be 5000 psi, unless otherwise indicated. Add air-entraining admixtures at the mixer to produce between 4 and 6 percent air by volume. 15 days minimum prior to concrete placement, submit a mix design for each strength and type of concrete. Submit a complete list of materials including type; brand; source and amount of cement, complementary cementitious materials, and admixtures; and applicable reference specifications. Submit mill test and all other test for cement, complementary cementitious materials, aggregates, and admixtures. Provide documentation of maximum nominal aggregate size, gradation analysis, percentage retained and passing sieve, and a graph of percentage retained verses sieve size. Provide mix proportion data using at least three different water-cementitious material ratios for each type of mixture, which produce a range of strength encompassing those required for each type of concrete required. If source material changes, resubmit mix proportion data using revised source material.

Provide only materials that have been proven by trial mix studies to meet the requirements of this specification, unless otherwise approved in writing by the Contracting Officer. Indicate clearly in the submittal where each mix design is used when more than one mix design is submitted. Resubmit data on concrete components if the qualities or source of components changes. For previously approved concrete mix designs used within the past twelve months, the previous mix design may be re-submitted without further trial batch testing if accompanied by material test data conducted within the last six months. Obtain mix design approval from the contracting officer prior to concrete placement.

1.4.2 Certificates: Record Requirement

ASTM C94/C94M. Submit mandatory batch ticket information for each load of ready-mixed concrete.

1.5 DELIVERY, STORAGE, AND HANDLING.

1.5.1 Transportation

1.5.1.1 Transporting Members

Transport members in a manner to avoid excessive stresses that could cause

SECTION 03 45 33 Page 7 cracking or other damage.

1.5.1.2 Lateral Deflection or Vibration

Any noticeable indication of lateral deflection or vibration during transportation must be corrected by rigid bracing between members or by means of lateral trussing.

1.5.2 Storage

1.5.2.1 Storage Areas

Storage areas for precast members must be stabilized, and suitable foundations must be provided, so differential settlement or twisting of members will not occur.

1.5.2.2 Stacked Members

Stack members with adequate dunnage and bracing to control cracking, distortion, warping or other physical damage. Stack members such that lifting devices will be accessible and undamaged.

1.5.3 Handling of Members

The location of pickup points for handling of the members and details of the pickup devices must be shown in shop drawings. Members must be handled only by means of approved devices at designated locations.

Members must be maintained in an upright position at all times and picked up and supported as shown in approved shop drawings.

PART 2 PRODUCTS.

2.1 SYSTEM DESCRIPTION.

Precast members must be the product of a manufacturer specializing in the production of precast concrete members.

2.1.1 Design Requirements

Design Requirements for Changes to Original Design. If design changes from that provided, design precast members in accordance with ACI 318M ACI 318 and the PCI MNL-120. Design precast members (including connections) for the design load conditions and spans indicated, and handling and erection stresses, and for additional loads imposed by openings and supports of the work of other trades. Design precast members for handling without cracking in accordance with the PCI MNL-120.

2.1.1.1 Loads

Loadings for members and connections must include all dead load, live load, applicable lateral loads such as wind and earthquake, applicable construction loads such as handling, erection loads, and other applicable loads.

2.1.1.2 Drawing and Design Calculation Information

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Drawing and Design Calculation Information. Submit drawings and design calculations indicating complete information for the fabrication, handling, and erection of the precast member. Include a cover page with the design calculations, signed and sealed by the registered design professional who prepared the design. Drawings must not be reproductions of contract drawings. Design calculations, drawings of precast members, and (including connections) must be made by a registered professional engineer experienced in the design of precast concrete members, and submitted for approval prior to fabrication. The drawings must indicate, as a minimum, the following information:

a. Plans, elevations and other drawing views showing the following:

(1) Member piece marks locating and defining products furnished by the manufacturer.

(2) Headers for openings.

(3) Location and size of openings

(4) Relationships to adjacent material.

(5) Joints and openings between members and between members and other construction.

(6) Location of field installed anchors.

(7) Erection sequences and handling requirements

(8) Areas receiving toppings and magnitude of topping thickness.

Identify areas where topping is an integral part of the structural capacity of the precast members.

(9) Lifting and erection inserts

b. Elevations, sections and other details for each member showing the following:

(1) Connections between members and connections between members and other construction.

(2) Connections for work of other trades and cast-in items and their relation to other trades.

(3) Dimensioned size and shape for each member with quantities, position and other details of reinforcing steel, anchors, inserts and other embedded items.

(4) Lifting, erection and other handling devices and inserts.

(5) Surface finishes of each member.

(6) Estimated cambers

e. Magnitude, schedule and sequence of tensioning and detensioning prestressing strands.

f. Strength properties for concrete, steel and other materials.

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g. Methods for storage and transportation.

h. Description of loose, cast-in and field hardware.

i. All dead, live, handling, erection and other applicable loads used in the design.

j. Signature and seal of the registered design professional who prepared the design.

2.2 MATERIALS.

2.2.1 Cementitious Materials

2.2.1.1 Portland Cement

Unless otherwise specified, provide cement that conforms to ASTM

C150/C150M Type I or II and meets low alkali content Requirements.

Contractor shall use ASTM C150/C150M Type III where high early strength is required.

2.2.2 Water

Water must comply with the requirements of ASTM C1602/C1602M. Minimize the amount of water in the mix. Improve workability by adjusting the grading rather than by adding water. Water must be potable free from injurious amounts of oils, acids, alkalis, salts, organic materials, or other substances deleterious to concrete. Submit test report showing water complies with ASTM C1602/C1602M.

2.2.3 Aggregates

ASTM C33/C33M, except as modified herein. Furnish aggregates for exposed concrete surfaces from one source. Provide aggregates that do not contain any substance which may be deleteriously reactive with the alkalies in the cement. Submit test report showing compliance with ASTM C33/C33M.

2.2.4 Grout

2.2.5.1 Nonshrink Grout

ASTM C1107/C1107M.

2.2.5.2 Cementitious Grout

Must be a mixture of portland cement, sand, and water. Proportion one part cement to approximately 2.5 parts sand, with the amount of water based on placement method.

2.2.6 Admixtures

2.2.6.1 Air-Entraining

ASTM C260/C260M.

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2.2.6.2 Accelerating

ASTM C494/C494M, Type C or E.

2.2.6.3 Water Reducing

ASTM C494/C494M, Type A, E, or F.

2.2.7 Reinforcement

2.2.7.1 Reinforcing Bars

ASTM A615/A615M, Grade 60; ASTM A706/A706M, Grade 60; or ASTM A996/A996M, Grade 60.

Epoxy-coated steel bars must comply with the requirements of ASTM A775/A775M or ASTM A934/A934M, including written certifications for coating material and coated bars, sample of coating material, and 0.5 pounds of patching material.Submit written certification with the delivery of the bars.

Zinc-coated (galvanized) bars must comply with the requirements of

ASTM A767/A767M, Class II coating, galvanized after fabrication.

2.2.7.2 Wire

ASTM A1064/A1064M.

2.2.7.3 Welded Wire Reinforcement

ASTM A1064/A1064M.

2.2.7.4 Supports for Concrete Reinforcement

Include bolsters, chairs, spacers, and other devices necessary for proper spacing, supporting, and fastening reinforcement bars and wire in place.

Ensure legs of supports in contact with formwork for sections that will be exposed to weather are hot-dip galvanized after fabrication, plastic coated, or corrosion-resistant steel bar supports.

2.3 PRODUCTION QUALITY CONTROL PROCEDURES.

2.3.1 Forms

Brace forms to prevent deformation. Forms must produce a smooth, dense surface. Use forms and form-facing materials that are nonreactive with concrete such as wood, metal, plastic, or other approved materials.

Conform to the shapes, lines, and dimensions indicated and are within the limits of the specified fabrication tolerances. Chamfer exposed edges of columns and beams 3/4 inch, unless otherwise indicated. Provide threaded or snap-off type form ties.

2.3.2 Tolerances

Fabricate structural precast concrete members of shapes, lines and dimensions indicated, so each finished member complies with PCI MNL-135 product tolerances as well as position tolerances for cast-in items.

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2.3.3 Reinforcement Placement

ACI 318MACI 318 and PCI MNL-116 for placement and splicing. Place and secure steel bars, welded-wire reinforcement, and other reinforcement by means of metal bar supports and spacers. Reinforcement may be preassembled before placement in forms. Provide exposed connecting bars, or other approved connection methods, between precast and cast-in-place construction. Remove any excess mortar that adheres to the exposed connections

2.3.4 Inserts

When the ends of the prestressed member will be exposed, recess the prestressing stands using inserts. After detensioning, remove inserts and fill the recess with nonshrink grout.

2.3.5 Built-In Anchorage Devices

Position, anchor, and locate anchorage devices where they do not affect the position of the main reinforcement or placing concrete. Bearing plates; set level, aligned properly, and anchored in the exact location indicated.

2.3.6 Lifting Devices

Provide lifting devices designed for 100-percent impact, and of materials sufficiently ductile to ensure visible deformation before fracture.

2.3.7 Blockouts

Provide blockouts as indicated.

2.3.8 Identification Markings

Clearly mark each structural section in a permanent manner to indicate its location and orientation in the building and the pickup points.

Ensure each structural section has the date of casting plainly indented in the unexposed face of the concrete.

2.3.9 Concrete

2.3.9.1 Concrete Mixing

ASTM C94/C94M. Mixing operations must produce batch-to-batch uniformity of strength, consistency, and appearance.

2.3.9.2 Concrete Placing

PCI MNL-116.

2.3.9.3 Concrete Curing

PCI MNL-116.

2.3.10 Surface Finish

Repairs located in a bearing area must be approved by the Contracting

Officer prior to repairs. Defects must be repaired or rejected as

SECTION 03 45 33 Page 12 specified in paragraph ACCEPTANCE/REJECTION OF DEFECTS.

2.3.11 Acceptance/Rejection of Defects

2.3.11.1 Minor Defects

All honeycombed areas, chipped corners, air pockets over 1/4 inch in diameter, and other minor defects involve less than 36 square inches of concrete must be repaired. Form offsets of fins over 1/8 inch must be ground smooth. All unsound concrete must be removed from defective areas prior to repairing. All surfaces permanently exposed to view must be repaired by a blend of portland cement and white cement properly proportioned so that the final color when cured will be the same as adjacent concrete. Precast members containing hairline cracks which are visible and are less than 0.01 inches in width, may be accepted, except that cracks larger than 0.005 inches in width for surfaces exposed to the weather must be repaired.

2.3.11.2 Major Defects

Major defects are those which involve more than 36 square inches of concrete or expose stressing tendons or reinforcing steel. If one or more major defects appear in a member, it will be rejected. Cracks of a width of more than 0.25 mm 0.01 inch will be cause for rejection of the member.

2.4 TESTS, INSPECTIONS, AND VERIFICATIONS.

At the option of the Contracting Officer, precast units may be inspected by the Contracting Officer. Precast units must be inspected by the QC

Representative prior to being transported to the job site. The Contractor must give notice 7 days prior to the time the units will be available for inspection. Neither the exercise nor waiver of inspection will affect the

Government's right to enforce contractual provisions after units are installed.

PART 3 EXECUTION.

3.1 EXAMINATION.

Prior to erection, and again after installation, precast members must be checked for damage, such as cracking, spalling, and honeycombing.

As directed by the Contracting Officer, precast members that do not meet the surface finish requirements specified in paragraph SURFACE

FINISH must be repaired, or removed and replaced with new precast members.

3.2 ERECTION.

Precast members must be erected after the concrete has attained the specified compressive strength, unless otherwise approved by the precast manufacturer. Erect in accordance with the approved shop drawings. PCI

MNL-135 for tolerances. Provide a 1:500 tolerance, if no tolerance is specified. Brace precast members, unless design calculations submitted with the shop drawings indicate bracing is not required. Follow the manufacturer's recommendations for maximum construction loads. Place precast members level, plumb, square, and true within tolerances. Align member ends.

3.3 BEARING SURFACES.

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Must be flat, free of irregularities, and properly sized. Size bearing surfaces to provide for the indicated clearances between the precast member and adjacent precast members or adjoining field placed surfaces.

Correct bearing surface irregularities with nonshrink grout. Provide bearing pads where indicated or required. Do not use hardboard bearing pads in exterior locations. Place precast members at right angles to the bearing surface, unless indicated otherwise, and draw-up tight without forcing or distortion, with sides plumb.

3.4 ANCHORAGE.

Provide anchorage for fastening work in place. Conceal fasteners where practicable. Make threaded connections up tight and nick threads to prevent loosening.

3.5 WELDING

AWS D1.1/D1.1M, AWS D1.4/D1.4M for welding connections and reinforcing splices. Welding of epoxy-coated reinforcing is not allowed.

3.6 OPENINGS.

Holes or cuts requiring reinforcing to be cut, which are not indicated on the approved shop drawing, must only be made with the approval of the

Contracting Officer and the precast manufacturer. Drill holes less than

12 inches in diameter with a diamond tipped core drill. Ensure cuts are straight and at 90 degrees to the surfaces without breaking or spalling the edges.

3.7 GALVANIZING REPAIR.

Repair damage to galvanized coatings using ASTM A780/A780M zinc rich paint for galvanized surfaces damaged by handling, transporting, cutting, welding, bolting, or acid washing. Do not heat surfaces to which repair paint has been applied.

3.8 GROUTING.

Clean and fill keyways between precast members, and other indicated areas, solidly with nonshrink grout or cementitious grout. Provide reinforcing where indicated. Remove excess grout before hardening.

3.9 SEALANTS.

Provide as indicated and as specified in Section 07 92 00 JOINT SEALANTS.

3.10 PROTECTION AND CLEANING.

Protect exposed-to-view surfaces against staining and other damage until completion of the work.

Upon completion of installation, swept clean and leave ready slab surfaces to receive concrete floor topping, roofing, or other covering.

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