Cast-In-Place Concrete 03 30 00.pdf

FEDERAL AVIATION ADMINISTRATION JULY 2020

EASTERN SERVICE AREA STANDARD SPECIFICATION

CAST-IN-PLACE CONCRETE 03 30 00 - 1

SECTION 03 30 00 - CAST-IN-PLACE CONCRETE

PART 1 - GENERAL

1.1 SUMMARY

A. This Section specifies cast-in place concrete, including formwork, reinforcement, concrete materials, mixture design, placement procedures, and finishes, for the following:

1. Footings

2. Foundation walls

3. Slabs-on-grade

4. Concrete toppings

5. Concrete applications addressed in other specifications such as ductbanks, curb and gutter, and concrete paving.

1.2 DEFINITIONS

A. Cementitious Materials: Portland cement alone or in combination with one or more of the following: blended hydraulic cement, fly ash and other pozzolans, ground granulated blast-furnace slag, and silica fume; subject to compliance with requirements.

1.3 SUBMITTALS

A. Product Data: For each type of product indicated.

B. Design Mixtures: Submit proposed mix designs with recent field cylinder or lab tests for review prior to use. Mix shall be uniquely identified by mix numbers or other positive identification. Mix shall meet the requirements of ASTM C33 for course aggregate. Concrete shall comply with all the requirements of ASTM C94 for measuring, mixing, transporting, etc.

All concrete mix designs shall include a written description indicating where each particular mix is to be placed within the structure. All mix design submittals shall include tested, statistical back-up data conforming to the requirements of ACI 318 Chapter 5. For each concrete mixture, alternate design mixtures when characteristics of materials, project conditions, weather, test results, or other circumstances warrant adjustments, may be submitted for consideration on a case by case basis

1. Indicate amounts of mixing water to be withheld for later addition at Project site.

C. Steel Reinforcement Shop Drawings: Placing drawings that detail fabrication, bending, and placement. Include bar sizes, lengths, material, grade, bar schedules, stirrup spacing, bent bar diagrams, bar arrangement, splices and laps, mechanical connections, tie spacing, hoop spacing, and supports for concrete reinforcement.

D. Formwork Shop Drawings: Prepared by or under the supervision of a qualified professional engineer detailing fabrication, assembly, and support of formwork.

Kreiner, Jonathan CTR (FAA) Original design mix submittal criteria was clearly inadequate.

CAST-IN-PLACE CONCRETE 03 30 00 - 2

1. Shoring and Reshoring: Indicate proposed schedule and sequence of stripping formwork, shoring removal, and installing and removing reshoring.

E. Samples:

1. Vapor retarder.

2. Waterstops

3. Mockups of slab finishes

F. Welding certificates.

G. Qualification Data: For Installer, manufacturer, and testing agency.

H. Material Test Reports: For the following, from a qualified testing agency, indicating compliance with requirements:

1. Aggregates.

I. Material Certificates: For each of the following, signed by manufacturers:

1. Cementitious materials

2. Admixtures

3. Form materials and form-release agents

4. Steel reinforcement and accessories

5. Waterstops

6. Curing compounds

7. Slab treatments

8. Bonding agents

9. Adhesives

10. Vapor retarders

11. Semirigid joint filler

12. Joint-filler strips

13. Repair materials

J. Floor surface flatness and levelness measurements to determine compliance with specified tolerances.

K. Field quality-control test and inspection reports.

L. Minutes of preinstallation conference.

1.4 QUALITY ASSURANCE

A. Installer Qualifications: A qualified installer who employs on Project personnel qualified as ACI-certified Flatwork Technician and Finisher and a supervisor who is an ACI-certified Concrete Flatwork Technician.

B. Manufacturer Qualifications: A firm experienced in manufacturing ready-mixed concrete products and that complies with ASTM C 94/C 94M requirements for production facilities and equipment.

CAST-IN-PLACE CONCRETE 03 30 00 - 3

1. Manufacturer certified according to NRMCA's "Certification of Ready Mixed Concrete Production Facilities."

C. Testing Agency Qualifications: An independent agency, acceptable to resident engineer qualified according to ASTM C 1077 and ASTM E 329 for testing indicated, as documented according to ASTM E 548.

1. Personnel conducting field tests shall be qualified as ACI Concrete Field Testing Technician, Grade 1, according to ACI CP-01 or an equivalent certification program.

2. Personnel performing laboratory tests shall be ACI-certified Concrete Strength Testing Technician and Concrete Laboratory Testing Technician - Grade I. Testing Agency laboratory supervisor shall be an ACI-certified Concrete Laboratory Testing Technician - Grade II.

D. Source Limitations: Obtain each type or class of cementitious material of the same brand from the same manufacturer's plant, obtain aggregate from one source, and obtain admixtures through one source from a single manufacturer.

E. Welding: Qualify procedures and personnel according to AWS D1.4, "Structural Welding Code--Reinforcing Steel."

F. ACI Publications: Comply with the following unless modified by requirements in the Contract Documents:

1. ACI 301, "Specification for Structural Concrete," Sections 1 through 5

2. ACI 117, "Specifications for Tolerances for Concrete Construction and Materials."

G. Concrete Testing Service: Engage a qualified independent testing agency to perform material evaluation tests and to design concrete mixtures.

H. Preinstallation Conference: Conduct conference at Project site.

1. Before submitting design mixtures, review concrete design mixture and examine procedures for ensuring quality of concrete materials. Require representatives of each entity directly concerned with cast-in-place concrete to attend, including the following:

a. Contractor's superintendent.

b. Independent testing agency responsible for concrete design mixtures.

c. Ready-mix concrete manufacturer.

d. Concrete subcontractor.

2. Review special inspection and testing and inspecting agency procedures for field quality control, concrete finishes and finishing, hot-weather concreting procedures, curing procedures, construction contraction and isolation joints, and joint-filler strips, forms and form removal limitations, vapor-retarder installation, anchor rod and anchorage device installation tolerances, steel reinforcement installation, floor and slab flatness and levelness measurement, concrete repair procedures, and concrete protection.

CAST-IN-PLACE CONCRETE 03 30 00 - 4

1.5 DELIVERY, STORAGE, AND HANDLING

A. Steel Reinforcement: Deliver, store, and handle steel reinforcement to prevent bending and damage. Avoid damaging coatings on steel reinforcement.

B. Waterstops: Store waterstops under cover to protect from moisture, sunlight, dirt, oil, and other contaminants.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. In other Part 2 articles where titles below introduce lists, the following requirements apply to product selection:

1. Available Products: Subject to compliance with requirements, products that may be incorporated into the Work include, but are not limited to, products specified.

2. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, manufacturers specified.

2.2 FORM-FACING MATERIALS

A. Smooth-Formed Finished Concrete: Form-facing panels that will provide continuous, true, and smooth concrete surfaces. Furnish in largest practicable sizes to minimize number of joints.

1. Exterior-grade plywood panels, suitable for concrete forms, complying with DOC PS 1, and as follows:

a. Structural 1, B-B or better; mill oiled and edge sealed.

B. Rough-Formed Finished Concrete: Plywood, lumber, metal, or another approved material.

Provide lumber dressed on at least two edges and one side for tight fit.

C. Chamfer Strips: Wood, metal, PVC, or rubber strips, as indicated on the drawings.

D. Rustication Strips: Wood, metal, PVC, or rubber strips, kerfed for ease of form removal.

E. Form-Release Agent: Commercially formulated form-release agent that will not bond with, stain, or adversely affect concrete surfaces and will not impair subsequent treatments of concrete surfaces.

1. Formulate form-release agent with rust inhibitor for steel form-facing materials.

F. Form Ties: Factory-fabricated, removable or snap-off metal or glass-fiber-reinforced plastic form ties designed to resist lateral pressure of fresh concrete on forms and to prevent spalling of concrete on removal.

CAST-IN-PLACE CONCRETE 03 30 00 - 5

1. Furnish units that will leave no corrodible metal closer than 1 inch to the plane of exposed concrete surface.

2. Furnish ties that, when removed, will leave holes no larger than 1 inch in diameter in concrete surface.

3. Furnish ties with integral water-barrier plates to walls indicated to receive dampproofing or waterproofing.

2.3 STEEL REINFORCEMENT

A. Reinforcing Bars: ASTM A 615/A 615M, Grade 60, deformed.

B. Galvanized Reinforcing Bars: Where shown on drawings ASTM A 615/A 615M, Grade 60, deformed bars, ASTM A 767/A 767M, Class I zinc coated after fabrication and bending.

C. Plain-Steel Wire: ASTM A 82, galvanized.

D. Plain-Steel Welded Wire Reinforcement: ASTM A 185, plain, fabricated from as-drawn steel wire into flat sheets.

E. Galvanized-Steel Welded Wire Reinforcement: ASTM A 185, plain, fabricated from galvanized steel wire into flat sheets.

F. NOTE TO DESIGNER: FOR EXTREME MARINE ENVIRONMENTS-SPECIFY

GALVANIZED REBAR OR CORROSION INHIBITING ADMIXTURE.

2.4 FIBER REINFORCEMENT

A. In addition to the requirements specified above, provide fiber reinforced concrete in accordance with ASTM C1116 Type III synthetic fiber reinforced concrete, and as follows. Synthetic reinforcing fibers must be monofilament polypropylene fibers with a minimum of five (5) percent post-consumer recycled content. Provide fibers that have a specific gravity of 0.9, a minimum tensile strength of 70 ksi, graded per manufacturer, and specifically manufactured to an optimum gradation for use as concrete secondary reinforcement. Use a minimum of 1.5 pounds of fibers per cubic yard of concrete. Add fibers at the batch plant.

1. Approved Manufacturers:

a. Propex Fibermesh

b. Nycon

2.5 REINFORCEMENT ACCESSORIES

A. Joint Dowel Bars: ASTM A 615/A 615M, Grade 60, plain-steel bars, cut bars true to length with ends square and free of burrs.

B. Zinc Repair Material: ASTM A 780, zinc-based solder, paint containing zinc dust, or sprayed zinc.

CAST-IN-PLACE CONCRETE 03 30 00 - 6

C. Bar Supports: Bolsters, chairs, spacers, and other devices for spacing, supporting, and fastening reinforcing bars and welded wire reinforcement in place. Manufacture bar supports from steel wire, plastic, or precast concrete according to CRSI's "Manual of Standard Practice," of greater compressive strength than concrete and as follows:

1. For concrete surfaces exposed to view where legs of wire bar supports contact forms, use CRSI Class 1 plastic-protected steel wire or CRSI Class 2 stainless-steel bar supports.

2. For zinc-coated reinforcement, use galvanized wire or dielectric-polymer-coated wire bar supports.

2.6 CONCRETE MATERIALS

A. Cementitious Material: Use the following cementitious materials, of the same type, brand, and source, throughout Project:

1. Portland Cement: ASTM C 150, Type I or III. Supplement with the following:

a. Fly Ash: ASTM C 618, Class C.

B. Silica Fume: ASTM C 1240, amorphous silica.

C. Normal-Weight Aggregates: ASTM C 33, coarse aggregate or better, graded. Provide aggregates from a single source.

1. Maximum Coarse-Aggregate Size: 3/4 inch nominal.

2. Fine Aggregate: Free of materials with deleterious reactivity to alkali in cement.

D. Water: ASTM C 94/C 94M and potable.

2.7 ADMIXTURES

A. Air-Entraining Admixture: ASTM C 260.

B. Corrosion Inhibiting Admixture: ASTM C1582 NOTE TO DESIGNER: SPECIFY FOR

EXTREME MARINE ENVIRONMENTS.

C. Chemical Admixtures: Provide admixtures certified by manufacturer to be compatible with other admixtures and that will not contribute water-soluble chloride ions exceeding those permitted in hardened concrete. Do not use calcium chloride or admixtures containing calcium chloride.

1. Water-Reducing Admixture: ASTM C 494/C 494M, Type A.

2. Retarding Admixture: ASTM C 494/C 494M, Type B.

3. Water-Reducing and Retarding Admixture: ASTM C 494/C 494M, Type D.

4. High-Range, Water-Reducing Admixture: ASTM C 494/C 494M, Type F.

5. High-Range, Water-Reducing and Retarding Admixture: ASTM C 494/C 494M, Type G.

6. Plasticizing and Retarding Admixture: ASTM C 1017/C 1017M, Type II.

CAST-IN-PLACE CONCRETE 03 30 00 - 7

2.8 WATERSTOPS

A. Flexible Rubber Waterstops: CE CRD-C 513, for embedding in concrete to prevent passage of fluids through joints. Factory fabricate corners, intersections, and directional changes.

1. Manufacturers:

a. Greenstreak

b. Progress Unlimited, Inc.

c. Williams Products, Inc.

2. Profile: Flat, dumbbell with center bulb

3. Dimensions: 4 inches by 3/16 inch thick; nontapered

2.9 VAPOR RETARDERS

A. Plastic Vapor Retarder: ASTM E 1745, Class A. Include manufacturer's recommended adhesive or pressure-sensitive tape.

1. Products:

a. Fortifiber Corporation; Moistop Ultra [15] [10].

b. Raven Industries Inc.; Vapor Block [15] [10].

c. Reef Industries, Inc.; Griffolyn Type-[65G] [105].

B. Granular Fill: Clean mixture of crushed stone or crushed or uncrushed gravel; ASTM D 448, Size 57, with 100 percent passing a 1-1/2-inch sieve and 0 to 5 percent passing a No. 8 sieve.

C. Fine-Graded Granular Material: Clean mixture of crushed stone, crushed gravel, and manufactured or natural sand; ASTM D 448, Size 10, with 100 percent passing a 3/8-inch sieve, 10 to 30 percent passing a No. 100 sieve, and at least 5 percent passing No. 200 sieve;

complying with deleterious substance limits of ASTM C 33 for fine aggregates.

2.10 FLOOR AND SLAB TREATMENTS

A. Slip-Resistive Emery Aggregate Finish to be used at the exterior Cab walkway: Factory-graded, packaged, rustproof, nonglazing, abrasive, crushed emery aggregate containing not less than 50 percent aluminum oxide and not less than 20 percent ferric oxide; unaffected by freezing, moisture, and cleaning materials with 100 percent passing 3/8-inch sieve.

1. Products:

a. Anti-Hydro International, Inc.; Emery.

b. Dayton Superior Corporation; Emery Non-Slip.

c. Emeri-Crete, Inc.; Emeri-Topcrete.

d. Lambert Corporation; EMAG-20.

e. L&M Construction Chemicals, Inc.; Grip It.

f. Metalcrete Industries; Metco Anti-Skid Aggregate.

CAST-IN-PLACE CONCRETE 03 30 00 - 8

B. Penetrating Liquid Floor Treatment: Clear, chemically reactive, waterborne solution of inorganic silicate or siliconate materials and proprietary components; odorless; colorless; that penetrates, hardens, and densifies concrete surfaces.

1. Products:

a. Burke by Edoco; Titan Hard.

b. ChemMasters; Chemisil Plus.

c. ChemTec International; ChemTec One.

d. Conspec Marketing & Manufacturing Co., Inc., a Dayton Superior Company;

Intraseal.

e. Curecrete Distribution Inc.; Ashford Formula.

f. Dayton Superior Corporation; Day-Chem Sure Hard.

g. Euclid Chemical Company (The); Euco Diamond Hard.

h. Kaufman Products, Inc.; SureHard.

i. L&M Construction Chemicals, Inc.; Seal Hard.

j. Meadows, W. R., Inc.; Liqui-Hard.

k. Metalcrete Industries; Floorsaver.

l. Nox-Crete Products Group, Kinsman Corporation; Duranox.

m. Symons Corporation, a Dayton Superior Company; Buff Hard.

n. US Mix Products Company; US Spec Industraseal.

o. Vexcon Chemicals, Inc.; Vexcon StarSeal PS.

C. Sealing Compounds: chemically reactive solution of proprietary components; film-forming or penetrating; odorless liquid applied directly to hardened concrete surfaces (at least 28 days old) to reduce penetration of liquids or gases and the related absorption of spills; minimizing dusting and providing final finished surfaces that are easier to clean. For exterior applications, sealers shall protect concrete from freeze-thaw damage, chloride penetration from deicers, grease, oil, and other potentially harmful chemicals or foreign substances.

1. Products: may consist of acrylic or epoxy resins, silane or siloxane compounds.

Chlorinated rubber, urethanes, alpha methyl styrene compounds, linseed oil, and mineral spirit based compounds are not permitted. Epoxy sealers shall be limited to indoor applications. Specific application shall be in strict accordance with the manufacturer’s recommendations. Sealing Compound shall comply with ASTM C672 (scale resistance), AASHTO M224, and ACI Committees 330 and 362.

a. Euclid Chemical Company (The); Baracades, Chemstop, Euco, & Weather-Guard

b. Lambert Corporation; Exposite WB

c. Sherwin-Williams; H&C Concrete Sealer, AquArmor, & Corobond

d. Sika: Sikaguard, SikaPronto 19TF, Sika ComfortFloor, Sikadur 55 SLV

e. WR Grace; Procor,

2.11 CURING MATERIALS

A. Evaporation Retarder: Waterborne, monomolecular film forming, manufactured for application to fresh concrete.

1. Products:

The use of sealing compounds appeared to be missing from this specification.

CAST-IN-PLACE CONCRETE 03 30 00 - 9

a. Axim Concrete Technologies; Cimfilm.

b. Burke by Edoco; BurkeFilm.

c. ChemMasters; Spray-Film.

d. Conspec Marketing & Manufacturing Co., Inc., a Dayton Superior Company;

Aquafilm.

e. Dayton Superior Corporation; Sure Film.

f. Euclid Chemical Company (The); Eucobar.

g. Kaufman Products, Inc.; Vapor Aid.

h. Lambert Corporation; Lambco Skin.

i. L&M Construction Chemicals, Inc.; E-Con.

j. MBT Protection and Repair, Div. of ChemRex; Confilm.

k. Meadows, W. R., Inc.; Sealtight Evapre.

l. Metalcrete Industries; Waterhold.

m. Nox-Crete Products Group, Kinsman Corporation; Monofilm.

n. Sika Corporation, Inc.; SikaFilm.

o. Symons Corporation, a Dayton Superior Company; Finishing Aid.

p. Unitex; Pro-Film.

q. US Mix Products Company; US Spec Monofilm ER.

r. Vexcon Chemicals, Inc.; Certi-Vex EnvioAssist.

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

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

D. Water: Potable.

E. Clear, Waterborne, Membrane-Forming Curing Compound: ASTM C 309, Type 1, Class B, dissipating with fugitive dye.

1. Products:

a. Anti-Hydro International, Inc.; AH Curing Compound #2 DR WB.

b. Burke by Edoco; Aqua Resin Cure.

c. ChemMasters; Safe-Cure Clear.

d. Conspec Marketing & Manufacturing Co., Inc., a Dayton Superior Company;

W.B. Resin Cure.

e. Dayton Superior Corporation; Day Chem Rez Cure (J-11-W).

f. Euclid Chemical Company (The); Kurez DR VOX.

g. Kaufman Products, Inc.; Thinfilm 420.

h. Lambert Corporation; Aqua Kure-Clear.

i. L&M Construction Chemicals, Inc.; L&M Cure R.

j. Meadows, W. R., Inc.; 1100 Clear.

k. Nox-Crete Products Group, Kinsman Corporation; Resin Cure E.

l. Symons Corporation, a Dayton Superior Company; Resi-Chem Clear Cure.

m. Tamms Industries, Inc.; Horncure WB 30.

n. Unitex; Hydro Cure 309.

o. US Mix Products Company; US Spec Maxcure Resin Clear.

p. Vexcon Chemicals, Inc.; Certi-Vex Enviocure 100.

Offers assurance of proper coverage.

CAST-IN-PLACE CONCRETE 03 30 00 - 10

F. Clear, Waterborne, Membrane-Forming Curing Compound: ASTM C 309, Type 1, Class B, nondissipating, certified by curing compound manufacturer to not interfere with bonding of floor covering.

1. Products:

a. Anti-Hydro International, Inc.; AH Clear Cure WB.

b. Burke by Edoco; Spartan Cote WB II.

c. ChemMasters; Safe-Cure & Seal 20.

d. Conspec Marketing & Manufacturing Co., Inc., a Dayton Superior Company; Cure and Seal WB.

e. Dayton Superior Corporation; Safe Cure and Seal (J-18).

f. Euclid Chemical Company (The); Aqua Cure VOX.

g. Kaufman Products, Inc.; Cure & Seal 309 Emulsion.

h. Lambert Corporation; Glazecote Sealer-20.

i. L&M Construction Chemicals, Inc.; Dress & Seal WB.

j. Meadows, W. R., Inc.; Vocomp-20.

k. Metalcrete Industries; Metcure.

l. Nox-Crete Products Group, Kinsman Corporation; Cure & Seal 150E.

m. Symons Corporation, a Dayton Superior Company; Cure & Seal 18 Percent E.

n. Tamms Industries, Inc.; Clearseal WB 150.

o. Unitex; Hydro Seal.

p. US Mix Products Company; US Spec Hydrasheen 15 percent

q. Vexcon Chemicals, Inc.; Starseal 309.

G. Clear, Waterborne, Membrane-Forming Curing and Sealing Compound: ASTM C 1315, Type 1, Class A.

1. Products:

a. Burke by Edoco; Cureseal 1315 WB.

b. ChemMasters; Polyseal WB.

c. Conspec Marketing & Manufacturing Co., Inc., a Dayton Superior Company;

Sealcure 1315 WB.

d. Euclid Chemical Company (The); Super Diamond Clear VOX.

e. Kaufman Products, Inc.; Sure Cure 25 Emulsion.

f. Lambert Corporation; UV Safe Seal.

g. L&M Construction Chemicals, Inc.; Lumiseal WB Plus.

h. Meadows, W. R., Inc.; Vocomp-30.

i. Metalcrete Industries; Metcure 30.

j. Symons Corporation, a Dayton Superior Company; Cure & Seal 31 Percent E.

k. Tamms Industries, Inc.; LusterSeal WB 300.

l. Unitex; Hydro Seal 25.

m. US Mix Products Company; US Spec Radiance UV-25.

n. Vexcon Chemicals, Inc.; Vexcon Starseal 1315.

2.12 RELATED MATERIALS

A. Expansion- and Isolation-Joint-Filler Strips: ASTM D 1751, asphalt-saturated cellulosic fiber or ASTM D 1752, cork or self-expanding cork.

CAST-IN-PLACE CONCRETE 03 30 00 - 11

B. Bonding Agent: ASTM C 1059, Type II, non-redispersible, acrylic emulsion or styrene butadiene.

C. Epoxy Bonding Adhesive: ASTM C 881, two-component epoxy resin, capable of humid curing and bonding to damp surfaces, of class suitable for application temperature and of grade to suit requirements, and as follows:

1. Types IV and V, load bearing, for bonding hardened or freshly mixed concrete to hardened concrete.

D. Reglets: Fabricate reglets of not less than 0.0217-inch- thick, galvanized steel sheet.

Temporarily fill or cover face opening of reglet to prevent intrusion of concrete or debris.

E. Dovetail Anchor Slots: Hot-dip galvanized steel sheet, not less than 0.0336 inch thick, with bent tab anchors. Temporarily fill or cover face opening of slots to prevent intrusion of concrete or debris.

2.13 REPAIR MATERIALS

A. Repair Underlayment: Cement-based, polymer-modified, self-leveling product that can be applied in thicknesses from 1/8 inch and that can be feathered at edges to match adjacent floor elevations.

1. Cement Binder: ASTM C 150, Portland cement or hydraulic or blended hydraulic cement as defined in ASTM C 219.

2. Primer: Product of underlayment manufacturer recommended for substrate, conditions, and application.

3. Aggregate: Well-graded, washed gravel, 1/8 to 1/4 inch or coarse sand as recommended by underlayment manufacturer.

4. Compressive Strength: Not less than 4100 psi at 28 days when tested according to

ASTM C 109/C 109M.

B. Repair Overlayment: Cement-based, polymer-modified, self-leveling product that can be applied in thicknesses from 1/8 inch and that can be feathered at edges to match adjacent floor elevations.

1. Cement Binder: ASTM C 150, portland cement or hydraulic or blended hydraulic cement as defined in ASTM C 219.

2. Primer: Product of topping manufacturer recommended for substrate, conditions, and application.

3. Aggregate: Well-graded, washed gravel, 1/8 to 1/4 inch or coarse sand as recommended by topping manufacturer.

4. Compressive Strength: Not less than 5000 psi at 28 days when tested according to

ASTM C 109/C 109M.

2.14 CONCRETE MIXTURES, GENERAL

A. Prepare design mixtures for each type and strength of concrete, proportioned on the basis of laboratory trial mixture or field test data, or both, according to ACI 301.

CAST-IN-PLACE CONCRETE 03 30 00 - 12

1. Use a qualified independent testing agency for preparing and reporting proposed mixture designs based on laboratory trial mixtures.

B. Cementitious Materials: Limit percentage, by weight, of cementitious materials other than portland cement in concrete as follows:

1. Fly Ash: 25 percent.

2. Combined Fly Ash and Pozzolan: 25 percent.

3. Silica Fume: 10 percent.

C. Limit water-soluble, chloride-ion content in hardened concrete to 0.15 percent by weight of cement.

D. Admixtures: Use admixtures according to manufacturer's written instructions.

1. Use water-reducing or plasticizing admixture in concrete, as required, for placement and workability.

2. Use water-reducing and retarding admixture when required by high temperatures, low humidity, or other adverse placement conditions.

3. Use water-reducing admixture in pumped concrete, concrete for heavy-use industrial slabs and parking structure slabs, concrete required to be watertight, and concrete with a water-cementitious materials ratio below 0.50.

E. Color Pigment: Add color pigment to concrete placed adjacent to exposed precast concrete members according to manufacturer's written instructions and to result in hardened concrete color consistent with approved precast mockup.

2.15 CONCRETE MIXTURES FOR BUILDING ELEMENTS

A. Footings, Foundation walls, elevated concrete slabs, and any concrete not specified below or in other specification sections. Proportion normal-weight concrete mixture as follows:

1. Minimum Compressive Strength: 4000 psi at 28 days.

2. Maximum Water-Cementitious Materials Ratio: 0.50

3. Slump Limit: 8 inches for concrete with verified slump of 2 to 4 inches before adding high-range water-reducing admixture or plasticizing admixture, plus or minus 1 inch.

4. Air Content: Concrete exposed to severe freezing and thawing environments shall have 7 percent air entrainment for 3/4-inch nominal maximum aggregate size. Concrete exposed to moderate freezing and thawing environments shall have 4-6 percent air entrainment for 3/4-inch nominal maximum aggregate size. Concrete exposed to mild freezing and thawing environments shall have 4 percent or less air entrainment for 3/4-inch nominal maximum aggregate size.

B. Slabs-on-Grade: Proportion normal-weight concrete mixture as follows:

1. Minimum Compressive Strength 4000 psi at 28 days.

2. Minimum Cementitious Materials Content: 520 lb/cu. Yd.

3. Slump Limit: 5 inches, plus or minus 1 inch.

CAST-IN-PLACE CONCRETE 03 30 00 - 13

4. Air Content: Concrete exposed to severe freezing and thawing environments shall have 7 percent air entrainment for 3/4-inch nominal maximum aggregate size. Concrete exposed to moderate freezing and thawing environments shall have 4-6 percent air entrainment for 3/4-inch nominal maximum aggregate size. Concrete exposed to mild freezing and thawing environments shall have 4 percent or less air entrainment for 3/4-inch nominal maximum aggregate size.

C. Concrete Toppings: Proportion normal-weight concrete mixture as follows:

1. Minimum Compressive Strength: 4000 psi at 28 days.

2. Minimum Cementitious Materials Content: 520 lb/cu. Yd.

3. Slump Limit: 5 inches, plus or minus 1 inch.

4. Air Content: Concrete exposed to severe freezing and thawing environments shall have 7 percent air entrainment for 3/4-inch nominal maximum aggregate size. Concrete exposed to moderate freezing and thawing environments shall have 4-6 percent air entrainment for 3/4-inch nominal maximum aggregate size. Concrete exposed to mild freezing and thawing environments shall have 4 percent or less air entrainment for 3/4-inch nominal maximum aggregate size.

2.16 FABRICATING REINFORCEMENT

A. Fabricate steel reinforcement according to CRSI's "Manual of Standard Practice."

2.17 CONCRETE MIXING

A. Ready-Mixed Concrete: Measure, batch, mix, and deliver concrete according to ASTM C 94/C 94M, and furnish batch ticket information. Concrete batch tickets shall be time stamped when concrete is batched.

1. When air temperature is between 85 and 90 deg F, reduce mixing and delivery time from 1-1/2 hours to 75 minutes; when air temperature is above 90 deg F, reduce mixing and delivery time to 60 minutes. Concrete batches with longer delays shall be discarded.

B. Project-Site Mixing: Measure, batch, and mix concrete materials and concrete according to ASTM C 94/C 94M. Mix concrete materials in appropriate drum-type batch machine mixer.

1. For mixer capacity of 1 cu. yd. or smaller, continue mixing at least 1-1/2 minutes, but not more than 5 minutes after ingredients are in mixer, before any part of batch is released.

2. For mixer capacity larger than 1 cu. yd., increase mixing time by 15 seconds for each additional 1 cu. yd..

3. Provide batch ticket for each batch discharged and used in the Work, indicating Project identification name and number, date, mixture type, mixture time, quantity, and amount of water added. Record approximate location of final deposit in structure.

CAST-IN-PLACE CONCRETE 03 30 00 - 14

PART 3 - EXECUTION

3.1 FORMWORK

A. Design, erect, shore, brace, and maintain formwork, according to ACI 301, to support vertical, lateral, static, and dynamic loads, and construction loads that might be applied, until structure can support such loads.

B. Construct formwork so concrete members and structures are of size, shape, alignment, elevation, and position indicated, within tolerance limits of ACI 117.

C. Limit concrete surface irregularities, designated by ACI 347R as abrupt or gradual, as follows:

1. Class A, 1/8 inch for smooth-formed finished surfaces.

D. Construct forms tight enough to prevent loss of concrete mortar.

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

Provide crush or wrecking plates where stripping may damage cast concrete surfaces. Provide top forms for inclined surfaces steeper than 1.5 horizontal to 1 vertical.

1. Install keyways, reglets, recesses, and the like, for easy removal.

2. Do not use rust-stained steel form-facing material.

F. Set edge forms, bulkheads, and intermediate screed strips for slabs to achieve required elevations and slopes in finished concrete surfaces. Provide and secure units to support screed strips; use strike-off templates or compacting-type screeds.

G. Provide temporary openings for cleanouts and inspection ports where interior area of formwork is inaccessible. Close openings with panels tightly fitted to forms and securely braced to prevent loss of concrete mortar. Locate temporary openings in forms at inconspicuous locations. All openings shall be included on shop drawings and shall be preapproved by FAA.

H. Chamfer exterior corners and edges of permanently exposed concrete.

I. Form openings, chases, offsets, sinkages, keyways, reglets, blocking, screeds, and bulkheads required in the Work. Determine sizes and locations from trades providing such items.

J. Clean forms and adjacent surfaces to receive concrete. Remove chips, wood, sawdust, dirt, and other debris just before placing concrete.

K. Retighten forms and bracing before placing concrete, as required, to prevent mortar leaks and maintain proper alignment.

L. Coat contact surfaces of forms with form-release agent, according to manufacturer's written instructions, before placing reinforcement.

CAST-IN-PLACE CONCRETE 03 30 00 - 15

3.2 EMBEDDED ITEMS

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

1. Install anchor rods, accurately located, to elevations required and complying with tolerances in Section 7.5 of AISC's "Code of Standard Practice for Steel Buildings and Bridges."

2. Install reglets to receive waterproofing and to receive through-wall flashings in outer face of concrete frame at exterior walls, where flashing is shown at lintels, shelf angles, and other conditions.

3. Install dovetail anchor slots in concrete structures as indicated.

3.3 REMOVING AND REUSING FORMS

A. General: Structural concrete shall be stripped from forms when it has reached at least two-thirds of the 28 day design strength. Design, erection and removal of all formwork, shores, and reshores shall meet the requirements set forth in ACI 347, 318, and 301.

1. 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 material will not be acceptable for exposed surfaces. Apply new form-release agent.

C. When forms are reused, clean surfaces, remove fins and laitance, and tighten to close joints.

Align and secure joints to avoid offsets. Do not use patched forms for exposed concrete surfaces unless approved by COR.

3.4 SHORES AND RESHORES

A. Comply with ACI 318 and ACI 301 for design, installation, and removal of shoring and reshoring.

1. Do not remove shoring or reshoring until measurement of slab tolerances is complete.

B. Plan sequence of removal of shores and reshore to avoid damage to concrete. Locate and provide adequate reshoring to support construction without excessive stress or deflection.

3.5 VAPOR RETARDERS

A. Plastic Vapor Retarders: Place, protect, and repair vapor retarders according to ASTM E 1643 and manufacturer's written instructions.

1. Lap joints 6 inches and seal with manufacturers recommended tape.

Formwork removal cannot be governed by specific time and/or exposed ambient temperature(s) alone since sufficient cure time is actually controlled by additional factors including, but not necessarily limited to: amount of concrete mass within a form, cement type, water content, concrete constituents and admixtures.

CAST-IN-PLACE CONCRETE 03 30 00 - 16

B. Bituminous Vapor Retarders: Place, protect, and repair vapor retarders according to manufacturer's written instructions.

C. Granular Course: Provide fine-graded granular material, moisten, and compact with mechanical equipment to elevation tolerances of plus 0 inch or minus 3/4 inch. Cover with vapor retarder before applying concrete and reinforcement.

3.6 STEEL REINFORCEMENT

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

1. Do not cut or puncture vapor retarder. Repair damage and reseal vapor retarder before placing concrete.

B. Clean reinforcement of loose rust and mill scale, earth, ice, and other foreign materials that would reduce bond to concrete.

C. Accurately position, support, and secure reinforcement against displacement. Locate and support reinforcement with bar supports to maintain minimum concrete cover. Do not tack weld crossing reinforcing bars.

1. Weld reinforcing bars according to AWS D1.4, where indicated.

D. Set wire ties with ends directed into concrete, not toward exposed concrete surfaces.

E. Install welded wire reinforcement in longest practicable lengths on bar supports spaced to minimize sagging. Lap edges and ends of adjoining sheets at least one mesh spacing. Offset laps of adjoining sheet widths to prevent continuous laps in either direction. Lace overlaps with wire.

F. Zinc-Coated Reinforcement: Repair cut and damaged zinc coatings with zinc repair material according to ASTM A 780. Use galvanized steel wire ties to fasten zinc-coated steel reinforcement.

3.7 JOINTS

A. General: Construct joints true to line with faces perpendicular to surface plane of concrete.

B. Construction Joints: Install so strength and appearance of concrete are not impaired, at locations indicated or as approved by COR.

1. Place joints perpendicular to main reinforcement. Continue reinforcement across construction joints, unless otherwise indicated. Do not continue reinforcement through sides of strip placements of floors and slabs.

2. Form keyed joints as indicated. Embed keys at least 1-1/2 inches into concrete.

3. Use a bonding agent at locations where fresh concrete is placed against hardened or partially hardened concrete surfaces.

4. Use epoxy-bonding adhesive at locations where fresh concrete is placed against hardened or partially hardened concrete surfaces.

Granular material should be placed below the vapor retarder.

CAST-IN-PLACE CONCRETE 03 30 00 - 17

C. Contraction Joints in Slabs-on-Grade: Form weakened-plane contraction joints, sectioning concrete into areas as indicated. Construct contraction joints for a depth equal to at least one-fourth of concrete thickness as follows:

1. Grooved Joints: Form contraction joints after initial floating by grooving and finishing each edge of joint to a radius of 1/8 inch. Repeat grooving of contraction joints after applying surface finishes. Eliminate groover tool marks on concrete surfaces.

2. Sawed Joints: Form contraction joints with power saws equipped with shatterproof abrasive or diamond-rimmed blades. Cut 1/8-inch- wide joints into concrete when cutting action will not tear, abrade, or otherwise damage surface and before concrete develops random contraction cracks.

D. Isolation Joints in Slabs-on-Grade: After removing formwork, install joint-filler strips at slab junctions with vertical surfaces, such as column pedestals, foundation walls, and other locations, as indicated.

1. Extend joint-filler strips full width and depth of joint, terminating flush with finished concrete surface, unless otherwise indicated.

2. Terminate full-width joint-filler strips not less than 1/2 inch or more than 1 inch below finished concrete surface where joint sealants, specified in Section 07 92 00 "Joint Sealants," are indicated.

3. Install joint-filler strips in lengths as long as practicable. Where more than one length is required, lace or clip sections together.

E. Doweled Joints: Install dowel bars and support assemblies at joints where indicated. Lubricate or asphalt coat one-half of dowel length to prevent concrete bonding to one side of joint.

3.8 WATERSTOPS

A. Flexible Waterstops: Install in construction joints and at other joints indicated to form a continuous diaphragm. Install in longest lengths practicable. Support and protect exposed waterstops during progress of the Work. Field fabricate joints in waterstops according to manufacturer's written instructions.

3.9 CONCRETE PLACEMENT

A. Before placing concrete, verify that installation of formwork, reinforcement, and embedded items is complete and that required inspections have been performed.

B. Before test sampling and placing concrete, water may be added at Project site, subject to limitations of ACI 301 and approval by COR.

1. Do not add water to concrete after adding high-range water-reducing admixtures to mixture.

C. Deposit concrete continuously in one layer or in horizontal layers of such thickness that no new concrete will be placed on concrete that has hardened enough to cause seams or planes of weakness. If a section cannot be placed continuously, provide construction joints as indicated.

Deposit concrete to avoid segregation.

CAST-IN-PLACE CONCRETE 03 30 00 - 18

1. Deposit concrete in horizontal layers of depth to not exceed formwork design pressures and in a manner to avoid inclined construction joints.

2. Consolidate placed concrete with mechanical vibrating equipment according to ACI 301.

3. Do not use vibrators to transport concrete inside forms. Insert and withdraw vibrators vertically at uniformly spaced locations to rapidly penetrate placed layer and at least 6 inches into preceding layer. Do not insert vibrators into lower layers of concrete that have begun to lose plasticity. At each insertion, limit duration of vibration to time necessary to consolidate concrete and complete embedment of reinforcement and other embedded items without causing mixture constituents to segregate.

D. Cold-Weather Placement: Comply with ACI 306.1 and as follows. Protect concrete work from physical damage or reduced strength that could be caused by frost, freezing actions, or low temperatures.

1. When average high and low temperature is expected to fall below 40 deg F for three successive days, maintain delivered concrete mixture temperature within the temperature range required by ACI 301.

2. Do not use frozen materials or materials containing ice or snow. Do not place concrete on frozen subgrade or on subgrade containing frozen materials.

3. Do not use calcium chloride, salt, or other materials containing antifreeze agents or chemical accelerators unless otherwise specified and approved in mixture designs.

E. Hot-Weather Placement: Comply with ACI 301 and as follows:

1. Maintain concrete temperature below 90 deg F at time of placement. Chilled mixing water or chopped ice may be used to control temperature, provided water equivalent of ice is calculated to total amount of mixing water. Using liquid nitrogen to cool concrete is Contractor's option.

2. Fog-spray forms, steel reinforcement, and subgrade just before placing concrete. Keep subgrade uniformly moist without standing water, soft spots, or dry areas.

3.10 FINISHING FORMED SURFACES

A. Rough-Formed Finish: As-cast concrete texture imparted by form-facing material with tie holes and defects repaired and patched. Remove fins and other projections that exceed specified limits on formed-surface irregularities.

1. Apply to concrete surfaces not exposed to public view.

B. Smooth-Formed Finish: As-cast concrete texture imparted by form-facing material, arranged in an orderly and symmetrical manner with a minimum of seams. Repair and patch tie holes and defects. Remove projections that exceed specified limits on formed-surface irregularities.

1. Apply to concrete surfaces exposed to public view, to receive a rubbed finish, to be covered with a coating or covering material applied directly to concrete.

C. Rubbed Finish: Apply the following to smooth-formed finished as-cast concrete where indicated:

CAST-IN-PLACE CONCRETE 03 30 00 - 19

1. Smooth-Rubbed Finish: Not later than one day after form removal, moisten concrete surfaces and rub with carborundum brick or another abrasive until producing a uniform color and texture. Do not apply cement grout other than that created by the rubbing process.

D. Related Unformed Surfaces: At tops of walls, horizontal offsets, and similar unformed surfaces adjacent to formed surfaces, strike off smooth and finish with a texture matching adjacent formed surfaces. Continue final surface treatment of formed surfaces uniformly across adjacent unformed surfaces, unless otherwise indicated.

3.11 FINISHING FLOORS AND SLABS

A. General: Comply with ACI 302.1R recommendations for screeding, restraightening, and finishing operations for concrete surfaces. Do not wet concrete surfaces.

B. Scratch Finish: While still plastic, texture concrete surface that has been screeded and bull-floated or darbied. Use stiff brushes, brooms, or rakes to produce a profile amplitude of 1/4 inch in 1 direction.

1. Apply scratch finish to surfaces to receive concrete floor toppings, to receive mortar setting beds for bonded cementitious floor finishes.

C. Float Finish: Consolidate surface with power-driven floats or by hand floating if area is small or inaccessible to power driven floats. Restraighten, cut down high spots, and fill low spots.

Repeat float passes and restraightening until surface is left with a uniform, smooth, granular texture.

1. Apply float finish to surfaces to receive trowel finish.

2. High spots shall be cut down and low spots filled during this procedure to produce a surface level conforming with ASTM E 1155 tolerances as follows:

a. Minimum overall area F Flatness of FF-20 and minimum overall area F Levelness of FL-17.

b. Minimum local area F Flatness of FF-15 and minimum local area F Levelness of

FL-13.

D. Trowel Finish: After applying float finish, apply first troweling and consolidate concrete by hand or power-driven trowel. Continue troweling passes and restraighten until surface is free of trowel marks and uniform in texture and appearance. Grind smooth any surface defects that would telegraph through applied coatings or floor coverings.

1. Finish and measure surface so gap at any point between concrete surface and an unleveled, freestanding, 10-foot- long straightedge resting on 2 high spots and placed anywhere on the surface does not exceed 1/8 inch.

2. The finish surface shall produce a finished surface conforming to ASTM E1155 tolerance as follows:

a. Minimum overall area F Flatness of FF-30 and minimum overall area F Levelness of FL-25.

CAST-IN-PLACE CONCRETE 03 30 00 - 20

b. Minimum local area F Flatness of FF-18 and minimum local area F Levelness of

FL-13.

E. Trowel and Fine-Broom Finish: Apply a first trowel finish to surfaces where ceramic or quarry tile is to be installed by either thickset or thin-set method. While concrete is still plastic, slightly scarify surface with a fine broom.

1. Comply with flatness and levelness tolerances for trowel finished floor surfaces.

F. Broom Finish: Apply a broom finish to exterior concrete platforms, steps, and ramps, and elsewhere as indicated.

1. Immediately after float finishing, slightly roughen trafficked surface by brooming with fiber-bristle broom perpendicular to main traffic route. Coordinate required final finish with COR before application.

G. Slip-Resistive Finish: Before final floating, apply slip-resistive aggregate finish where indicated and to concrete stair treads, platforms, and ramps. Apply according to manufacturer's written instructions and as follows:

1. Uniformly spread 25 lb/100 sq. ft of dampened slip-resistive aggregate over surface in 1 or 2 applications. Tamp aggregate flush with surface, but do not force below surface.

2. After broadcasting and tamping, apply float finish.

3. After curing, lightly work surface with a steel wire brush or an abrasive stone and water to expose slip-resistive aggregate.

3.12 FINISHING FIBER REINFORCED TOPPING SLABS

A. Strike Off/Bull Floating/Darbying

1. Manual, vibratory or laser screeds may be used during strike off operations. Due to vibratory screeds limiting the possibility of exposed fibers it is recommended that it be incorporated into the screed process

2. The concrete should not be overworked during finishing process. Overworking the concrete will bring fibers to the surface and will cause crazing.

B. Bleed Water

1. Fiber reinforcement concrete bleeds more evenly than plain concrete which can make it seem that initial set has occurred and the finishing process can occur too early.

2. Finishing may commence after the following conditions are met: consolidation has taken place by laser guided screeds, vibrator truss screeds, hand rodding, bull floating, or darbying, the bleed water has evaporated and a finisher’s footprint leaves only a quarter inch deep impression.

3. Water shall not be sprinkled on surface to facilitate finish because it could cause serious crazing, dusting or scaling.

C. Machine Troweling

1. Fibers standing perpendicular to the surface indicate premature troweling operations. If fibers start to show visibility at the concrete surface, troweling shall be immediately stopped, thirty (30) minutes should be allowed to pass and then trowling shall commence.

CAST-IN-PLACE CONCRETE 03 30 00 - 21

2. Floating should start with blades flat. If finishing disks are used, it is recommended the slab should be initially floated with a walk behind trowel.

3. Finishing shall be accomplished by walk behind machine trowels, ride-on double or triple trowels. A sufficient quantity of troweling shall be provided to produce the specified finish the earliest time after water sheen fades from the concrete surface and the concrete can support the weight of the troweling machine without adversely affecting the specified finish and floor flatness requirements. The blades should be kept as flat as possible for as long as possible and then slowly increase the angle as the concrete finish is obtained. If fibers start to appear on the surface, it indicates premature troweling. If fibers appear on the surface the process should be immediately stopped a time of ten to fifteen minutes should pass before troweling commences again.

4. If a broom or rake finish is desired, the broom or rake shall be applied in one direction and may expose some fibers. If fibers are exposed during this process the contractor is responsible to provide a light sandblasting or lightly apply a widespread propane torch to remove fiber remnants.

D. Saw Cutting

1. Saw cutting shall follow ACI recommended guidelines. A sample five (5) foot long saw cut shall be tested. If saw cut exhibits fiber raveling, the operator should terminate cutting and return to cut the slab thirty minutes later (30). Slab may have to be tested multiple times based on ambient conditions, concrete temperature and curing environment.

3.13 MISCELLANEOUS CONCRETE ITEMS

A. Filling In: Fill in holes and openings left in concrete structures, unless otherwise indicated, after work of other trades is in place. Mix, place, and cure concrete, as specified, to blend with in-place construction. Provide other miscellaneous concrete filling indicated or required to complete the Work.

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

C. Equipment Bases and Foundations: Provide machine and equipment bases and foundations as shown on Drawings. Set anchor bolts for machines and equipment at correct elevations, complying with diagrams or templates from manufacturer furnishing machines and equipment.

3.14 CONCRETE PROTECTING AND CURING

A. General: Protect freshly placed concrete from premature drying and excessive cold or hot temperatures. Comply with ACI 306.1 for cold-weather protection and ACI 301 for hot-weather protection during curing.

B. Evaporation Retarder: Apply evaporation retarder to unformed concrete surfaces if hot, dry, or windy conditions cause moisture loss approaching 0.2 lb/sq. ft. x h before and during finishing operations. Apply according to manufacturer's written instructions after placing, screeding, and bull floating or darbying concrete, but before float finishing.

CAST-IN-PLACE CONCRETE 03 30 00 - 22

C. Unformed Surfaces: Begin curing immediately after finishing concrete. Cure unformed surfaces, including floors and slabs, concrete floor toppings, and other surfaces.

D. Cure concrete according to ACI 308.1, by one or a combination of the following methods:

1. Moisture Curing: Keep surfaces continuously moist for not less than seven days with the following materials:

a. Water.

b. Continuous water-fog spray.

c. Absorptive cover, water saturated, and kept continuously wet. Cover concrete surfaces and edges with 12-inch lap over adjacent absorptive covers.

2. Moisture-Retaining-Cover Curing: Cover…