DEEP Standardized Cold Storage Building - Tech Specs 2 of 2 - 20260618.pdf

SECTION 00 01 01

TITLE PAGE

Project Manual

Volume 2 of 2

DEEP STANDARDIZED COLD STORAGE BUILDING

AT THOMASTON GARAGE

THOMASTON, CT

PROJECT # DEPA00013203605

State of Connecticut

Department of Energy and Environmental Protection Engineering, Sustainability and Safety Division

Engineering Unit

CT DEEP Commissioner - Katherine S. Dykes

Project Manual Date: June 18, 2026

CT DEEP PROJECT MANUAL (Rev. 7/2025)

SECTION 042200

CONCRETE UNIT MASONRY

Construction Documents – Issued for Bid

June 18, 2026

DEEP Standardized Cold Storage Building

Thomaston, CT

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SECTION 00 01 10

TABLE OF CONTENTS

Construction Documents – Issued for Bid

June 18, 2026

VOLUME 2 of 2 - TECHNICAL SPECIFICATIONS

DIVISION 02 EXISTING CONDITIONS Not Used

Section No. Title Page Count

024113 Site Demolition

DIVISION 03 CONCRETE Not Used

Building Technical Structural Specifications Shown on Sheet S-00

Civil Structural Specification Follows Below

033000 Cast-in-Place Concrete 6

Attachment: Section 6.01 Concrete for Structures and Section 6.02 Reinforcing Steel

Attachment: Standard Specification Section M.01 Aggregates 3

Attachment: Standard Specification Section M.03 Portland and Hydraulic Cement Concrete

Attachment: Standard Specification Section M.06. Metals 4

DIVISION 04 MASONRY Not Used

042200 Concrete Unit Masonry 17

047200 Cast Stone Masonry 8

DIVISION 05 METALS Not Used

See Section 133419 Metal Building Systems

055000 Metal Fabrications 9

DIVISION 06 WOOD, PLASTICS AND COMPOSITES Not Used

DIVISION 07 THERMAL AND MOISTURE PROTECTION Not Used

07 11 13 Bituminous Dampproofing 4

07 14 18 Liquid Waterproofing Membrane 12

See Section 133419 Metal Building Systems

DIVISION 08 OPENINGS Not Used

081113 Hollow Metal Doors and Frames 6

083323 Overhead Coiling Doors 7

087100 Door Hardware 11

DIVISION 09 FINISHES Not Used

09 96 00 High Performance Coatings 9

DIVISION 10 SPECIALTIES Not Used

104416 Fire Extinguishers 3

DIVISION 11 EQUIPMENT Not Used

DIVISION 12 FURNISHINGS Not Used

DIVISION 13 SPECIAL CONSTRUCTION Not Used

133419 Metal Building Systems 28

DIVISION 14 CONVEYING SYSTEMS Not Used

DIVISION 15 RESERVED

DIVISION 16 RESERVED

DIVISION 17 RESERVED

DIVISION 18 RESERVED

DIVISION 19 RESERVED

DIVISION 20 RESERVED

DIVISION 21 FIRE SUPPRESSION Not Used

DIVISION 22 PLUMBING Not Used

DIVISION 23 HEATING, VENTILATING AND AIR CONDITIONING Not Used

230100 Mechanical General Requirements 20

230513 Common Motor Requirements for HVAC Equipment 3

230553 Identification for HVAC Equipment 5

230593 Testing, Adjusting, and Balancing for HVAC 9

233113 Metal Ducts 9

233300 Air Duct Accessories 8

233423 HVAC Power Ventilators 6

233713 Diffusers, Registers and Grilles 3

DIVISION 26 ELECTRICAL Not Used

260100 Electrical General Requirements 22

260519 Low-Voltage Electrical Power Conductors and Cables 6

260526 Grounding and Bonding for Electrical Systems 6

260529 Hangers and Supports for Electrical Systems 6

260533 Raceways and Boxes for Electrical Systems 10

260553 Identification for Electrical Systems 7

262726 Wiring Devices 6

DIVISION 27 COMMUNICATIONS Not Used

DIVISION 28 ELECTRONIC SAFETY AND SECURITY Not Used

DIVISION 29 RESERVED

DIVISION 30 RESERVED

DIVISION 31 EARTHWORK Not Used

311000 Site Preparation 2

312200 Site Grading 3

312316 Excavation 3

312317 Rock Excavation 4

312319 Dewatering 2

312323 Backfilling 7

312333 Trenching 6

312500 Soil Erosion and Sediment Control 4

315000 Sheeting and Bracing 4

DIVISION 32 EXTERIOR IMPROVEMENTS Not Used

320500 Restoration of Surfaces 2

321100 Base Course 7

321200 Flexible Paving 4

Attachment: Standard Specification Section 4.06 Bituminous Concrete 12

Attachment: Standard Specification Section M.04 Bituminous Concrete Materials

321623 Sidewalks 5

329200 Turf Establishment 4

DIVISION 33 UTILITIES Not Used

Section No. Title Page Count

333100 Sanitary Sewer Pipe and Fittings 6

334000 Storm Drainage Systems 5

DIVISION 34 TRANSPORTATION Not Used

DIVISION 35 WATERWAYS AND MARINE Not Used

DIVISION 36 RESERVED

DIVISION 37 RESERVED

DIVISION 38 RESERVED

DIVISION 39 RESERVED

DIVISION 40 PROCESS INTEGRATION Not Used

DIVISION 41 MATERIAL PROCESSING Not Used

DIVISION 42 PROCESS HEATING, COOLING, AND DRYING Not Used

DIVISION 43

PROCESS GAS AND LIQUID HANDLING, PURIFICATION, AND STORAGE

EQUIPMENT

Not Used

DIVISION 44 POLLUTION CONTROL EQUIPMENT Not Used

DIVISION 45 INDUSTRY SPECIFIC MANUFACTURING EQUIPMENT Not Used

DIVISION 46 RESERVED

DIVISION 47 RESERVED

DIVISION 48 RESERVED

DIVISION 49 RESERVED

DIVISION 50 PROJECT-SPECIFIC AVAILABLE INFORMATION Not Used

Page Count

50 60 00 FM Global Checklist for Roofing Systems 3

50 70 00 Statement of Special Inspections 9

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SECTION 033000

CAST-IN-PLACE CONCRETE

Construction Documents – Issued for Permit/Bid

SECTION 033000 - CAST-IN-PLACE CONCRETE

PART 1 - GENERAL

1.1 SECTION INCLUDES

A. Cast-in-place concrete for building aprons.

1.2 RELATED REQUIREMENTS

A. Section 31 23 16 - Excavation

B. Section 31 23 23 - Backfilling

1.3 REFERENCE STANDARDS

A. See Sections 6.01 and M.03 of the Standard Specifications as attached.

B. See Sections 6.02 and M.06.01 of the Standard Specifications as attached.

C. ASTM A767 - Standard Specification for Zinc-Coated (Galvanized) Steel Bars for Concrete Reinforcement.

D. ASTM A884 - Standard Specification for Epoxy-Coated Steel Wire and Welded Wire Reinforcement.

E. ASTM C206 - Standard Specification for Finishing Hydrated Lime.

F. ASTM C387 - Standard Specification for Packaged, Dry Combined Materials for Concrete and High Strength Mortar.

G. ASTM C1714 - Standard Specification for Pre-blended Dry Mortar Mix for Unit Masonry.

H. AASHTO M 284 - Standard Specification for Epoxy-Coated Reinforcing Bars: Materials and Coating Requirements.

I. TT-S-00230C Federal Specification - Sealing Compound: Elastomeric Type, Single Component.

1.4 SUBMITTALS

A. Product Data:

1. Submit concrete mix designs.

2. Submit product literature, including material and mill certificates.

B. Certifications - Submit the name, address, and telephone number of concrete plant proposed for use, proposed mix design, and a certification that:

1. The batch plant used to produce the concrete has been inspected and approved by the Chief, Materials Section of the Connecticut Department of Transportation and that such approval is current and effective throughout the period when the concrete is produced for this Project.

2. The concrete delivered to the project site conforms in all respects to the requirements of the mixture class specified.

C. Delegated Design Submittal - Submit a Cold-Weather Concreting Plan if concrete placement or curing operations plan to take place during ambient air-temperatures below 40°F.

D. Reinforcing steel shop drawings.

E. Field Quality Control Submittal - Submit concrete delivery slips.

1.5 QUALITY ASSURANCE

A. Comply with governing codes and regulations.

B. Provide at least one person who shall be thoroughly familiar with the specified requirements, completely trained and experienced in the necessary skills, and who shall be present at the Project site and shall direct all work performed under this Section. Use adequate numbers of skilled workmen.

C. Prepare design mixes for each type of concrete, using previously tested and approved materials.

These mix designs shall be prepared under the supervision of a concrete technologist experienced in the special considerations of materials and mixes.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Portland Cement Concrete

1. Conform to Section M.03 of the Standard Specifications, as attached, for the class of concrete specified on the Drawings or indicated elsewhere within these specifications.

2. Implementing substitutions for concrete ingredients following approval of design mixes is prohibited. Same materials must be used throughout construction of the Project, with adequate checking of the aggregate to assure uniformity with materials submitted for mix designs.

3. Admixtures other than those specified shall be used only when and as approved by the Engineer.

4. Calcium Chloride is prohibited.

5. No concrete shall be delivered to the project site until mix designs have been approved.

B. Reinforcement

1. Deformed Steel Bars - Conform to Section M.06, Article M.06.01 of the Standard Specifications, as attached. Galvanized after fabrication shall conform to ASTM A767, class 1, including supplemental requirements.

2. Welded Wire Mesh - Conform to Section M.06, Article M.06.01 of the Standard Specifications, as attached. Galvanized after fabrication shall conform to ASTM A767, class 1, including supplemental requirements.

3. Supports for reinforcement - Wire bar supports, such as ferrous metal chairs and bolsters, shall conform to industry practice as described in the CRSI “Manual of Standard Practice of the Concrete Reinforcing Steel Institute”. All bolsters or chairs which bear against the forms for exposed surfaces shall be equipped with snug fitting, high density, polyethylene tips which provide 1/2-inch minimum clearance between the metal and any exposed surface. For galvanized or epoxy-coated reinforcement, all wire bar supports and bar clips shall be galvanized, epoxy or plastic coated. Do not use wood and other unacceptable materials.

C. Aggregate

1. Conform to Section M.01 of the Standard Specifications, as attached, for the class of concrete specified on the Drawings or indicated elsewhere within these specifications.

D. Grout - Non-metallic, non-shrink type, “Five Star” premixed grout, as manufactured by U.S.

Grout Corp.

E. Preformed Expansion Joint Filler - Conform to Section M.03, Article M.03.08-4(a) of the Standard Specifications as attached.

F. Joint Seal - Shall be one component polyurethane base elastomeric sealant conforming to federal specification TT-S-00230C Type II - Class A.

G. Backfill Materials - As shown on the Drawings and in accordance with Section 31 23 23.

H. Penetrating Sealer Protective Compound - shall be a single component, 100% silane or silane siloxane from the list of materials below. The materials shall be selected in anticipation of the expected ambient and surface temperature at the time of installation.

The following products may be used when ambient and surface temperatures at 40°F and above:

SIL-ACT ATS-100 (Silane) Advanced Chemical Technologies, Inc.

9608 North Robison Ave.

Oklahoma City, OK 73114 405-843-2585 www.advchemtech.com

Armor SX 5000 EXT-100 or SX 5000 WB (Silane Siloxane) Foundation Armor, LLC.

472 Amherst St. STE 14 Nashua, NH 03063 866-306-0246 www.foundationarmor.com

Aquinil Plus 100 (Silane) ChemMasters 300 Edwards Street Madison, OH 44057 440-428-2105, 800-486-7866 www.chemmasters.net/Aquanil100.php

The following product may be used when ambient and surface temperatures are 20°F and above:

Certi-Vex Penseal 244 100% (Silane) Vexcon Chemicals 7240 State Road Philadelphia, PA 19135 888-839-2661 www.Vexcon.com

PART 3 - EXECUTION

3.1 PERFORMANCE

A. Portland Cement Concrete - Conform to Section 6.01, Article 6.01.03 of the Standard Specifications as attached.

B. Reinforcement - Conform to Section 6.02, Article 6.02.03 of the Standard Specifications as attached.

C. Grout - Store, mix and place non-shrink grout in strict accordance with manufacturer's instructions as approved by the Engineer.

D. Preformed Expansion Joint Filler - The expansion joint fillers shall be continuous. Do not use damaged or repaired joint filler unless approved by the Engineer. Hold the expansion joint filler in a vertical position.

E. Joint Seal - Store, mix and place joint seal in strict accordance with manufacturer’s written instructions as approved by the Engineer.

F. Backfill Materials - As shown on the Drawings and in accordance with Section 31 23 23.

http://www.advchemtech.com/ http://www.foundationarmor.com/ http://www.chemmasters.net/Aquanil100.php

G. Penetrating Sealer Protective Compound

1. Surface Preparation - Concrete surfaces to which penetrating sealer will be applied shall be dry, clean and free of grease, oil and other surface contaminants. New concrete and newly placed repair concrete shall be allowed to cure for at least 28 days before applying sealer. After rain or water cleaning, allow existing concrete surfaces to dry for at least 8 hours before applying sealer. Dry surfaces may be cleaned by sweeping with brushes or brooms, and blowing clean with oil-free, compressed air. Take care not to damage the concrete surface finish during cleaning operations. Care should be taken so that cleaning methods do not damage joint sealants or other components of structure.

2. Application - Application of the sealer can only begin after the Engineer evaluates the concrete surfaces for cleanliness and moisture and determined that the conditions are appropriate for application.

The sealer shall saturate the concrete surface with a rate of application of 200 square feet per gallon of sealer. The dispersion shall run six to eight inches down a vertical surface from the spray pattern. The maximum run-down is 12 inches. Monitor and record the num-ber of square feet per gallon of sealer used to verify that the required application rate is being met. Additional sealer may be needed if surfaces are porous, rough or textured.

The Engineer will inspect the concrete surface during application and after the sealer has had adequate time to penetrate. As a test, water sprayed from a bottle on the sealed surface shall bead up and not be absorbed. Should water be absorbed into the concrete at a test area, additional areas shall be tested to determine which areas should receive additional application of sealer. Apply additional sealer to the identified areas until absorption of wa-ter is prevented.

3.2 FIELD QUALITY CONTROL

A. Employ a laboratory to test concrete once per day or every seventy-five (75) cubic yards of concrete placement if more than seventy-five (75) cubic yards are poured within 24-hours. Testing methods shall be in accordance with ASTM C31, ASTM C143, ASTM C172, ASTM C231, and

ASTM C1064.

B. The Owner may employ a laboratory for acceptance testing of concrete. Such testing does not relieve the Contractor of responsibility for quality control for the Work and delivering the Work in compliance with specification requirements.

C. Cooperate with and provide access to the Work for the testing laboratory.

D. Should testing of a material fail to meet the specification requirements, the Contractor will be notified, and the Contractor shall resolve the problem as appropriate.

3.3 ATTACHMENTS

A. Section 6.01 - Concrete for Structures of the Standard Specifications. Subsections 6.01.04 through

6.01.05 are not included and are not applicable to this Contract.

B. Section 6.02 - Reinforcing Steel of the Standard Specifications. Subsections 6.02.04 through

6.02.05 are not included and are not applicable to this Contract.

C. Section M.01 - Aggregates of the Standard Specifications.

D. Section M.03 - Portland Cement Concrete of the Standard Specifications.

E. Section M.06 - Metals - Reinforcing Steel of the Standard Specifications.

END OF SECTION 033000

6.01

SECTION 6.01

CONCRETE FOR STRUCTURES

6.01.01 Description

6.01.02 Materials

6.01.03 Construction Methods

I. Contractor Quality Control (QC) Requirements for Bridge Deck and Parapet Construction

1. General

2. Contractor Organization

3. Concrete Mix Design

4. Transportation and Delivery of Concrete

5. Placement and Finishing of Concrete

6. Curing of Concrete

7. Contractor QC testing

8. Quality Control Manager (QCM)

9. Pre-Placement Meeting

10. Submission

11. Test Results/CQCP Changes

II. Requirements for New Construction

1. Falsework and Forms

2. Protection from Environmental Conditions

3. Transportation and Delivery of Concrete

4. Acceptance Testing and Specimens

5. Progression Cylinders and Compressive Strength Specimens

6. Handling and Placing Concrete

7. Finishing Plastic Concrete

8. Bearing Surfaces

9. Curing Concrete

10. Finishing Concrete Surfaces

11. Mortar, Grout, Epoxy and Joint Seal

12. Application of Loads

13. Dispute Resolution

III. Additional Requirements for Surface Repairs and Structural Repairs

1. Work Area Access and Shielding

2. Concrete Removal

3. Surface Preparation

4. Installation of Embedded Galvanic Anodes

5. Welded Wire Fabric in Vertical and Overhead Surface Repairs

6. Formwork

7. Concrete Placement and Curing

8. Form Removal and Sequence of Repair

9. Finishing

10. Sounding of Completed Repairs

11. Sealing Concrete Surfaces

6.01.04 Method of Measurement

1. Concrete used for New Construction

2. Underwater Concrete

3. Concrete used for Surface or Structural Repairs

4. Joint Filler

5. Closed Cell Elastomer

6.01.05 Basis of Payment

1. Concrete

2. Underwater Concrete

3. Concrete Used for Structural Steel Repairs or Surface Repairs

4. Joint Filler

5. Closed Cell Elastomer

03 30 00-1 CTDOT Form 819 July 2024

6.01.01 Description: This item shall include cast-in-place (CIP) concrete for use in new construction, surface repair or structural repair of bridges and culverts, walls, catch basins, drop inlets and other incidental construction. The concrete shall be composed of Portland cement, pozzolans, fine and coarse aggregate, admixtures and water, prepared and constructed in accordance with these specifications, at the locations and of the form dimensions and class shown on the plans, or as directed by the Engineer.

The use of concrete from dry batch or central mixed plants is permitted for all CIP concrete mixtures.

6.01.02 Materials: The materials for this work shall meet the requirements of M.03. Surface or structural repair concrete shall be documented on the delivery ticket, as required in 6.01.03-II-3(a), as having the plastic properties necessary for confined placement to ensure appropriate workability for consolidation within the forms.

6.01.03 Construction Methods:

I. Concrete Quality Control (QC) Requirements for All Bridge Deck and Bridge Parapet Construction: The Contractor must demonstrate to the Engineer that the materials and work that will be provided by their field staff, subcontractors, and suppliers meets Contract specification requirements.

This effort shall be documented with a Concrete Quality Control Plan (CQCP) and shall address the communication with all parties, on-site inspection, sampling and testing frequency necessary to keep the production, placement and finishing operations in control, to determine when an operation has gone out of control and anticipated procedure to correct the situation in a timely manner.

1. General provide an overview of the means and methods anticipated to perform the work including any anticipated conditions that may need additional attention (such as seasonal conditions requiring heating or cooling of concrete)

2. Contractor Organization address authority levels/duties by position and name of persons holding those positions; include those who have decision making authority with regard to quality control, materials, sampling and testing who can be contacted by the Engineer

3. Concrete Mix Design identify concrete supplier(s); provide copies of all applicable mix designs to field staff; and address submittal timeframe

4. Transportation and Delivery of Concrete ability to ensure continuous delivery to the Project to meet the requirements of the mix design and a corrective procedure if it does not meet Project requirements; include a provision for the addition of admixtures and follow up testing

5. Placement and Finishing of Concrete identify and describe:

(a) placement equipment

(b) placement method(s) to be used (chute, pump, hopper or other)

(c) starting point and direction of placement (logistical sequencing)

(d) slip forming, formwork, stay-in-place forms or other forming method(s)

(e) joint construction method(s)

(f) process and documentation that the elevations, base, forms, reinforcement (including support chairs and ties), utility inserts or any other appurtenance installations have been inspected by the Contractor prior to concrete placement

(g) equipment and method(s) to be used for vibrating and consolidating concrete

(h) procedure for verifying adequate consolidation and how segregation will be addressed

(i) schedule and method(s) to be used for finishing all exposed surfaces

6. Curing of Concrete describe schedule and method(s) for curing of concrete and how the method(s) will be monitored and maintained

7. Contractor QC testing identify person(s) or firms responsible for Contractor QC testing and provide copies of their certification(s) (see 6.01.03-II-5), and testing facility location(s). In addition, describe the process used for communication between the QC testing personnel and the Contractor project staff;

describe what measures will be taken when test results are out of compliance; this shall include what increased frequency of testing is to be performed to verify that concrete properties are in compliance; the threshold at which time placement ceases; describe what protective measures will be used in case of unforeseen weather

8. The CQCP shall include the name and qualifications of a Quality Control Manager (QCM) provided by the Contractor. The QCM shall be responsible for the administration of the CQCP, and any modifications that may become necessary. The QCM shall have the ability to direct all Contractor personnel on the Project during concreting operations and must communicate directly with the concrete

03 30 00-2 supplier. The QCM shall be certified as either a Concrete Transportation Construction Inspector by the American Concrete Institute (ACI) or a NETTCP Concrete Inspector.

9. The CQCP must include a provision for pre-placement meeting(s) to be held with representatives of the Engineer, the concrete supplier, the QCM supervising the work.

(a) Timing and number of the meeting(s) will be determined by the complexity of the mix design or placement.

(b) Non-Standard mix designs that require trial placements will be discussed at the Preconstruction

Meeting to remind the Contractor of the time needed for testing. Additional meeting(s) should be scheduled at least 90 days prior to first use of non-standard mix designs, to allow suppliers to perform trial batches and testing.

(c) Discussions shall include the configuration and specific application that the concrete will be used for, plastic properties and workability, any mix design challenges, trial placement procedures and subsequent trial results, timing and quantities. Refer to 6.01.03-II-6(e) for additional requirements.

10. The CQCP shall be submitted to the Engineer and concrete supplier for review and comment a minimum of 30 days prior to production or placement. Production and placement shall not occur until all comments of the Engineer and supplier have been addressed by the Contractor. Changes to the CQCP based on data not available at time of submittal may be added via addendum.

11. The Contractor shall provide the Engineer QC test results within 48 hours after testing or inspection in a format acceptable to the Engineer. The Contractor shall also maintain complete records of all QC tests.

Review of the CQCP does not relieve the Contractor of its responsibility to comply with the Project specifications. The Contractor may modify the CQCP as work progresses and must document the changes in writing prior to resuming operations. These changes include but are not limited to changes in quality control procedures or personnel.

II. Requirements for New Construction:

1. Falsework and Forms: Falsework is considered to be any temporary structure which supports structural elements of concrete, steel, masonry or other material during the construction or erection. Forms are to be considered to be the enclosures or panels which contain the fluid concrete and withstand the forces due to its placement and consolidation. Forms may in turn be supported on falsework.

This work shall consist of the construction and removal of falsework and forms that are designed by the Contractor in the execution of the work, and whose failure to perform properly could adversely affect the character of the Contract work or endanger the safety of adjacent facilities, property, or the public. Forms shall be mortar tight. Forms and falsework shall be of sufficient rigidity and strength to safely support all loads imposed and to produce in the finished structure the lines and grades indicated in the Contract documents. Forms shall also impart the required surface texture and rustication and shall not detract from the uniformity of color of the formed surfaces. Forms shall be made of wood, steel or other material approved by the Engineer.

(a) Design: The design of falsework and formwork shall conform to the AASHTO Guide Design

Specifications for Bridge Temporary Works, or to other established and generally accepted design codes such as ACI Standard ACI 347-Recommended Practice for Concrete Formwork or specific form or falsework manufacturer specifications. When other than new or undamaged materials are used, appropriate reductions in allowable stresses, and decreases in resistance factors or imposed loads shall be used for design.

(b) Loads: The design of the falsework and forms shall be based on load factors specified in the AASHTO LRFD Bridge Design Specifications and all applicable load combinations shall be investigated. The design load for falsework shall consist of the sum of appropriate dead and live vertical loads and any horizontal loads. As a minimum, dead loads shall include the weight of the falsework and all construction material to be supported. The combined unit weight of concrete, reinforcing and pre-stressing steel, and forms that is supported shall be assumed to be not less than:

1. Normal-weight concrete: 0.16 kip/ft3

2. Lightweight concrete: 0.13 kip/ft3

Live loads shall consist of the actual weight of any equipment to be supported, applied as concentrated loads at the points of contact and a uniform load of not less than 0.02 kip/ft2 applied over the area supported, plus 0.075 kip/ft applied at the outside edge of deck overhangs.

The horizontal load used for the design of the falsework bracing system shall be the sum of the horizontal loads due to equipment; construction sequence including unbalanced hydrostatic forces

03 30 00-3 from fluid concrete and traffic control devices; stream flow, when applicable; and an allowance for wind. However, in no case shall the horizontal load to be resisted in any direction be less than 2% of the total dead load.

For post-tensioned structures, the falsework shall also be designed to support any increase in or redistribution of loads caused by tensioning of the structure. Loads imposed by falsework onto existing, new, or partially completed structures shall not exceed those permitted in 6.01.03-II-12, Application of Loads.

(c) Working Drawings: The working drawings for falsework and formwork shall be prepared in accordance with 1.05.02 whenever the falsework or formwork exceeds 14.0 feet high or whenever vehicular, marine, or pedestrian traffic may travel under or adjacent to the falsework or formwork.

Working drawings shall include the sequence, method and rate of placement of the concrete.

Manufacturer catalog cuts or written installation procedures shall be provided for any clips, braces, hangers or other manufactured parts used with the formwork or falsework.

(d) Construction: Forms and falsework shall be built true to lines and grades shall be strong, stable, firm, mortar-tight and adequately braced or tied, or both. They shall be designed and constructed to withstand all loads and pressures including those imposed by plastic concrete, taking full account of the stresses due to the rate of placement, effect of vibration and conditions brought about by construction methods. Forms and falsework shall be constructed to compensate for variations in camber of supporting members and allow for deflections.

Falsework and formwork shall be chamfered at all sharp corners, unless otherwise ordered or permitted, and shall be given a slight bevel or draft in the case of projections to ensure satisfactory removal. Materials for falsework and formwork and their supports, ties and bracing, shall be of the type, quality and strength to achieve the structural requirements. Form material in contact with concrete shall provide the finished concrete surface smoothness as specified in 6.01.03-II-10, Finishing Concrete Surfaces, and shall have a uniform appearance.

Falsework and formwork shall be treated with form oil or other release agent approved by the Engineer before the reinforcing steel is placed or self-releasing forms approved by the Engineer may be used. Release agents which will adhere to or discolor the concrete shall not be used.

Falsework and formwork for concrete surfaces exposed to view shall produce a smooth surface of uniform texture, free of voids, indentations, protrusions and bulges. Panels lining falsework and formwork shall be arranged so that the joint lines form a symmetrical pattern conforming to the general lines of the structure. The same type of form-lining material shall be used throughout each element of a structure. Falsework and formwork shall be sufficiently rigid so that the undulation of the concrete surface shall not exceed 1/4 inch when checked with a 4 foot straightedge or template.

For non-exposed surfaces the falsework and formwork shall be sufficiently rigid so that the undulation of the concrete surface shall not exceed 1/2 inch when checked with a 4 foot straightedge or template.

Metal ties and anchors to hold the falsework and formwork in alignment and location shall be so constructed that the metal work can be removed to a depth of at least 2 inches from the concrete surface without damage to the concrete. All cavities resulting from the removal of metal ties shall be filled after removal of forms with cement mortar of the same proportions used in the body of the work or other materials approved by the Engineer, and the surface finished smooth and even, and if exposed in the finished work, shall be similar in texture and color of adjacent surfaces. With permission of the Engineer, the Contractor need not remove from the underneath side of bridge decks portions of metal devices used to support reinforcing steel providing such devices are of material, or are adequately coated with material, that will not rust or corrode. When coated reinforcing steel is required, all metal ties, anchorages, or spreaders that remain in the concrete shall be of corrosion-resistant material or coated with a dielectric material.

Forms shall be clean and clear of all debris. For narrow walls and columns where the bottom of the form is inaccessible, an access opening will be allowed in the form and falsework for cleaning out extraneous material.

(e) Vacant

(f) Bridge Decks: After erection of beams and prior to placing falsework and forms, the Contractor shall take elevations along the top of the beam at the points shown on the plans or as directed by the Engineer. The Contractor shall calculate the haunch depths and provide them to the Engineer a minimum of 7 days prior to installing the falsework and forms. The Contractor shall also provide

03 30 00-4 calculations for the setting of the overhang brackets based on the final beam deflection. These calculations shall be based on the final proposed deck grade and parapet elevations.

Falsework or formwork for deck forms on girder bridges shall be supported directly on the girders so that there will be no appreciable differential settlement during placing of the concrete. Girders shall be either braced and tied to resist any forces that would cause rotation or torsion in the girders caused by the placing of concrete for diaphragms or decks, or shown to be adequate for those effects.

Unless specifically permitted, welding of falsework support brackets or braces to structural steel members or reinforcing steel shall not be allowed.

(g) Stay-In-Place Metal Forms for Bridge Decks: These forms may be used if shown in the Contract documents or approved by the Engineer. Prior to the use of such forms and before fabricating any material, the Contractor shall submit working drawings to the Engineer for review in accordance with 1.05.02. These drawings shall include the proposed method of form construction, erection plans including placement plans, attachment details, weld procedure(s), material lists, material designation, gage of all materials, and the details of corrugation. Also, copies of the form design computations shall be submitted with the working drawings. Any changes necessary to accommodate stay-in-place forms, if approved, shall be at no cost to the Department.

The metal forms shall be designed on the basis of the dead load of the form, reinforcement and the plastic concrete, including the additional weight of concrete [considered to be equivalent to the weight imposed by an additional concrete thickness equal to 3% of the proposed deck thickness, but not to exceed 0.3 inch] due to the deflection of the metal forms, plus 50 psf for construction loads.

The allowable stress in the corrugated form and the accessories shall not be greater than 0.725 times the yield strength of the furnished material and the allowable stress shall not exceed 36,000 psi. The span for design and deflection shall be the clear distance between edges of the beams or girders less 2 inches and shall be measured parallel to the form flutes. The maximum deflection under the weight of plastic concrete, reinforcement, and forms shall not exceed 1/180 of the form span or 0.5 inches, whichever is less. In no case shall the loading used to estimate this deflection be less than 120 psf. The permissible form camber shall be based on the actual dead load condition. Camber shall not be used to compensate for deflection in excess of the foregoing limits. The form support angles shall be designed as a cantilever and the horizontal leg of the form support angle shall not be greater than 3 inches.

No stay-in-place metal forms shall be placed over or be directly supported by the top flanges of beams or girders. The form supporting steel angles may be supported by or attached to the top flanges.

Stay-in-place metal forms shall not be used in bays where longitudinal slab construction joints are located, under cantilevered slabs such as the overhang outside of fascia members, and bridges where the clearance over a salt-laden body of water is less than 15 feet above mean high water level.

Welding to the top flanges of steel beams and girders is not permitted in the areas where the top flanges are in tension, or as indicated on the plans. Alternate installation procedures shall be submitted addressing this condition.

Drilling of holes in pre-stressed concrete beams or the use of power-actuated tools on the prestressed concrete beams for fastening of the form supports to the pre-stressed concrete beams will not be permitted. Welding of the reinforcing steel to the pre-stressed units is not permitted.

All edges of openings cut for drains, pipes, and similar appurtenances shall be independently supported around the entire periphery of the opening. All fabricated stay-in-place metal forms shall be unloaded, stored at the Project Site at least 4 inches above the ground on platforms, skids or other suitable supports and shall be protected against corrosion and damage and handled in such a manner as to preclude damage to the forms. Damaged material shall be replaced at no additional cost to the State.

Any exposed form or form support metal where the galvanized coating has been damaged, shall be thoroughly cleaned, wire brushed, then coated with 2 coats of Zinc Dust Zinc Oxide primer, MIL- DTL-24441 or another product acceptable to the Engineer.

The forms shall be installed from the topside in accordance with the manufacturer's recommended installation procedures. The form supports shall ensure that the forms retain their correct dimensions and positions during use at all times. Form supports shall provide vertical adjustment to maintain design slab thickness at the crest of corrugation, to compensate for variations in camber of beams and girders and to allow for deflections. Stay-in-place metal forms shall have a minimum depth of

03 30 00-5 the form valley equal to 2 inches. The forms shall have closed tapered ends. Lightweight filler material shall be used in the form valleys.

All field cutting shall be done with a steel cutting saw or shears including the cutting of supports, closures and cutouts Flame cutting of forms is not permitted.

All welding shall be performed by Department-certified welders in accordance with 1.05.17, Welding. Welding of forms to supports is not permitted.

The steel form supports shall be placed in direct contact with the flange of stringer or floor beam flanges and attached by bolts, clips, welding where permitted, or other approved means. Form sheets shall not be permitted to rest directly on the top of the stringer or floor beam flanges. The forms shall be securely fastened to form supports with self-drilling fasteners and shall have a minimum bearing length of 1 inch at each end. In the areas where the form sheets lap, the form sheets shall be securely fastened to one another by fasteners at a maximum spacing of 18 inches.

The ends of the form sheets shall be securely attached to the support angles with fasteners at a maximum spacing of 18 inches or 2 corrugation widths, whichever is less.

The depth of the concrete slab shall be as shown on the plans and the corrugated forms shall be placed so that the top of the corrugation will coincide with the bottom of the deck slab. No part of the forms or their supports shall protrude into the slab. All reinforcement in the bottom reinforcement mat shall have a minimum concrete cover of 1 inch unless noted otherwise on the plans.

The completed stay-in-place metal form system shall be sufficiently tight to prevent leakage of mortar. Where forms or their installation are unsatisfactory in the judgment of the Engineer, either before or during placement of the concrete, the Contractor shall correct the defects before proceeding with the work.

(h) Construction Joints: Construction joints other than those shown on the plans will not be permitted without prior approval of the Engineer. In joining fresh concrete to concrete that has already set, the work already in place shall have all loose and foreign material removed, and the surface roughened and thoroughly drenched with water.

All reinforcing steel shall extend continuously through joints. Where unplanned construction joints may be needed, they shall be constructed as directed by the Engineer.

(i) Expansion and Contraction Joints: Expansion and contraction joints shall be constructed at the locations and in accordance with the details specified in the Contract. The forming of joint openings nts include open joints, filled joints, joints sealed with sealants, joints reinforced with steel armor plates or shapes, paraffin coated joints, and joints with combinations of these features.

Open joints shall be placed at locations designated on the plans and shall be formed by the insertion and subsequent removal of templates of wood, metal or other suitable material. The templates shall be so constructed that their removal may be readily accomplished without damage to the work.

Filled joints shall be made with joint filler, the materials for which shall meet the requirements of the plans and of these specifications.

For mechanical joint systems, the concrete shall be placed in such a manner that does not interfere with the movement of the joint.

(j) Pipes, Conduits and Utility Installations: The Contractor shall coordinate the installation of pipes, conduits and utilities as shown on the plans and in accordance with the Contract or as directed by the Engineer. The openings accommodating such pipe, conduit and utility installations shall be incorporated into the formwork by the Contractor.

(k) Anchorages: Anchor bolts and systems shall be set to the requirements of the plans and Contract.

Anchor bolts and systems shall be clean and free of dirt, moisture or other foreign materials at the time of installation. The anchor bolts and systems shall be installed prior to placing concrete.

the concrete or in formed holes. The anchorages shall be installed into drilled or formed holes having a diameter and a depth suitable to receive the bolts in accordance with the grout reinforcement. All holes shall be perpendicular to the plane surface. The Contractor shall take every precaution necessary to prevent damage to the concrete due to freezing of water or grout in anchor bolt holes.

03 30 00-6

(l) Ornament or Reverse Moulds: Ornamental work, when so noted on the plans, shall be formed by the use of reverse moulds. These moulds shall be produced by a qualified manufacturer approved by the Engineer. They shall be built in accordance with the general dimensions and appearance shown on the plans. The Contractor shall submit all detailed drawings, models, or carvings for review by the Engineer before the moulds are made.

The Contractor shall be responsible for their condition at all times, and shall be required to remove and replace any damaged or defective moulds at no additional cost to the State.

The surfaces of the moulds shall be given a coating of form release agent to prevent the adherence of concrete. Any material which will adhere to or discolor the concrete shall not be used.

Form Liners, if required, shall be installed as specified elsewhere.

(m) Removal of Falsework and Forms: The Contractor shall consider the location and character of the structure, the weather, the materials used in the mix, and other conditions influencing the early strength of the concrete when removing forms and falsework. Methods of removal likely to cause damage to the concrete surface shall not be used. Supports shall be removed in such a manner as to permit the structure to uniformly and gradually take the stresses due to its own weight. For structures of 2 or more spans, the sequence of falsework release shall be as specified in the Contract or approved by the Engineer.

Removal shall be controlled by field-cured cylinder tests. The removal shall not begin until the concrete has achieved 75% of the design compressive strength. To facilitate finishing, side forms carrying no load may be removed after 24 hours with the permission of the Engineer, but the curing process must be continued for 7 days.

When the results of field-cured cylinder tests are unavailable, the time periods listed in Table 6.01.03-1, exclusive of days when the temperature drops below 40°F, may govern the removal of forms.

Table 6.01.03-1 Time Restrictions for Removal of Formwork

Structure Element Minimum Time Period Arch Centers, centering under beams, pier caps, and unsupported elements

14 days

Slabs on grade, Abutments and Walls 24 hours Columns 2 days Bridge Decks 28 days

The Contractor may submit for review and approval by the Engineer, alternate methods to determine the in-place strength of the concrete for removal of forms and falsework.

2. Protection from Environmental Conditions: The concrete shall be protected from damage due to weather or other environmental conditions during placing and curing periods. In-place concrete that has been damaged by weather conditions shall be either repaired to an acceptable condition or removed and replaced as determined by the Engineer.

(a) Rain Protection: The placement of concrete shall not commence or continue unless adequate protection satisfactory to the Engineer is provided by the Contractor.

(b) Hot Weather Protection: When the ambient air temperature is above 90°F, the forms, which will come in contact with the mix shall be cooled to below 90°F for a minimum of 1 hour prior to and 1 hour after completion of the concrete placement by means of a water spray or other methods satisfactory to the Engineer.

(c) Cold Weather Protection: When there is a probability of ambient air temperature below 40°F during placement and curing, a Cold-Weather Concreting Plan shall be submitted to the Engineer for review and comment. The Plan shall detail the methods and equipment, including temperature measuring devices that will be used to ensure that the required concrete and air temperatures are maintained.

1. Placement: The forms, reinforcing steel, steel beam flanges, and other surfaces which will come in contact with the mix shall be heated to a minimum of 40°F, by methods satisfactory to the Engineer, for a minimum of 1 hour prior to, and maintained throughout, concrete placement.

2. Curing: For the first 6 days, considered the initial cure period, the concrete shall be maintained at a temperature of not less than 45°F and the air temperature surrounding the structure shall be maintained at a temperature of not less than 60°F. When the concrete mix includes pozzolans or

03 30 00-7 slag, the initial cure period shall be increased to 10 days. After the initial cure period, the air surrounding the structure shall be maintained above 40°F for an additional 8 days. If external heating is employed, the heat shall be applied and withdrawn gradually and uniformly so that no part of the concrete surface is heated to more than 90°F or caused to change temperature by more than 20°F in 8 hours. The Engineer may reduce or increase the amount of time that the structure must be protected or heated based on an indication of in-place concrete strength acceptable to the Engineer.

(d) Additional Requirements for Bridge Decks: Prior to the application of curing materials, all the concrete placed on bridge decks shall be protected from damage due to rapid evaporation by methods acceptable to the Engineer. During periods of low humidity (less than 60% relative humidity), sustained winds of 25 mph or more, or ambient air temperatures greater than 80ºF the Contractor shall provide written details of additional measures to be taken during placement and curing.

Protection may include increasing the humidity of the surrounding air with fog sprayers and employing wind-breaks or sun-shades. Additional actions may include reduction of the temperature of the concrete prior to placement, scheduling placement during the cooler times of days or nights, or any combination of these actions.

(e) Concrete Exposed to Salt Water: No Construction joints shall be formed between the levels of extreme low water and extreme high water or the upper limit of wave action as determined by the Engineer.

3. Transportation and Delivery of Concrete: All material delivered to the Project shall be supplied by a producer qualified in accordance with M.03. The producer shall have sufficient plant capacity and trucks to ensure continuous delivery at the rate required to prevent the formation of cold joints.

(a) Material Documentation: All vendors producing concrete must have their weigh scales and mixing plant automated to provide a detailed delivery ticket. Delivery tickets must include the following information:

1. State of Connecticut

2. Name of producer, identification of plant

3. Date and time of day

4. Type of material

5. Cubic yards of material contained

6. Project number, purchase order number, name of Contractor (if other than producer)

7. Truck identification number

8. Weights of individual aggregate, cement, water, and any admixtures

9. Water/cement ratio, and

10. Additional water allowance in gallons A State inspector may be present to monitor batching or weighing operations.

The Contractor shall notify the Engineer immediately if there is a malfunction of the recording system in the automated plant or weigh scales.

Manually written tickets containing all required information may be allowed for up to 1 hour after malfunction but must be signed by an authorized representative of the producer.

(b) Transportation of Mixture: Trucks delivering concrete shall be qualified in accordance with M.03.

If the concrete mix arrives at the Project with a slump lower than required, additional water may be as a means to temper the concrete. This tempering may only be done after the Engineer and Contractor are notified. The quantity of water in gallons added to the concrete cannot exceed the allowance shown on the delivery ticket. The Contractor is responsible for subsequent testing of the concrete to demonstrate suitable workability has been achieved.

The concrete shall be completely discharged into the forms within 1-1/2 hours from the batch time indicated on the delivery ticket. This time may be extended if the measured temperature of the concrete is below 90ºF. This time may also be reduced if the temperature of the concrete is over 90º F. Rejected concrete shall be disposed of by the Contractor at no cost to the State.

The addition of chemical admixtures or air entrainment admixtures at the Project Site, to increase the workability or to alter the time of set, will only be permitted if prior approval has been granted by the Engineer. The addition of air entrainment admixtures at the Project Site will only be

03 30 00-8 performed or representative. The Contractor is responsible for follow-up quality control testing to verify compliance with the Specifications.

4. Acceptance Testing and Test Specimens: The Contractor shall furnish the facilities and concrete required for sampling, transport to the testing location in the field, performing field testing and for casting sample cylinders for compressive-strength determinations. The Department will furnish personnel for sampling and casting Acceptance specimens and the number of specimens required will be determined by

(a) Temperature, Air Content and Slump: Field testing in accordance with AASHTO T-a frequency determined by the Engineer.

(b) Acceptance Testing and Compressive Strength Specimens: Concrete samples are to be taken at the point of placement into the forms or molds. Representatives of the Engineer will sample the mix.

Table 6.01.03-2 Plastic Properties of Portland Cement Concrete

Standard Mix Class Air Content Slump Concrete

Temperature PCC0334Z1 (3300 psi)

6.0 +/- 1.5% See note 3.

60º-90º F

PCC0336Z1 (3300 psi) PCC0446Z1 (4400 psi)

PCCXXX8Z1 7.5 +/- 1.5%

Modified Standards2 6.0 +/- 1.5% 2

Special Provision Mix4 As specified 1 Z Exposure Factor 0,…