DFS1FD 03 30 00 CAST-IN-PLACE CONCRETE 072226DR - pdf.pdf

DARTMOUTH FIRE STATION NO. 1

NEW FUEL DEPOT

DARTMOUTH, MASSACHUSETTS 22 JULY 2026

RT ARCHITECTS, INC.

CAST-IN-PLACE CONCRETE

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SECTION 03 30 00

PART 1 - GENERAL

1.01 RELATED DOCUMENTS

A. All the Contract Documents, including Drawings, General Conditions, and all Sections of Division 01 - General Requirements, apply to the Work of this Section.

1.02 DESCRIPTION OF WORK

A. The Work of this Section shall include, but not be limited to, furnishing and installation of the following:

1. All cast-in-place concrete as shown and noted on the Drawings, including but not limited to, slabs on grade and concrete filled bollards

2. Finishing.

3. Expansion joints and expansion joint fillers

4. Sealing and curing of cast-in-place concrete

1.03 RELATED WORK SPECIFIED ELSEWHERE

A. Carefully examine all the Contract Documents for requirements which affect the Work of this Section.

B. Other Specification Sections which directly relate to the Work of this Section include, but are not limited to, the following:

1. Section 01 00 00 General Requirements

2. Section 26 00 00 Electrical

3. Section 31 20 00 Earthwork

4. Section 31 22 70 Sedimentation and Erosion Control

5. Section 32 12 16 Paving and Surfacing

6. Section 32 55 40 Above Ground Storage Tank and Equipment

1.04 INTENT OF WORK

A. Except as specified otherwise herein, concrete shall be batched, mixed, placed, tested, and cured in accordance with the American Concrete Institute's "Structural Concrete for Buildings" ACI 301.

B. Subcontractor shall schedule his Work and notify all trades in ample time so that provision for their Work can be made without delaying the progress of the project.

C. It is the intention of the Drawings and specifications to produce concrete which will present an acceptable finished appearance. Imperfections of material or Workmanship shall be corrected as the Engineer directs, at the Sub- Contractor's expense.

D. All the Work that is to be inserted in the forms for attachment of other Work is not described in detail. Sub-Contractor shall carefully examine all drawings and other Sections of these specifications for the extent and detail of all such Work and coordinate this Work with other trades.

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E. It will be the Subcontractor's responsibility to insure that all concrete surfaces are completely free of any conditions which will adversely affect its finished appearance or the application of a specified finish.

F. Failure to comply with these requirements will require removal of sufficiently large Sections of the Work, as determined by the Architect and Engineer, in order to properly integrate the Section to be replaced with the architectural and structural requirements of the total project. All such removal and replacement shall be made at the expense of the Subcontractor at no additional cost to the Owner.

1.05 QUALITY ASSURANCE

A. Except as modified by the requirements specified herein and/or the details on the Drawings, all Work included in this Section shall conform to the applicable provisions of the following codes and standards:

1. 2009 International Building Code

2. Massachusetts State Building Code CMR 780, 8th Edition

3. American Concrete Institute (ACI):

a. "Building Code Requirements for Reinforced Concrete", ACI 318-04

b. "Specifications for Structural Concrete for Buildings". ACI 301-05 and ACI SP-09

c. ACI 302.1R-04, "Guide for Concrete Floor and Slab Construction"

d. ACI 304.R-00 "Guide for Measuring, Mixing, Transporting and Placing Concrete”

e. Committee ACI 305R-10, "Hot Weather Concreting”

f. Committee ACI 306R-10, "Cold Weather Concreting"

4. American Society for Testing and Materials (ASTM): The specifications and standards hereinafter referred to latest editions, including but not limited to, ASTM E 1155-96 (Reapproved 2001), Standard Test Method for Determining FF Floor Flatness and FL Floor Levelness.

B. Laboratory Tests and Mix Designs

1. General: Testing of cement and aggregate analysis will be performed by a qualified testing laboratory selected and paid for by the Owner. The laboratory shall perform all tests requested and authorized by the Architect and noted in the statement of special inspections. Tests and services shall consist of the following:

a. Test results of Portland cement in accordance with ASTM C150 and C114 shall be furnished by the Concrete supplier.

b. Analysis of aggregates in accordance with ASTM C33, and sieve analysis of fine and coarse aggregates in accordance with ASTM C136.

2. Samples: Subcontractor shall furnish and deliver identified samples of all materials required for analysis and tests in the amounts required by the Testing Laboratory, without charge. The samples will be selected by the Architect or the Testing Laboratory. Deliver samples of cement and aggregates to the Testing Laboratory at least 30 days prior to use on the job.

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3. Mix Designs:

a. All mix designs shall be proportioned in accordance with Section 4.4 (trial batches) of ACI 318-95. Cost of mix design preparation shall be paid by the Subcontractor. If trial batches are used, they shall be prepared by a recognized independent testing laboratory approved by the Architect. All mix designs for each class of concrete must be approved by the Architect prior to their use in the project. Sub-Contractor shall be responsible for incorporating into the structure concrete of the minimum strengths specified.

C. Environmental Conditions

1. Cold Weather Requirements:

a. Concrete shall not be mixed or placed when the temperature is below 40 degrees F. or when conditions indicate that the temperature will fall below 40 degrees F. within 72 hours, without adequate protection approved by the Architect.

b. Concrete temperature shall be maintained, when deposited, at not less than 60 degrees F. In cold weather, the reinforcement, forms, and ground which concrete will contact must be completely free of frost.

c. The concrete and formwork must be kept at a temperature of not less than 50 degrees F. for not less than 72 hours after placing.

2. Hot Weather Requirements: The maximum placing temperature of the concrete, when deposited, shall be 90 degrees F. If the weather causes the placing temperature to exceed 90 degrees F., the mix shall be cooled by wetting the aggregate or other appropriate method as approved by the Architect.

D. Field inspection and testing of concrete shall be in accordance with Chapter 17 of the Massachusetts State Building Code.

1.06 SUBMITTALS

A. Provide submittals in accordance with requirements of Section 01 33 00 – Submittal Procedures.

B. Provide concrete mix design (including admixtures), test reports, mill certification for Portland Cement, certification for Aggregate non-reactivity, ACI certification of concrete plant, and all other required materials in accordance with requirements of this Section and the Contract Documents.

C. Submit shop and erection drawings for reinforcing steel (electronically) and manufacturer’s data for other associated products for Architect’s review.

D. Provide shop drawings for fabricating and placing reinforcing steel. Show all required information for cutting, bending and placing reinforcing bars, and show all accessories and support bars on placing drawings. Indicate suitable marks for placing bars.

E. Fabrication of any material or performing of any work prior to the final approval of the shop drawings will be entirely at the risk of the Contractor.

F. The Contractor is responsible for furnishing and installing materials called for in Contract Documents, even though these materials may have been omitted from reviewed shop drawings.

G. Before being submitted to the Architect, all shop drawings shall be properly checked and coordinated by the Fabricator and by the Contractor and shall be stamped and signed accordingly. Drawings not complying with these requirements will be returned unchecked and stamped, “Not Reviewed”.

H. At least one copy of each approved Shop Drawing shall be kept available in the Contractor’s field office. Drawings not bearing evidence of release for construction by the Architect/Engineer shall not be kept on the job.

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PART 2 - PRODUCTS

2.01 CONCRETE

A. Portland Cement: Low alkali ASTM C-150 Type 1 at all exposed concrete. Type I and II elsewhere. All cement of each type shall be from a single source. Cement to have 20% flyash with loss on ignition not exceeding 6%, in compliance with ACI 226.3R and ASTM C-618 or up to 25% ACI 226.1R and ASTM C-989 covering blast-furnace slag (grades 100 or 120).

B. Only one color of cement, all of the same manufacturer, shall be used for the Work.

C. Do not use Type III cement without Architect's approval.

2.02 CONCRETE MIX

A. Concrete shall conform to ASTM C94. One copy of the Certificate of Delivery required by ASTM C 94 shall be delivered to the Architect immediately upon arrival of each load of concrete at the site.

B. All concrete shall be proportioned within the following limitations, as indicated in Table A.

TABLE A

Class of Concrete 4000 Psi Min. Compressive Strength @ 7 Days 3300 Psi Min. Compressive Strength @ 28 Days 4670 Psi U.S. Gallons for 94 Lb. Bags 5.5 Absolute Ration By Weight(W/C) 0.48 Consistency Range-Slump(Inches) 4-6 Max. Size of Coarse Aggregate ¾ In.

* For exposed to weather concrete, the maximum w/c shall be 0.45. Use high-range water reducing admixture for w/c equal to or less than 0.45. For all other concrete with a w/c greater than 0.45, use a mid-range water reducing agent. All Concrete containing the high range water reducing admixture (superplasticizer) shall have a maximum slump of 8" unless otherwise directed by the Architect. All other concrete shall have a maximum slump of 4" for footings and retaining walls, and 5" for other members.

C. The exact proportions for the mix, including amounts of admixture (if any), and water, shall be determined as hereinbefore specified under "Mix Designs", based on cement and aggregates submitted by the Subcontractor, and subject to the approval of the Architect.

D. If greater amounts of cement than those specified above are required because of Subcontractor's operations, such as pumping concrete, no increase in the Contract amount will be permitted for this reason.

E. Air-Entrainment: The air content in all concrete exposed to weathering shall be maintained at 4 to 6 percent for ground level exterior Work. The air content for other concrete exposed to weathering shall be 3 to 5 percent. All interior slabs on grade shall not contain air entraining agent and shall have an air content not exceeding 3 percent.

F. All concrete for slabs on grade shall be placed as controlled concrete. The preparation, delivery, depositing, compaction and curing shall be monitored.

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2.03 ADMIXTURES

A. No calcium chloride admixtures are permitted in the concrete.

B. Except as otherwise specified, use of concrete admixtures shall conform to ACI 212.

C. Admixtures employed shall be produced and serviced by established, reputable manufacturer and used in compliance with manufacturer's recommendations.

D. Air entraining agent shall conform to ASTM C 260..

1. When a high range water reducing (HRWR) admixture is used, air-entraining admixture shall be a neutralized vinsol resin solution.

2. When requested by the Architect, certification attesting to compliance with these specifications shall be furnished.

E. Water reducing agent shall conform to ASTM C 494, Type A..

F. Water reducing agent-retarder shall conform to ASTM C 494, Type D.

G. Superplasticizers: Where permitted by the Architect and where indicated in the approved concrete design mix, a high-range water-reducing (HRWR) admixture (superplasticizers) may be used subject to the following requirements:

1. When a high range water-reducing admixture is used, the air-entraining admixture shall be a neutralized vinsol resin solution.

2. Concrete shall arrive at the job site having a slump conforming to the requirements specified in Paragraph 2.01.

HRWR shall be added after the concrete has been thoroughly mixed and the desired initial slump has been achieved.

3. Water to cement ratio shall not exceed 5.0 gallons per hundredweight (0.42 weight basis).

4. Pretesting of the concrete shall be performed under the guidance of the admixture manufacturer's representative to determine dosage, addition times, and compatibility with other admixtures and mixture constituents.

5. HRWR shall be added at the job site and shall be dispensed to the truck mixer using automatic dispensing equipment which accurately measures dosage.

6. Slump after addition of HRWR to concrete shall be no greater than is necessary for proper placement and compaction.

7. Air tests shall be run on the admixtured concrete as placed, and air content shall be within the specified limits.

8. Dosage of HRWR admixture shall be as indicated below. Dosage listed is the quantity of admixture recommended per sack of cement when cement content is reduced.

Product Dosage Melment 25 fl.oz.

WRDA-19 15 fl. oz.

H. Concrete Moisture Vapor Reduction Admixture (MVRA): Concrete moisture vapor reduction admixture for all interior slab (on ground and elevated) and structural roof deck construction shall be a non-toxic, liquid admixture that is specifically designed to have a natural chemical reaction with pre-existing elements inside the concrete to eliminate the route of moisture vapor emission through the slab by restricting the integral capillary system. The chemical reaction forms a permanent barrier (capillary break) that is integral to the concrete, insoluble and irremovable.

1. Provide Barrier One High Performance Concrete Admixture, as manufactured by Barrier One, Inc.., or Architect/Structural Engineer approved equal by Hycrete, Inc. or Specialty Products Group (SPG), that meets or exceeds the below project specific performance requirements at the expense of the concrete moisture vapor reduction admixture (MVRA) manufacturer.

2. Project specific quality control process to include but not limited to:

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a. Independent procurement of one cylinder per day of placement of concrete containing MVRA; do not proceed without MVRA representative being present Independent testing of all cylinders for hydraulic conductivity per ASTM D5084 Assessing each cylinder for maximum flow of 6.0 E-08 cm/sec

b. Should any cylinder exceed the maximum flow, procure a core from that day’s placement

c. Independently test core for hydraulic conductivity per ASTM D5084

d. Should any core exceed the maximum flow, provide a topical moisture mitigation system for all areas not meeting the stated limit; moisture mitigation system to include all labor, material and warranty that meets or exceeds the terms of the concrete moisture vapor reduction admixture manufacturer’s warranty

3. Warranty requirements: Said product must be installed according to and in compliance with the manufacturer’s published data sheet to include but not limited to dosing instructions, onsite representation requirements, and the use of an ASTM E 1745 vapor retarder, installed following ASTM E 1643 and ASTM F 710 guidelines; suspended concrete slabs do not require a vapor retarder.

a. MVRA Manufacturer’s warranty shall include:

1. Term: Life of the concrete

2. Repair and/or removal of failed flooring

3. Placement of a topical moisture remediation system

4. Replacement of flooring materials like original installed to include material and labor

b. MVRA Manufacturer shall provide an adhesion warranty to match the term of the adhesive manufacturer’s warranty in accordance with the MVRA manufacturer’s requirements for conveyance of such.

2.04 AGGREGATE

A. Except as otherwise noted, aggregate shall conform to ASTM C 33 for normal weight concrete.

B. Maximum size aggregate for Sections 16 in. or greater in thickness shall be 1-1/2 in. Maximum size aggregate for Sections less than 16 in. thick shall be 3/4-in. 3/8” Aggregate may be used for concrete on steel decking.

C. Maximum size of aggregate shall in no case exceed that permitted by ACI 318.

2.05 WATER

A. Water shall conform to ASTM C 94, Section 4.1.3.

2.06 GROUT

A. Grout shall be mixed in the proportions of one part Portland cement to two parts sand, by volume. Only sufficient water shall be used to enable grout to barely hold its shape when squeezed into a ball in the hand. Sand for grout shall be ASTM C 33 Fine Aggregates.

B. Nonshrink grout shall be pre-mixed non-shrinking, high strength grout. Compressive strength in 28 days shall be 5,000 psi minimum, but in no case less than the specified strength of the adjacent concrete. Manufacturer shall provide evidence that the material meets the requirements of the COE CRD-C 621 (558). Grout permanently exposed to view shall be nonoxidizing; metallic grout may be used in other locations.

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2.07 CURING AND SEALING AGENTS

A. Curing and sealing agents shall be compatible with applied floor finishes. Coordinate Work with requirements of Section 09 91 13 – Painting for application of colored floor sealer. Do not use curing / sealer on floors planned to receive flooring /finishes.

2.08 EXPANSION JOINTS

A Expansion joints (or compressible fillers) shall be 1/2 in. wide and shall be filled with preformed joint filler. Filler shall be a preformed, non-bituminous type joint filler conforming to ASTM D 1752, Type II, Sealtight Cork Expansion Joint Filler, as manufactured by W.R. Meadows, Inc., or Architect approved equal.

1. Joint filler shall be one piece for the full depth and width of the joint. Use of multiple pieces of lesser dimensions to make up the required depth and width of the joint will not be permitted.

B. Unless otherwise indicated on the Drawings, expansion joints shall be located 30 ft. o.c., maximum.

C. Where indicated on the Drawings, expansion joints shall be doweled.

1. Steel dowels shall be greased on one end; plastic-coated dowels will not require greasing.

2.09 CONTROL JOINTS

A. Control joints shall be saw cut with diamond blade concrete that cuts into concrete slab surface at least 1 in., but not less than 25% of slab depth.

B. Unless otherwise indicated on the Drawings, control joints at interior slabs-on-grade shall be located 12’ – 6” o.c., maximum. At exterior sidewalk slabs, joints shall not exceed 6’-0” o.c.

C. Reinforcing shall continue through control joints.

D. At sidewalk slabs, provide formed joints.

2.10 SLEEVES

A. Sleeves shall be galvanized steel Schedule 40 conforming to ASTM A53 or schedule 40 PVC

2.11 PIPE TO WALL PENETRATION SEALS

A. Pipes passing through waterproof surfaces shall have a pipe to wall penetration seal assembly equal to Link-Seal, manufactured by Thunderline Corporation or approved equal.

1. Each pipe seal shall be furnished complete with wall sleeve and wall penetration seal.

2. Wall sleeve shall be steel and shall have integral waterstop and anchor collar.

3. Wall penetration seal shall be a modular mechanical type, with interlocking synthetic rubber links shaped to continuously fill the annular space between the pipe and the wall sleeve.

4. Service designation shall be Type "S" for corrosive service with glass reinforced nylon plastic pressure plate, stainless steel bolts and nuts, and EPDM rubber sealing element.

B. All other pipes passing through concrete not indicated to be waterproofed shall have only the wall sleeve Model WS.

Sealing of these pipes is not required.

1. Other pipe sleeve material other than the Link-Seal will be considered subject to the approval of the Architect.

C. Pipe sleeves and seals shall be properly sized in accordance with the sleeve manufacturer’s recommendations to ensure a completely watertight seal upon completion of the installation.

2.12 NOT USED

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2.13 CONTROL JOINT FILLER

A. Provide control joint filler as follows, and as approved by the Architect:

1. Urethane joint filler: Pourthane by W.R. Meadows

2. Epoxy joint filler-Sikadur 5 INS/SC by Sika

3. Rapid set polymer joint filler-Chemtron CP2010 by Chemtron Polymers Inc.

2.14 MISCELLANEOUS ITEMS

A. Welded deformed Bar Anchors: Gun-applied.

B. Headed Stud Anchors: Headed studs welded by full-fusion process.

C. Bolts: Conform to ASTM A 307, carbon steel with regular hexagon nuts conforming to ASTM A 563, and carbon steel washers conforming to ASTM F 436.

D. Weepholes: Schedule 40 PVC pipe.

PART 3 - EXECUTION

3.01 CONCRETE MIXING

A. All concrete shall be ready-mixed concrete and shall be mixed and delivered in accordance with the requirements of "Specifications for Ready-Mixed Concrete", ASTM C94 to produce concrete with the required slump and air content.

B. The concrete producer shall furnish with each load of concrete a numbered delivery ticket showing name of Contractor, name and location of project, date and time batched, truck number, number of cubic yards in load, specified strength, slump, and mix design number.

C. In the event concrete is mixed at a central batching plant, the delivery shall be arranged so that intervals between batches are kept at a minimum, and in any event not more than thirty (30) minutes. Trucks shall be in first class condition and kept in constant rotation during delivery.

D. When concrete is delivered in a truck mixer or agitator, no water from the truck-water system or elsewhere shall be added after the initial introduction of mixing water for the batch, except when on arrival at the job site the slump of the concrete is less than that specified. Such additional water to bring the slump within required limits shall be injected into the mixer. The drum or blades shall be turned an additional 30 revolutions or more at mixing speed until the concrete is within the proper slump limits if not in violation of the requirements of Paragraph 5.

E. Discharge of concrete after initial batching shall be completed within 90 minutes, or before the drum has revolved 300 revolutions, whichever comes first, after the introduction of the mixing water to the cement and aggregates or the introduction of the cement to the aggregates. In hot weather (as defined by ACI) the discharge of the concrete shall be completed within 60 minutes.

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3.02 CONCRETE PLACEMENT

A. Before placing concrete, forms and space to be occupied by concrete shall be thoroughly cleaned, and reinforcing steel and embedded metal shall be free from dirt, oil, mill scale, loose rust, paint, and other material which might tend to reduce bond. The geotechnical engineer shall review the subgrade material prior to the placement of concrete, forms, and rebar.

B. Existing concrete, earth, and other water-permeable material against which new concrete is to be placed shall thoroughly damp when concrete is placed. There shall be no free water on surface.

C. Concrete which has set or partially set before placing shall not be employed. Retempering of concrete will not be permitted.

D. Segregation of the concrete shall be prevented during handling; should any segregation occur, the concrete shall be remixed before it is placed. Concrete shall be placed in the forms in horizontal layers not over 1 to 2 ft. thick.

Concrete shall not be allowed to drop freely more than 4 ft. If the free drop to the point of placement must exceed 4 ft., the Contractor shall obtain the approval of the Architect for the proposed method of depositing the concrete. The concrete shall not be required to flow over distances greater than 3 ft. in any direction in the forms or on the ground, unless otherwise permitted by the Architect.

E. Concrete shall be thoroughly spaded, and tamped, and vibrated to secure a solid and homogeneous mass, thoroughly worked around reinforcement and into corners of forms.

F. Provide concrete where required for filling of steel bollards provided under the Work of Section 05 50 00 – Metal Fabrications.

3.03 TESTING OF CONCRETE

A. Field Inspection and Testing shall be in accordance with the testing program requirements of Chapter 17-Special Inspections of the Massachusetts State Building Code.

B. Slump Tests: The Testing Laboratory will make slump tests of concrete during placing of concrete in accordance with ASTM C143. Air content shall be tested in accordance with requirements of the Statement of Special Inspections.

Slump test shall be made for each set of test cylinders or as noted on the Contract Drawings.

C. Compression Tests:

1. The Testing Laboratory will prepare and cure compression test samples at the Owner's expense. One set of at least four cylinders will be made in accordance with ASTM C31 from each 50 cubic yards of concrete, or fraction thereof, placed each day. Additional cylinders required by the Contractor for the early removal of forms shall be made at the Contractors expense.

2. One cylinder from each set will be tested at 7 days for information. Two cylinders shall be tested at 28 days for acceptance in accordance with ASTM C39.

3. The fourth cylinder from each set shall be kept until the 28 day test reports on the second and third cylinders in the same set has been received by the Architect.

4. The strength level shall be considered satisfactory so long as the averages of all sets of three consecutive strength test results equal or exceed the specified strength f'c, and no individual strength test result falls below the specified strength f'c by more than 500 psi.

5. In the event the average compressive strength of the two 28 day cylinders does not achieve the required level, the Architect may elect to test the fourth cylinder immediately or test it after 56 days

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6. If the result is below the required level, the Architect may require test cores of the hardened structure to be taken by the Testing Laboratory in accordance with ASTM C42. If such test indicates that the core specimen is below the strength level required by ACI 318-95, Chapter, the concrete in question shall be removed and replaced without cost to the Owner. Any other Work damaged as a result of this concrete removal shall be replaced with new materials to the satisfaction of the Architect at no additional cost to the Owner. The cost of coring will be deducted from the Contract amount. Where core cylinders have been taken by the Testing Laboratory and the concrete proves to be satisfactory, the cutout Sections shall be restored to the original condition in a manner satisfactory to the Architect at no additional cost to the Owner.

3.04 SUBMITTAL OF CONCRETE TEST REPORTS

A. Concrete test reports submitted by the testing laboratory shall contain the following information:

1. Name and location of project

2. Name of Architect/Engineer

3. Name of Contractor

4. Name of concrete producer

5. Delivery ticket number

6. Date and time batched

7. Date and item sampled, with identification number or letter for each specimen

8. Temperature of concrete

9. Temperature of air

10. Slump

11. Air content and unit weight of concrete

12. Mix reported used

13. Approximate number of cubic yards represented by sample

14. Location or portion of structure represented by sample

15. Description of initial curing of test specimens

16. Date of test and age of specimen

17. Compressive strength PSI

18. Statement signed by laboratory supervisor that all applicable ASTM Standards performed by the laboratory have been followed, except as noted.

3.05 CONVEYING AND PLACING CONCRETE

A. Notification: The Engineer shall be notified at least 72 hours in advance of the placing of any concrete.

B. Foundation bearing area under footings and slabs shall be approved by the Testing Agency before placing concrete.

C. Forms: Before placing concrete, forms shall be thoroughly inspected. All chips, dirt, and other foreign matter shall be removed, all temporary bracing and cleats taken out, all openings for pipes, sleeves, and other similar related penetrations shall be properly boxed, all forms properly secured in their correct position and made tight, all reinforcements, anchors, and embedded items secured in their proper places. Concrete which may be on the forms or reinforcement, and which is set and dry, shall be cleaned off, and the forms and steel washed off before proceeding.

Remove water and all foreign matter from forms and excavations. Unless otherwise directed, sand or sandy soil shall be moist but not saturated just prior to placing concrete.

1. To permit satisfactory finishing, forms shall be removed from the vertical faces of the concrete without damaging the surface. Immediately after stripping forms, any fins or projections left by the forms will be chipped off, and the surfaces rubbed smooth.

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2. Form tie holes and other voids and faults shall be patched. All voids, faults, honeycombs, and similar surface deficiencies shall be cleaned out, roughened, thoroughly wetted, coated with neat cement paste, and filled with mortar of cement and sand in the same proportions, materials, and color as used in the concrete. The surface of the patch shall be flush with the surrounding surface after finishing operations are complete. Surface shall be kept continuously damp until patches are firm enough to be rubbed without damage

3. Rubbing shall be performed while the surface is wet using a carborundum or cement sand brick, to achieve a smooth, uniform, even textured finish. Patched and chipped areas shall be blended to match as closely as possible the appearance of the rest of the surface. No cement wash or plastering will be permitted, and no mortar shall be used except in accordance with requirements of the Contract Documents.

D. Vertical surfaces of concrete which will be concealed in finished structure shall be formed to produce a "rough form finish", as defined in ACI 301.

E. Vertical surfaces of concrete which will be exposed in finished structure shall be formed to produce a "smooth formed -rubbed finish", as defined in ACI 301.

3.06 CONCRETE SLAB FINISHES

A. All exterior slabs surfaces shall be screeded, leveled, floated and steel troweled. Mechanical troweling machines may be used if the desired finish and level tolerances can be obtained by their use, but finishing shall be by hand troweling at edges and areas inaccessible to machine trowels.

1. Scratch Finish: Apply scratch finish to monolithic slab surfaces to receive concrete floor topping or mortar setting beds for tile, Portland cement terrazzo, and other bonded applied cementitious finish flooring material, and where indicated.

a. After placing slabs, finish surface to tolerances of FF 38 (floor flatness) and FL 25 (floor levelness) measured in accordance with requirements of ASTM E 1155. (Note: FL 25 applies to slabs-on-grades only – not suspended / elevated slabs.) Slope surfaces uniformly to drains where required. After leveling, roughen surface before final set with stiff brushes, brooms, or rakes.

2. Float Finish: Apply float finish to monolithic slab surfaces to receive trowel finish and other finishes as specified;

slab surfaces to be covered with membrane or elastic waterproofing, membrane or elastic roofing, or epoxy terrazzo, and where indicated.

a. After screeding, consolidating, and leveling concrete slabs, do not work surface until ready for floating. Begin floating, using float blades or float shoes only, when surface water has disappeared, or when concrete has stiffened sufficiently to permit operation of power-driven floats, or both. Consolidate surface with power-driven floats or by hand-floating if area is small or inaccessible to power units. Finish surfaces to tolerances of FF 38 (floor flatness) and FL 25 (floor levelness) measured in accordance with requirements of ASTM E 1155. Cut down high spots and fill low spots. Uniformly slope surfaces to drains. Immediately after leveling, refloat surface to a uniform, smooth, granular texture. (Note: FL 25 applies to slabs-on-grades only – not suspended / elevated slabs.)

3. Trowel Finish: Apply a trowel finish to monolithic slab surfaces exposed to view and slab surfaces to be covered with resilient flooring, carpet, ceramic or thin-set quarry tile, paint, or another thin film-finish coating system.

a. After floating, begin first trowel-finish operation using a power-driven trowel. Begin final troweling when surface produces a ringing sound as trowel is moved over surface. Consolidate concrete surface by final hand-troweling operation, free of trowel marks, uniform in texture and appearance, and finish surfaces to tolerances of FF 50 (floor flatness) and FL 33 (floor levelness) measured in accordance with requirements of ASTM E 1155. Grind smooth any surface defects that would telegraph through applied floor covering system.

(Note: FL 33 applies to slabs-on-grades only – not suspended / elevated slabs.)

b. Finish and measure surface so gap at any point between concrete surface and an unleveled freestanding 10-foot long straightedge, resting on two high spots and placed anywhere on the surface, does not exceed ⅛”.

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C. Non-slip Broom Finish: Apply a non-slip broom finish to exterior concrete platforms, steps, and ramps, and elsewhere as indicated.

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

E. The addition of cement, sand, water, or mortar to slab surfaces while finishing concrete is strictly prohibited.

F. All surfaces shall be finished to the tolerances noted above. Particular care shall be taken to finish troweling around the edges of slabs so finish surface at edges shall be at same elevations as the rest of the top surface of the slab.

G. Slabs shall be laid to temporary screeds set level at the proper elevations. Screeds to be pipe or metal. Wet screeds will not be allowed. Screeds shall be set no further apart than 12’-0” on center.

H. Mark-off lines shall be formed with curbed edging tool, neat and true to line, uniform throughout. Conform to markings shown on Drawings.

I. Immediately following finishing operations, arrises at edges and both sides of expansion joints shall be rounded to a 1/4 in. radius. Control joints shall be scored into slab surface with scoring tool. Adjacent edges of control joint shall at same time be finished to a 1/4 in. radius.

J. Where finishing is performed before end of curing period, concrete shall not be permitted to dry out, and shall be kept continuously moist from time of placing until end of curing period, or until curing membrane is applied.

3.07 CONTROL JOINTS

A. Control joints in slab surfaces shall be located as shown on the Contract Drawings. Control joints may be made by sawing a continuous slot to a depth of 1/4 the thickness of the slab. Joints shall be spaced at intervals indicated on Contract drawings and shall be made in the concrete slabs-on-grade within 24 hours after placement of concrete.

B. Control joints and/or construction joints in walls shall be spaced at 40'-0" O.C. maximum and shall align with masonry control joints where applicable. Joints shall be made with a 1/2" deep chamfer strip on each face of the walls.

3.08 FILLING TIE ROD AND BOLT HOLES

A. Holes resulting from the removal of bolts or tie rods shall be solidly filled with cement grout. Holes passing entirely through concrete members shall be filled from the inside face, with a plunger-type grease gun or other device that will force the mortar through to the outside face, holding a piece of canvas at the exterior surface to assure complete filling.

Holes which do not pass entirely through shall be filled, using tools which will permit the opening to be packed thoroughly full. Excess mortar at the faces of filled holes shall be struck off flush, with canvas.

03 30 00 - 13

3.09 CURING

A. It is essential that concrete be kept continuously damp from time of placement until end of specified curing period. It is equally essential that water not be added to surface during floating and troweling operations, and not earlier 24 hours after concrete placement. Between finishing operations surface shall be protected from rapid drying by a covering of waterproofing paper. Surface shall be damp when the covering is placed over it, and shall be kept damp by means of a fog spray of water, applied as often as necessary to prevent drying, but not sooner than 24 hours after placing concrete. None of the water so applied shall be troweled or floated into surface.

B. Concrete surfaces, not otherwise specified, shall be cured by being kept wet with clean water for a period of not less than seven days after placing. Each day the forms are left in place, and kept wet enough to prevent the opening of joints in the forms and the drying out of the concrete, will be counted as one day of curing.

C. Concrete surfaces shall be cured by completely covering with curing paper or by use of a curing compound.

1. Concrete cured using curing paper shall be completely covered with paper with seams lapped at least 2 in. and sealed with tape. Concrete surface shall not be allowed to become moistened within 24 hours of placing concrete. During curing period surface shall be checked frequently, and sprayed with water or curing compound, as applicable, as often as necessary to prevent drying, but not earlier than 24 hours after placing concrete.

2. Concrete cured with a curing compound shall have curing compound applied at a rate of 200 sq. ft. per gallon. A second coat of the specified curing and sealing compound shall be applied to all exposed concrete slab.

3. Concrete surfaces to receive paint, waterproofing, damproofing, thin-set adhesives and coatings, and similar applied materials which require bond and adhesion to concrete surfaces, shall be cured using curing paper. The use of curing compounds on these surfaces will not be permitted.

4. Concrete surfaces in apparatus bay that will be shot blasted and receive epoxy coatings shall be treated in accordance with manufacturer’s recommendations.

5. Unless otherwise directed by the Architect, curing period shall be seven days, minimum.

3.10 COLD WEATHER CONCRETING

A. Materials for concrete shall be heated when concrete is mixed, placed, or cured when the mean daily temperature is below 40 degrees F., or is expected to fall to below 40 degrees F., within 72 hours, and the concrete after placing shall be protected by covering, heat, or both.

B. Details of handling and protecting of concrete during freezing weather shall be subject to the approval and direction of the Architect. Procedures shall be in accordance with provisions of ACI 306.

3.11 HOT WEATHER CONCRETING

A. Concrete just placed shall be protected from the direct rays of the sun and the forms and reinforcement just prior to placing shall be sprinkled with cold water. Every effort shall be made to minimize delays which will result in excessive mixing of the concrete after arrival on the job.

B. During periods of excessively hot weather (95 degrees F. or above), ingredients in the concrete shall be cooled insofar as possible and cold mixing water shall be used to maintain the temperature of the concrete at permissible levels, all in accordance with the provisions of ACI 305. Any concrete with a temperature above 95 degrees F., when ready for placement, will not be acceptable and will be rejected.

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C. Temperature records shall be maintained throughout the period of hot weather, including but not limited to, air temperature, general weather conditions, ie: wind speed, velocity, and direction, clear or cloudy, and relative humidity.

Records shall include checks on temperatures of concrete as delivered and after placing in forms. Data should be correlated with the progress of the Work so that conditions surrounding the construction of any part of the structure can be ascertained.

3.12 NOT USED

3.13 NOT USED

3.14 EXPANSION JOINT

A. Expansion joint shall be 1/2 in. wide, clean, dry, and free of loose material, dirt, oil and grease, and shall be formed in the concrete to required width with preformed joint filler in place. Joint filler shall extend the full length of the expansion joint.

1. Depth of filler shall extend to the full thickness of the concrete in vertical surfaces and in concealed horizontal surfaces.

2. Depth of filler in exposed horizontal surfaces shall form a 1/2 in. deep sealant recess below finished surface.

3.15 SAW CUT JOINT

A. Saw cut joints shall be made following finishing as soon as the concrete surface is firm enough not be torn or damaged by the blade, (within 24 hours after placement), and before random shrinkage cracks can form in the concrete rface.

B. Saw cut shall be made accurately to the dimensions, line, and spacings indicated.

3.16 INTERIOR JOINTS OF SLAB ON GRADE

A. All interior construction and control joints, where noted on the Drawings, shall be filled with the specified epoxy joint filler or urethane joint sealer. These compounds shall be mixed and installed in strict accordance with the directions of the manufacturer.

B. The epoxy joint filler shall not be installed until 90 days after slab placement

3.17 NOT USED

3.18 PROTECTION OF CONCRETE SURFACES

A. Concrete and insulating concrete surfaces shall be protected from traffic or damage until surfaces have hardened sufficiently. If necessary, 1/2 in. thick plywood sheets shall be used to protect the exposed surface.

3.19 DEFECTIVE WORK

A. The following Work will be considered defective and may be ordered by the Architect to be removed and replaced at no additional cost to the Owner:

1. Concrete incorrectly formed

2. Concrete not plumb or level

3. Concrete not achieving specified strength

4. Concrete containing rock pockets, voids, honeycomb, or cold joints

5. Concrete containing wood or foreign matter

6. Concrete otherwise not in accordance with requirements of the Contract Documents

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3.20 REPAIR OF DEFECTIVE AREAS:

A. Immediately after stripping forms, patch minor defects, including but not limited to form-tie holes, voids, faults, honeycombing, and similar related surface deficiencies, before concrete is thoroughly dry. Remove ledges and bulges.

Repair gravel pockets by cutting out to solid surface, form key, and thoroughly dampen. Apply the specified bonding compound. Place patching mortar consisting of 1 part cement to 2 parts fine sand, after the bonding compound has dried. Compact fine sand, after the bonding compound has dried. Compact mortar into place and neatly finish to exactly match surface texture. Grind or fill surfaces to produce level, true planes. Patching of honeycombed areas to gravel pockets which, in the Architect's opinion, are too large and unsatisfactory for mortar patching as described above, is to be cut out to solid surface, keyed, and packed solid with matching concrete to produce firm bond and surface. Patching shall match adjacent surfaces.

B. All structural repairs shall be made with an epoxy adhesive or mortar specified by the Structural Engineer of Record thru the administration of the Architect for the type of repair required.

3.21 AS-CAST FORMED FINISHES

A. Vertical surfaces of concrete concealed in finished structure shall be formed to produce a "rough form finish", as defined in ACI 301. Vertical surfaces of concrete exposed in finished structure shall be formed to produce a "smooth formed - rubbed finish", as defined in ACI 301.

B. Provide a smooth-formed finish as imparted by the approved form-facing material, arranged in an orderly and symmetrical manner with a minimum of seams. Remove fins and other projections exceeding specified limits on formed-surface irregularities. Repair and patch tie holes and defects.

C. Not later than one day after form removal, at areas of exposed architectural concrete as indicated on the Drawings, moisten concrete surfaces and rub with carborundum brick or another approved abrasive until producing a uniform color and texture. Do not apply cement grout other than that created by the rubbing process.

D. Install pre-manufactured concrete formliners in accordance with the approved manufacturer’s written requirements at locations and in patterns as indicated on the Drawings or otherwise approved on-site by the Architect.

3.22 CLEANING

A. All waste and debris caused by the Work of this Section shall be removed and legally disposed of daily, in accordance with requirements of Section 01 50 00 - Temporary Facilities and Controls.

END OF SECTION