EXH_G_379013 Spec_03410.pdf

PRECAST SHIELD BLOCKS 13-2-40

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SECTION 03410

PRECAST CONCRETE SHIELD BLOCKS

PART 1 – GENERAL

1.01 SCOPE

A INCLUDED: All labor, materials and equipment required in connection with furnishing and delivery of precast concrete work, including but not limited to, the following:

1. Precast reinforced concrete shielding blocks, complete with embedded items as shown.

2. Reinforcing bars and support chairs.

3. Forms

4. Shop and setting drawings.

B RELATED WORK SPECIFIED ELSEWHERE:

1. Embedded items are specified on drawings.

2. Materials are specified on drawings.

C QUALIFICATIONS:

1. Acceptable manufacturers: A company specializing in providing precast concrete products and services normally associated with the industry for at least five years.

When requested by Fermilab, written evidence shall be submitted to show experience, qualifications and adequacy of plant capability and facilities for performance of

Subcontract requirements.

2. Casting Site: The precast elements are to be cast at a regular manufacturing plant familiar with casting the type of precast elements shown on the drawings. All elements are to be cast at one site.

3 Subcontractor’s Responsibility:

a. Examine the drawings and specifications. Supplementary items necessary to complete the work, though not explicitly shown or specified, shall be included.

b. Provide shop drawings showing in detail complete information relating to manufacture and installation of precast concrete work, including dimensions, reinforcing details, lifting inserts and lifting procedures, embedded items and formwork details.

d. Do not cast blocks until Fermilab has approved the formwork.

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e. Do not cast blocks until Fermilab has inspected and approved the reinforcement.

1.02 REFERENCES

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

B. The edition/revision of the referenced publications shall be the latest date as of the date of the

Contract Documents, unless otherwise specified.

C. American Concrete Institute (ACI):

1. ACI 211.1 Selecting Proportions for Normal-Density and High-Density Concrete -

Guide.

2. ACI 301 Specifications for Concrete Construction.

3. ACI 305.1 Specification for Hot Weather Concreting.

4. ACI 306.1 Standard Specification for Cold Weather Concreting.

5. ACI 309R-05 Guide for Consolidation of Concrete.

6. ACI 318 Building Code Requirements for Structural Concrete.

D. American Welding Society (AWS):

1. AWS D1.1 Structural Welding Code - Steel.

E. American Society of Testing Materials (ASTM):

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

2. ASTM A 123 Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products.

3. ASTM A 153 Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel

Hardware.

4. ASTM A 615 Standard Specification for Deformed and Plain Carbon-Steel Bars for

Concrete Reinforcement.

5. ASTM C 33 Standard Specification for Concrete Aggregates.

6. ASTM C 42 Standard Test Method of Obtaining and Testing Drilled Cores and

Sawed Beams of Concrete.

7. ASTM C 94 Standard Specification for Ready-Mixed Concrete.

8. ASTM C 150 Standard Specification for Portland Cement.

9. ASTM C 260 Standard Specification for Air-Entraining Admixtures for Concrete.

10. ASTM C 494 Standard Specification for Chemical Admixtures for Concrete.

11. ASTM C 618 Standard Specification for Coal Fly Ash and Raw or Calcined Natural

Pozzolan for Use in Concrete.

12. ASTM C 1077 Standard Practice for Agencies Testing Concrete and Concrete

Aggregates for Use in Construction and Criteria for Testing Agency Evaluation.

13. ASTM C 1107 Standard Specification for Packaged Dry, Hydraulic-Cement Grout

(Nonshrink).

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14. ASTM E 329 Standard Specification for Agencies Engaged in Construction

Inspection, Testing, or Special Inspection.

F. Concrete Reinforcing Steel Institute (CRSI):

1. CRSI MSP Manual of Standard Practice.

G. Precast/Prestressed Concrete Institute (PCI):

1. PCI MNL 116 Manual for Quality Control for Plants and Production of Structural

Precast Concrete Products.

2. PCI MNL 120 PCI Design Handbook - Precast and Prestressed Concrete.

3. PCI MNL 124 Design for Fire Resistance of Precast Prestressed Concrete.

H. Steel Structures Painting Council (SSPC):

1. SSPC Paint 20 Paint Specification No. 20 Zinc-Rich Primers (Type I, 'Inorganic', and

Type II, 'Organic').

1.03 SUBMITTALS

A. General: Submit the following in accordance with Conditions of the Contract and Exhibit A and

Supplementary Terms and Conditions.

B. Shop Drawings: Submit shop drawings prepared by or under the supervision of a qualified structural engineer detailing fabrication and installation of precast concrete units. Indicate member dimensions and cross-sections; locations, sizes, and types of reinforcement, including special reinforcement; and lifting devices necessary for handling and erection.

1. Indicate layout and dimensions, and identify each precast concrete unit corresponding to sequence and procedure of installation. Indicate welded connections by AWS standard symbols. Detail loose, cast-in, and field hardware; inserts; connections; and joints, including, but not limited to, accessories and construction at openings in precast units.

C. Design Mixes: Submit design mixes for each concrete mix. Submit revised mix proportions when characteristics of materials, project conditions, weather, test results, or other circumstances warrant adjustments.

D. Certification: Submit welder certificates signed by the Subcontractor certifying that welders comply with requirements specified under the quality assurance article.

E. Photographs: For each block, document with photographs rebar and embed locations prior to concrete pour. Submit photographs of rebar/embed placements for Fermilab’s record.

1.04 TESTING:

A. Tests of the design mix to establish the suitability of any material used in precast concrete shall be made prior to the beginning of the work at a design laboratory approved by Fermilab. All costs in connection with preliminary tests shall be included in the Subcontract price. Preliminary test reports shall be furnished to Fermilab in triplicate, before fabrication is started.

B. Plant shall maintain a full range of quality control data including tests of content, aggregates, water, casting time, curing time and temperature.

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C. Fermilab reserves the right to have its designated representative conduct slump tests and secure cylinder samples during any precast element pour at the plant site. For this reason, 48 hour notice shall be given to Fermilab prior to the fabrication of any precast element. Inconvenience to the fabricator for these tests will not constitute grounds for claiming additional money or time in the Subcontract.

D. Fermilab reserves the right to have its designated representative conduct reinforcement and embedment inspection prior to any precast element pour at the plant site. For this reason, 48 hour notice shall be given to Fermilab prior to the fabrication of any precast element.

Inconvenience to the fabricator for these tests will not constitute grounds for claiming additional money or time in the Subcontract.

PART 2 - PRODUCTS

2.01 FORMWORK

A. Forms: Any suitable material can be used for the shield blocks.

1. Formwork shall be designed to achieve the dimensional tolerances required on the drawings.

2. Forms to be designed for casting of a precast unit every 72 hours.

2.02 REINFORCING MATERIALS

A. Reinforcing Bars: Comply with ASTM A 615, Grade 60, deformed.

B. Supports for Reinforcement: Provide supports for reinforcement, including, but not limited to, bolsters, chairs, spacers, and other devices for spacing, supporting, and fastening reinforcing, complying with CRSI recommendations. Where legs of supports are in contact with forms, provide supports with legs that are protected with plastic (CRSI, Class 1) or stainless steel (CRSI, Class 2).

2.03 CONCRETE MATERIALS

A. Portland Cement: Comply with ASTM C 150, Type I or Type III.

1. Use only one brand and type of cement throughout the Project, unless otherwise acceptable to Fermilab.

B. Fly Ash: Comply with ASTM C 618, Class C.

C. Normal Weight Aggregates: Comply with ASTM C 33. Provide Class 4S aggregate for helium pipe enclosure units.

D. Water: Provide potable water.

E. Admixtures, General: Provide admixtures for concrete that contain not more than 0.1 percent chloride ions by mass of portland cement or cementitious material.

F. Air-Entraining Admixture: Comply with ASTM C 260, certified by manufacturer to be compatible with other required admixtures.

G. Water-Reducing Admixture: Comply with ASTM C 494, Type A.

H. High-Range, Water-Reducing Admixture: Comply with ASTM C 494, Type F.

I. Water-Reducing and Accelerating Admixture: Comply with ASTM C 494, Type E.

J. Water-Reducing and Retarding Admixture: Comply with ASTM C 494, Type D.

2.04 CONCRETE MIXES

A. Prepare design mixes for the type of concrete required.

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1. Limit use of fly ash to not exceed, in aggregate, 20 percent of the portland cement by weight.

B. Design mixes may be prepared by a qualified independent testing agency or by qualified precast manufacturing plant personnel at precast fabricator's option.

C. Normal Weight Concrete:

1. Proportion mixes by either laboratory trial batch or field test data methods according to

ACI 211.1 and ACI 301, using materials to be used on the Project, to provide normal weight concrete with the following properties:

a. Compressive Strength (28 Day): 5000 psi (34 474 kPa).

b. Maximum Water Cementitious Materials Ratio at Point of Placement: 0.40.

2. Add air-entraining admixture at manufacturer's prescribed rate to result in normal weight concrete at point of placement having an air content as follows, with a tolerance of plus or minus 1-1/2 percent:

a. Air content for blocks units shall be 2.5 to 4.5 percent.

D. Use water-reducing; high-range, water-reducing; water-reducing and accelerating; or water-reducing and retarding admixtures according to manufacturer's directions.

E. Concrete mix design adjustments may be proposed when characteristics of materials, project conditions, weather, test results, or other circumstances warrant.

2.05 FABRICATION

A. Accurately construct forms, mortar-tight, of sufficient strength to withstand pressures due to concrete placing operations, and temperature changes. Maintain formwork to provide completed precast concrete units of shapes, lines, and dimensions indicated, within fabrication tolerances specified on the drawings.

1. Coat surfaces of forms with bond breaking compound before reinforcement is placed.

Provide commercial formula, form coating compounds that will not bond with, stain, or adversely affect concrete surfaces and that will not impair subsequent treatments of concrete surfaces requiring bond or adhesion. Apply in compliance with manufacturer's instructions.

B. Accurately position built-in anchorage devices and secure to formwork. Locate anchorages where they do not affect the position of the main reinforcement or placing of concrete. Do not relocate embedments, unless acceptable to Fermilab.

C. Comply with the recommendations of CRSI MSP for fabricating, placing, and supporting reinforcement.

1. Clean reinforcement of loose rust and mill scale, earth, and other materials that reduce or destroy the bond with concrete.

2. Accurately position, support, and secure reinforcement against displacement by formwork, construction, or concrete placement operations. Locate and support reinforcement by metal chairs, runners, bolsters, spacers, and hangers, as required.

3. Place reinforcement to obtain at least the minimum coverages for concrete protection.

Arrange, space, and securely tie bars and bar supports to hold reinforcement in position while placing concrete. Set wire ties so ends are directed into concrete, not toward exposed concrete surfaces.

C. Concrete mixing shall comply with requirements and with ASTM C 94. Following concrete batching, no additional water may be added.

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D. Place concrete in a continuous operation to prevent seams or planes of weakness from forming in precast units. Comply with requirements of ACI 304R for measuring, mixing, transporting, and placing concrete.

1. Thoroughly consolidate placed concrete by internal and external vibration without dislocating or damaging reinforcement and built-in items. Use equipment and procedures complying with ACI 309R.

2. Comply with ACI 306R procedures for cold weather concrete placement.

3. Comply with ACI 305R procedures for hot weather concrete placement.

G. Cure concrete according to the requirements of PCI MNL 116 by moisture retention without heat or by accelerated heat curing, using low-pressure live steam or radiant heat and moisture.

H. Finish unformed surfaces by trowel, unless otherwise indicated. Consolidate concrete, bring to proper level with straightedge, float, and trowel to a smooth, uniform finish.

I. Precast concrete units shall be carefully packed and loaded for shipment and all necessary precautions shall be taken against damage in transit. Units shall be stored at the site, off the ground, where directed and properly protected against staining. Delivered materials which, in the opinion of Fermilab do not conform to the requirements of these Specifications, may be rejected and shall be replaced with acceptable materials at no additional cost to Fermilab.

J. Fermilab reserves the right to reject any blocks because of honeycombs, spalls, fins, form lines, stains, excessive cracks, or embedded items not properly located. In the event a block is rejected it shall be replaced by the Subcontractor at no additional cost to Fermilab.

2.06 Delivery

A. Delivery of blocks is to be included. The blocks are to be delivered to a designated location on the Fermilab site for off-loading by Fermilab.

B. The blocks will arrive so that they can be off-loaded by either an overhead crane or a fork truck.

Blocks should be transported on cribbing.

C. Delivery will be coordinated with Fermilab and the Subcontractor will provide 48-hour notice of delivery.

END OF SECTION 03410