03 15 00 00 10 - Concrete Accessories.docx

DIVISION 03 - CONCRETE

SECTION 03 15 00.00 10

CONCRETE ACCESSORIES

08/10

PART 1 GENERAL

This guide specification covers the requirements for expansion joints, contraction joints and water-stops used in concrete construction. This guide will be used in conjunction with Section 03 31 01.00 10 CAST-IN-PLACE STRUCTURAL CONCRETE FOR CIVIL WORKS.

1.1 UNIT PRICES

1.1.1 Waterstops

1.1.1.1 Payment

Payment will be made for costs associated with waterstops, including labor, materials and use of all equipments and tools required to complete the waterstop work. No separate payment will be made for expansion and contraction joints which are included in the costs for the items to which work for expansion and contraction joints are incidental.

1.1.1.2 Measurement

Waterstops will be measured for payment by the linear foot in place. In computing the quantity of the waterstops, no allowance will be made for laps. No separate measurement will be made for expansion and contraction joints which are included in the costs for the items to which work for expansion and contraction joints are incidental.

1.1.1.3 Unit of Measure

Unit of measure: linear foot.

1.2 REFERENCES

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

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS

(AASHTO)

AASHTO T 111 (2009) Standard Method of Test for Mineral Matter or Ash in Asphalt Materials

AMERICAN HARDBOARD ASSOCIATION (AHA)

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

ASME INTERNATIONAL (ASME)

ASME BPVC SEC IX (2010) BPVC Section IX-Welding and Brazing Qualifications

ASTM INTERNATIONAL (ASTM)

ASTM A 1011 (2010) Standard Specification for Steel, Sheet, and Strip, Hot-Rolled, Carbon, Structural, High-Strength Low-Alloy and High-Strength Low-Alloy with Improved Formability and Ultra-High Strength

ASTM A 109/A 109M (2008) Standard Specification for Steel, Strip, Carbon (0.25 Maximum Percent), Cold-Rolled

ASTM A 167 (1999; R 2009) Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip

ASTM A 480 (2010) Standard Specification for General Requirements for Flat-Rolled Stainless and Heat-Resisting Steel Plate, Sheet, and Strip

ASTM B 152 (2009) Standard Specification for Copper Sheet, Strip, Plate, and Rolled Bar

ASTM B 370 (2009) Standard Specification for Copper Sheet and Strip for Building Construction

ASTM C 919 (2008) Use of Sealants in Acoustical Applications

ASTM D 1751 (2004; R 2008) Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Non-extruding and Resilient Bituminous Types)

ASTM D 1752 (2004a; R 2008) Standard Specification for Preformed Sponge Rubber Cork and Recycled PVC Expansion

ASTM D 2628 (1991; R 2005) Standard Specification for Preformed Polychloroprene Elastomeric Joint Seals for Concrete Pavements

ASTM D 2835 (1989; R 2007) Lubricant for Installation of Preformed Compression Seals in Concrete Pavements

ASTM D 4 (1986; R 2010) Bitumen Content

ASTM D 412 (2006ae2) Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers - Tension

ASTM D 471 (2006e1) Standard Test Method for Rubber Property - Effect of Liquids

ASTM D 5249 (1995; R 2006) Backer Material for Use with Cold-and Hot-Applied Joint Sealants in Portland-Cement Concrete and Asphalt Joints

ASTM D 6 (1995; R 2006) Loss on Heating of Oil and Asphaltic Compounds

ASTM D 7116 (2005) Standard Specification for Joint Sealants, Hot Applied, Jet Fuel Resistant Types, for Portland Cement Concrete Pavement

U.S. ARMY CORPS OF ENGINEERS (USACE)

COE CRD-C 513 (1974) Corps of Engineers Specifications for Rubber Waterstops

COE CRD-C 572 (1974) Corps of Engineers Specifications for Polyvinylchloride Waterstops

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for Contractor Quality Control approval. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Waterstops; G

SD-03 Product Data

Preformed Expansion Joint Filler; G

Sealant; G

Waterstops; G

SD-04 Samples

Lubricant for Preformed Compression Seals; G

Field-Molded Type; G

Non-metallic Materials; G

Waterstops; G

Splicing Waterstops; G

SD-07 Certificates

Preformed Expansion Joint Filler; G

Sealant; G

Waterstops; G

1.4 DELIVERY, STORAGE, AND HANDLING

Protect material delivered and placed in storage off the ground from moisture, dirt, and other contaminants. Deliver sealants in the manufacturer's original unopened containers. Remove sealants from the site whose shelf life has expired.

PART 2 PRODUCTS

2.1 CONTRACTION JOINT STRIPS

Contraction joint strips shall be 1/8 inch thick tempered hardboard conforming to AHA A135.4, Class 1. In lieu of hardboard strips, rigid polyvinylchloride (PVC) or high impact polystyrene (HIPS) insert strips specifically designed to induce controlled cracking in slabs on grade may be used. Such insert strips shall have removable top section.

2.2 PREFORMED EXPANSION JOINT FILLER

Expansion joint filler shall be preformed material conforming to ASTM D 1751 or ASTM D 1752, Type I, or resin impregnated fiberboard conforming to the physical requirements of ASTM D 1752. Submit certified manufacturer's test reports for pre-molded expansion joint filler strips, compression seals and lubricant, and metallic waterstops to verify compliance with applicable specification. Unless otherwise indicated, filler material shall be 3/8 inch thick and of a width applicable for the joint formed. Backer material, when required, shall conform to ASTM D 5249.

2.3 SEALANT

Elastomeric joint seals (ASTM D 2628) will be used in compression type joints. For slabs receiving considerable fuel spillage, the hot-applied jet-fuel resistant type should be used when a thermoplastic elastomeric rubber (TPE-R) waterstop is not specified.

Joint sealant shall conform to the following:

2.3.1 Preformed Polychloroprene Elastomeric Type

ASTM D 2628.

2.3.2 Lubricant for Preformed Compression Seals

ASTM D 2835. Submit a piece not less than 9 ft of 1 inch nominal width or wider seal or a piece not less than 12 ft of compression seal less than 1 inch nominal width. Provide one quart of lubricant.

2.3.3 Field-Molded Type

ASTM D 7116. Sealant shall be Type M, Grade P or NS, Class 25, Use T or NT for horizontal joints. Type M, Grade NS, Class 25, use NT for vertical joints. Bond breaker material shall be polyethylene tape, coated paper, metal foil or similar type materials. The back-up material shall be compressible, non-shrink, nonreactive with sealant, and non-absorptive material type such as extruded butyl or polychloroprene rubber. Submit One gallon of field-molded sealant and one quart of primer (when primer is recommended by the sealant manufacturer) identified to indicate manufacturer, type of material, quantity, and shipment or lot represented.

2.3.4 Hot-Applied Jet-Fuel Resistant Type

ASTM D 7116, Type I, II, III

2.4 WATERSTOPS

Shop fabricate intersection and change of direction waterstops. Submit a sample of each material consisting of a piece not less than 12 inches long cut from each 200 feet of finished waterstop furnished, but not less than a total of 4 linear feet of each type and size furnished. For spliced segments of waterstops to be installed in the work, furnish one spliced sample of each size and type for every 50 splices made in the factory and every 10 splices made at the job site for inspection and testing. Make the spliced samples using straight run pieces with the splice located at the mid-length of the sample and finished as required for the installed waterstop. The total length of each spliced sample shall be not less than 12 inches long. Submit waterstop materials and splice samples for inspection and testing identified to indicate manufacturer, type of material, size and quantity of material and shipment represented.

2.4.1 Flexible Metal

Copper waterstops shall conform to ASTM B 152/B 152M and ASTM B 370, O60 soft anneal temper and 0.686 mm 20 oz mass per sq ft sheet thickness. Stainless steel waterstops shall conform to ASTM A 167 and ASTM A 480, UNS S30453 (Type 304L), and 0.9525 mm 0.0375 inch (20 gauge) thick strip.

2.4.2 Rigid Metal

Flat steel waterstops shall conform to ASTM A 109/A 109M, No. 2 (half hard) temper, No. 2 edge, No. 1 (matte or dull) finish or ASTM A 1011, Grade 40.

2.4.3 Non-Metallic Materials`

Non-metallic waterstops shall be manufactured from a prime virgin resin; reclaimed material is not acceptable. The compound shall contain plasticizers, stabilizers, and other additives to meet specified requirements. Rubber waterstops shall conform to COE CRD-C 513. Polyvinylchloride waterstops shall conform to COE CRD-C 572. Thermoplastic elastomeric rubber waterstops shall conform to ASTM D 471. Submit a piece not less than 300 mm 12 inch long cut from each 61 m 200 ft of finished waterstop furnished, but not less than a total of 1 m 4 ft of each type, size, and lot furnished. One splice sample of each size and type for every 50 splices made in the factory and every 10 splices made at the job site. Make the splice samples using straight run pieces with the splice located at the mid-length of the sample and finished as required for the installed waterstop. The total length of each splice shall be not less than 300 mm 12 inches long.

2.5 TESTS, INSPECTIONS, AND VERIFICATIONS

2.5.1 Splicing Waterstops

2.5.1.1 Procedure and Performance Qualifications

Demonstrate procedure and performance qualifications for splicing waterstops in the presence of the Contracting Officer. Submit procedures for splicing waterstops for approval.

2.5.1.2 Non-Metallic Waterstops

Demonstrate procedure and performance qualifications for splicing non-metallic waterstops by the manufacturer at the factory and the Contractor at the job site by each making three spliced samples of each size and type of finished waterstop.

2.5.1.3 Metal Waterstops

Demonstrate procedure and performance qualifications for splicing metal waterstops at the job site by the Contractor. The brazing procedure, brazers and brazing operators for splicing copper waterstops shall be qualified in accordance with Part QB (Brazing), Article XI (Brazing, General Requirements), paragraph QB-170 (Peel Tests) and other applicable requirements of Articles XI, XII, and XIII of ASME BPVC SEC IX. The welding procedure and welders for splicing stainless steel waterstops shall be qualified in accordance with the manufacturer's recommendations.

PART 3 EXECUTION

3.1 INSTALLATION

Joint locations and details, including materials and methods of installation of joint fillers and waterstops, shall be as specified and indicated. In no case shall any fixed metal be continuous through an expansion or contraction joint.

3.1.1 Contraction Joints

Contraction joints may be constructed by inserting tempered hardboard strips or rigid PVC or HIPS insert strips into the plastic concrete using a steel parting bar, when necessary, or by cutting the concrete with a saw after concrete has set. Make joints 1/8 inch to 3/16 inch wide and extend into the slab one-fourth the slab thickness, minimum, but not less than 1 inch.

3.1.1.1 Joint Strips

Provide strips of the required dimensions and as long as practicable. After the first floating, groove the concrete with a tool at the joint locations. Insert the strips in the groove and depress them until the top edge of the vertical surface is flush with the surface of the slab. Float and finish the slab as specified. Working of the concrete adjacent to the joint shall be the minimum necessary to fill voids and consolidate the concrete. Where indicated, saw out the top portion of the strip after the curing period to form a recess for sealer. Discard the removable section of PVC or HIPS strips and leave the insert in place. Maintain true alignment of the strips during insertion.

3.1.1.2 Sawed Joints

Saw joints early enough to prevent uncontrolled cracking in the slab, but late enough that this can be accomplished without appreciable spalling. Cutting shall be started as soon as the concrete has hardened sufficiently to prevent raveling of the edges of the saw cut. Cutting shall be completed before shrinkage stresses become sufficient to produce cracking. Use concrete sawing machines that are adequate in number and power, and with sufficient replacement blades to complete the sawing at the required rate. Cut joints to true alignment and in sequence of concrete placement. Remove sludge and cutting debris. Form reservoir for joint sealant.

3.1.1.3 Bond Breaker

Coat joints requiring a bond breaker with curing compound or with bituminous paint. Protect waterstops during application of bond breaking material to prevent them from being coated.

3.1.2 Expansion Joints

Use preformed expansion joint filler in expansion and isolation joints in slabs around columns and between slabs on grade and vertical surfaces where indicated. Extend the filler to the full slab depth, unless otherwise indicated. neatly finish the edges of the joint with an edging tool of 1/8 inch radius, except where a resilient floor surface will be applied. Where the joint is to receive a sealant, the filler strips shall be installed at the proper level below the finished floor with a slightly tapered, dressed and oiled wood strip temporarily secured to the top to form a recess to the size shown on the drawings. Remove the wood strip after the concrete has set. Contractor may opt to use a removable expansion filler cap designed and fabricated for this purpose in lieu of the wood strip. Thoroughly clean the groove of laitance, curing compound, foreign materials, protrusions of hardened concrete, and any dust. If blowing out the groove use oil-free compressed air.

3.1.3 Joint Sealant

Fill sawed contraction joints and expansion joints in slabs with joint sealant, unless otherwise shown. Joint surfaces shall be clean, dry, and free of oil or other foreign material which would adversely affect the bond between sealant and concrete. Apply joint sealant as recommended by the manufacturer of the sealant.

3.1.3.1 Joints With Preformed Compression Seals

Install compression seals with equipment capable of installing joint seals to the prescribed depth without cutting, nicking, twisting, or otherwise distorting or damaging the seal or concrete and with no more than 5 percent stretching of the seal. Cover the sides of the joint and, if necessary, the sides of the compression seal with a coating of lubricant. Coat butt joints with liberal applications of lubricant.

3.1.3.2 Joints With Field-Molded Sealant

Do not seal joints when the sealant material, ambient air, or concrete temperature is less than 40 degrees F. When the sealants are meant to reduce the sound transmission characteristics of interior walls, ceilings, and floors the guidance provided in ASTM C 919 shall be followed. Coat joints requiring a bond breaker with curing compound or with bituminous paint. Install bond breaker and back-up material where required. Joints shall be primed and filled flush with joint sealant in accordance with the manufacturer's recommendations.

3.2 WATERSTOPS, INSTALLATION AND SPLICES

Install waterstops at the locations shown to form a continuous water-tight diaphragm. Embed the bottom of each waterstop a minimum of 6 inches in firm rock or sealed to other cut-off systems. Make adequate provision to support and completely protect the waterstops during the progress of the work. Repair or replace any waterstop punctured or damaged. Protect exposed waterstops during application of form release agents to avoid being coated. Provide suitable guards to protect exposed projecting edges and ends of partially embedded waterstops from damage when concrete placement has been discontinued. Accomplish splices with certified trained personnel using approved equipment and procedures.

3.2.1 Copper And Stainless Steel

Splices in copper waterstops shall be lap joints made by brazing. Splices in stainless steel waterstops shall be welded using a TIG or MIG process utilizing a weld rod to match the stainless. All welds shall not be annealed to maintain physical properties. Do not use carbon flame in the annealing process. Damaged waterstops shall be repaired by removing damaged portions and patching. Patches shall overlap a minimum of 1 inch onto undamaged portion of the waterstop.

3.2.2 Flat Steel

Splices in flat steel waterstops shall be properly aligned, butt welded, and cleaned of excessive material.

3.2.3 Non-Metallic

Fittings shall be shop made using a machine specifically designed to mechanically weld the waterstop. A miter guide, proper fixturing (profile dependant), and portable power saw shall be used to miter cut the ends to be joined to ensure good alignment and contact between joined surfaces. The splicing of straight lengths shall be done by squaring the ends to be joined. Maintain continuity of the characteristic features of the cross section of the waterstop (ribs, tabular center axis, protrusions, etc.) across the splice.

3.2.3.1 Rubber Waterstop

Splices shall be vulcanized or shall be made using cold bond adhesive as recommended by the manufacturer. Splices for TPE-R shall be as specified for PVC.

3.2.3.2 Polyvinyl Chloride Waterstop

Make splices by heat sealing the adjacent waterstop edges together using a thermoplastic splicing iron utilizing a non-stick surface specifically designed for waterstop welding. Use the correct temperature to sufficiently melt without charring the plastic. Reform waterstops at splices with a remolding iron with ribs or corrugations to match the pattern of the waterstop. The spliced area, when cooled, shall show no signs of separation, holes, or other imperfections when bent by hand in as sharp an angle as possible.

3.2.3.3 Quality Assurance

Edge welding will not be permitted. Compress or close center-bulbs when welding to non-center-bulb type. Waterstop splicing defects which are unacceptable include, but are not limited to the following: 1) Tensile strength less than 80 percent of parent section. 2) Free lap joints. 3) Misalignment of center-bulb, ribs, and end bulbs greater than 1/16 inch. 4) Misalignment which reduces waterstop cross section more than 15 percent. 5) Bond failure at joint deeper than 1/16 inch or 15 percent of material thickness. 6) Misalignment of waterstop splice resulting in misalignment of waterstop in excess of 1/2 inch in 10 feet. 7) Visible porosity in the weld area, including pin holes. 8) Charred or burnt material. 9) Bubbles or inadequate bonding. 10) Visible signs of splice separation when cooled splice is bent by hand at a sharp angle.

3.2.4 Non-Metallic Hydrophilic Waterstop Installation

Miter cut ends to be joined with sharp knife or shears. The ends shall be adhered with cyanacryiate (super glue) adhesive. When joining hydrophilic type waterstop to PVC waterstop, the hydrophilic waterstop shall be positioned as shown on the drawings. Apply a liberal amount of a single component hydrophilic sealant to the junction to complete the transition.

3.2.5 Preformed Plastic Adhesive Installation

The installation of preformed plastic adhesive waterstops shall be a prime, peel, place and pour procedure. Joint surfaces shall be clean and dry before priming and just prior to placing the sealing strips. The end of each strip shall be spliced to the next strip with a 1 inch overlap; the overlap shall be pressed firmly to release trapped air. During damp or cold conditions the joint surface shall be flashed with a safe, direct flame to warm and dry the surface adequately; the sealing strips shall be dipped in warm water to soften the material to achieve maximum bond to the concrete surface.

3.3 CONSTRUCTION JOINTS

Treat construction joints coinciding with expansion and contraction joints as expansion or contraction joints as applicable.

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