03 30 53.doc

LF SURFACE DRAINAGE

FA4626-11-R-0014

USACE / NAVFAC / AFCESA / NASA UFGS-03 30 53 (April 2008) Preparing Activity: USACE (CW) Superseding UFGS-03 30 04 (April 2006) UFGS-03 30 53.00 40 (July 2007)

UNIFIED FACILITIES GUIDE SPECIFICATIONS

References are in agreement with UMRL dated October 2010

SECTION 03 30 53

MISCELLANEOUS CAST-IN-PLACE CONCRETE

04/08

NOTE: This guide specification covers the requirements for projects involving amounts of concrete less than 380 cubic meters (500 cubic yards).

Edit this guide specification for project specific requirements by adding, deleting, or revising text. For bracketed items, choose applicable items(s) or insert appropriate information.

Remove information and requirements not required in respective project, whether or not brackets are present.

Comments, suggestions and recommended changes for this guide specification are welcome and should be submitted as a Criteria Change Request (CCR).

PART 1 GENERAL

NOTE: This specification requires furnishing all material and equipment, and performing all labor for the manufacturing, transporting, placing, finishing, and curing of concrete for recreation sites, road relocations, or other structures such as culvert headwalls, comfort stations, residences, or low head gate structures. Consideration should be given to using Section 03 31 01.00 10 CAST-IN-PLACE STRUCTURAL CONCRETE FOR CIVIL WORKS when the quantity of concrete is 380 cubic meters (500 cubic ) or greater per structure.

1.1 SUMMARY

Perform all work in accordance with ACI MCP PACK Parts 2 and 3.

1.2 REFERENCES

NOTE: This paragraph is used to list the publications cited in the text of the guide specification. The publications are referred to in the text by basic designation only and listed in this paragraph by organization, designation, date, and title.

Use the Reference Wizard's Check Reference feature when you add a RID outside of the Section's Reference Article to automatically place the reference in the Reference Article. Also use the Reference Wizard's Check Reference feature to update the issue dates.

References not used in the text will automatically be deleted from this section of the project specification when you choose to reconcile references in the publish print process.

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.

ACI INTERNATIONAL (ACI)

ACI MCP PACK

(2010) Manual of Concrete Practice

ASTM INTERNATIONAL (ASTM)

ASTM A 185/A 185M

(2007) Standard Specification for Steel Welded Wire Reinforcement, Plain, for Concrete

ASTM A 615/A 615M

(2009b) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

ASTM C 150/C 150M

(2009) Standard Specification for Portland Cement

ASTM C 260

(2006) Standard Specification for Air-Entraining Admixtures for Concrete

ASTM C 33/C 33M

(2008) Standard Specification for Concrete Aggregates

1.3 SUBMITTALS

NOTE: Review submittal description (SD) definitions in Section 01 33 00 SUBMITTAL PROCEDURES and edit the following list to reflect only the submittals required for the project. Submittals should be kept to the minimum required for adequate quality control.

A “G” following a submittal item indicates that the submittal requires Government approval. Some submittals are already marked with a “G”. Only delete an existing “G” if the submittal item is not complex and can be reviewed through the Contractor’s Quality Control system. Only add a “G” if the submittal is sufficiently important or complex in context of the project.

For submittals requiring Government approval on Army projects, a code of up to three characters within the submittal tags may be used following the "G" designation to indicate the approving authority. Codes for Army projects using the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO" for District Office (Engineering Division or other organization in the District Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project Office. Codes following the "G" typically are not used for Navy, Air Force, and NASA projects.

Choose the first bracketed item for Navy, Air Force and NASA projects, or choose the second bracketed item for Army projects.

Submit the following in accordance with Section 01 00 00 SUBMITTAL PROCEDURES:

SD-03 Product Data Ready-Mix Concrete

PART 2 PRODUCTS

2.1 MATERIALS

Submit manufacturer's literature from suppliers which demonstrates compliance with applicable specifications for the specified materials.

2.1.1 Cementitious Materials

Submit Manufacturer's certificates of compliance attesting that the concrete materials meet the requirements of the specifications. Provide cementitious materials that conform to the appropriate specifications listed:

2.1.1.1 Portland Cement

NOTES: Limit the use of air-entraining cement to concrete placements where separate batching of air-entraining admixture is not practical.

Tricalcium aluminate, for sulfate resistance, is limited to Type III cement. If high early strength is not required, specify Type II rather than Type I when moderate sulfate resistance is required, or Type V when high sulfate resistance is required.

Specify low-alkali cement when the aggregate is either silica or carbonate reactive.

ASTM C 150/C 150M, Type I/II. Use one brand of cement throughout Project unless otherwise acceptable to Contracting Officer.

2.1.2 Aggregates

NOTE: This note may be disregarded for regions where Alkali-Silica Reactivity (ASR) is not a concern. Some aggregate sources may exhibit an ASR potential. ASR is a potentially deleterious reaction between alkalis present in concrete and some siliceous aggregates, reference EM 1110-2-2000 paragraph 2-3b(6) and appendix D. Where ASR is known or suspected to pose a concern for concrete durability, it is recommended that aggregates proposed for use in concrete be evaluated to determine ASR potential and an effective mitigation. EM 1110-2-2000, provides recommendations for evaluating and mitigating ASR in concrete mixtures. Aggregate evaluations may not be practical for projects requiring small quantities of concrete (less than 190 cubic meters (250 cubic yards)).

Section 32 13 11 CONCRETE PAVEMENT FOR AIRFIELDS AND OTHER HEAVY-DUTY PAVEMENTS MORE THAN 7,700 CUBIC METERS (10,000 CUBIC YARDS), paragraph 2.2.1.2 Alkali-Silica Reactivity, provides a specification method for the Contractor to evaluate and mitigate ASR in concrete mixtures. The expansion limits specified in Section 32 13 11 are requirements for pavements and exterior slab construction. For structural concrete applications the measured expansion must be less than 0.10 percent. It may not be economical or practical to specify different test limit requirements for use on the same project, in which case the lower limit is required by the application The designer may use the specification method in Section 32 13 11 by incorporating the relevant paragraphs into this specification, or may use the following requirements (retain either the 0.10 or the 0.08 percent expansion limits as appropriate).

Fine and coarse aggregates shall meet the quality and grading requirements of ASTM C 33/C 33M Class Designations 4M or better. Provide aggregates from a single source for exposed concrete. For exposed exterior surfaces, do not use fine or coarse aggregates that contain substances that cause spalling.

2.1.3 Admixtures

Admixtures to be used, when required or approved, shall contain no more than 0.1 percent chloride ions. Retest chemical admixtures that have been in storage at the project site, for longer than 6 months or that have been subjected to freezing, at the expense of the Contractor at the request of the Contracting Officer and will be rejected if test results are not satisfactory.

2.1.3.1 Air-Entraining Admixture

Provide air-entraining admixture that meets the requirements of ASTM C 260.

Subject to compliance with requirements, products that may be incorporated in the Work include, but are not limited to, the following:

(1) Darex AEA or Daravair, W.R. Grace & Co.

(2) MB VR or Micro Air, Master Builders, Inc.

(3) Sika AER, Sika Corp.

2.1.3.2 Water-Reducing or Retarding Admixture

Water Reducing Admixture shall conform to ASTM C 494, Type A.

Subject to compliance with requirements, products that may be incorporated in the Work include, but are not limited to, the following:

(1) WRDA, W.R. Grace & Co.

(2) Pozzolith Normal or Polyheed, Master Builders, Inc.

(3) Prokrete N, Prokrete Industries.

(4) Plastocrete 161, Sika Corp.

High Range Water Reducing Admixture shall conform to ASTM C 494, Type F or Type G.

Subject to compliance with requirements, products that may be incorporated in the Work include, but are not limited to, the following:

(1) WRDA 19 or Daracem, W.R. Grace & Co.

(2) Rheobuild or Polyheed, Master Builders, Inc.

(3) Sikament 300, Sika Corp.

Water Reducing, Accelerating Admixture shall conform to ASTM C 494, Type E.

Subject to compliance with requirements, products that may be incorporated in the Work include, but are not limited to, the following:

(1) Daraset, W.R. Grace & Co.

(2) Pozzutec 20, Master Builders, Inc.

Water Reducing, Retarding Admixture shall conform to ASTM C 494, Type D.

Subject to compliance with requirements, products that may be incorporated in the Work include, but are not limited to, the following:

(1) Daratard 17, W.R. Grace & Co.

(2) Pozzolith R, Master Builders, Inc.

(3) Plastiment, Sika Corporation.

2.1.4 Water

Use fresh, clean, potable water for mixing and curing, free from injurious amounts of oil, acid, salt, or alkali.

2.1.5 Reinforcing Steel

NOTE: Delete this paragraph if Section 03 20 00.00 10 CONCRETE REINFORCING is to be used.

Also delete this paragraph if fibercrete is accepted for use by the Contracting Officer.

Provide reinforcing bars conforming to the requirements of ASTM A 615/A 615M, Grade 60. Grade 40 may be used for stirrups and ties. Welded steel wire fabric shall conform to the requirements of ASTM A 185/A 185M. Details of reinforcement not shown shall be in accordance with ACI MCP PACK Part 3, Chapters 7 and 12.

Use wire bar type supports complying with CRSI specifications. For slabs on grade, use supports with sand plates or horizontal runners where base material will not support chair legs. For exposed to view concrete surfaces where legs of supports are in contact with forms, provide supports with legs that are protected by plastic (CRSI, Class 1) or stainless steel (CRSI, Class 2).

2.1.6 Formwork

The design and engineering of the formwork as well as its construction, will be the responsibility of the Contractor. Plywood, metal, metal framed plywood faced, or other acceptable panel type materials to provide continuous, straight, smooth, exposed surfaces. Furnish in largest practicable sizes to minimize number of joints and to conform to joint system shown on drawings.

2.1.7 Form Release Agent

Provide commercial formulation form release agent with a maximum of 350 mg/l volatile organic compounds (VOCs) that will not bond with, stain, or adversely affect concrete surfaces and will not impair subsequent treatments of concrete surfaces.

2.1.8 Vapor Barrier

Provide vapor retarder that is resistant to deterioration when tested according to ASTM E 154. Provide polyethylene sheet not less than 8 mils thick.

2.1.9 Curing Materials

Provide curing materials conforming to the following requirements.

2.1.9.1 Membrane-Forming Curing Compound

Liquid type membrane forming curing compound complying with ASTM C 309, Type I, Class A. Moisture loss not more than 0.55 kg/sq. meter when applied at 200 sq. ft./gal.

Subject to compliance with requirements, products that may be incorporated in the Work include, but are not limited to, the following:

(1) Day Chem Cure and Seal, Dayton Superior Corp.

(2) Masterkure, Master Builders, Inc.

(3) Kure N Seal, Sonneborn Chemrex.

2.2 READY-MIX CONCRETE

Comply with requirements of ASTM C 94, and as specified. When air temperature is between 85 deg F (30 deg C) and 90 deg F (32 deg C), reduce mixing and delivery time from 1 1/2 hours to 75 minutes, and when air temperature is above 90 deg F (32 deg C), reduce mixing and delivery time to 60 minutes.

4000 psi minimum compressive strength as determined in 28 calendar days, water-cement ratio 0.40 maximum (air entrained).

Slump: Proportion and design mixes to result in concrete slump at point of placemen. For reinforced foundation systems: Not less than 1 inch and not more than 3 inches. Concrete containing high range water reducing admixture (superplasticizer): Not more than 8 inches after adding admixture to site verified 1 to 3 inch slump concrete.

h. Air-Entraining Admixtures Use air entraining admixture in exterior exposed concrete unless otherwise indicated. Add air entraining admixture at manufacturer's prescribed rate to result in concrete at point of placement having total air content with a tolerance of plus or minus 1 1/2 percent. Concrete structures and slabs exposed to freezing and thawing, deicer chemicals, or hydraulic pressure of 6.0 percent for 3/4 inch maximum aggregate.

Use water reducing admixture or high range water reducing admixture (superplasticizer) in concrete, as required, for placement and workability.

Use accelerating admixture in concrete slabs placed at ambient temperatures below 50 deg F (10 deg C).

Use high range water reducing admixture in pumped concrete, concrete for heavy use industrial slabs, rural concrete, parking structure slabs, concrete required to be watertight, and concrete with water cement ratios below 0.50.

Use admixtures for water reduction and set accelerating or retarding in strict compliance with manufacturer's directions.

NOTE: Ground granulated blast furnace slag and fly ash are materials listed in the EPA's Comprehensive Procurement Guidelines (CPG) (http://www.epa.gov/cpg/). If the Architect/Engineer determines that use of certain materials meeting the CPG content standards and guidelines would result in inadequate competition, do not meet quality/ performance specifications, are available at an unreasonable price or are not available within a reasonable time frame, the Architect/ Engineer may submit written justification and supporting documentation for not procuring designated items containing recovered material. Written justification may be submitted on a Request for Waiver Form to the .

PART 3 EXECUTION

3.1 GENERAL

Coordinate the installation of joint materials, vapor retarder/barrier, and other related materials with placement of forms and reinforcing steel.

3.2 FORMS

Design, erect, support, brace, and maintain formwork to support vertical, lateral, static, and dynamic loads that might be applied until concrete structure can support such loads. Construct formwork so concrete members and structures are of correct size, shape, alignment, elevation and position.

3.2.1 Construct forms to sizes, shapes, lines, and dimensions shown and to obtain accurate alignment, location, grades, level, and plumb work in finished structures. Provide for openings, offsets, sinkages, keyways, recesses, moldings, rustications, reglets, chamfers, blocking, screeds, bulkheads, anchorages and inserts, and other features required in the Work. Use selected materials to obtain required finishes. Solidly butt joints and provide backup at joints to prevent cement paste from leaking.

3.2.2 Chamfer exposed corners and edges as indicated, using wood, metal, PVC, or rubber chamfer strips fabricated to produce uniform smooth lines and tight edge joints.

3.2.3 Cleaning and Tightening: Thoroughly clean forms and adjacent surfaces to receive concrete. Remove chips, wood, sawdust, dirt, or other debris just before placing concrete. Retighten forms and bracing before placing concrete, as required, to prevent mortar leaks and maintain proper alignment.

3.3 PLACING REINFORCEMENT

Comply with Concrete Reinforcing Steel Institute's recommended practice for "Placing Reinforcing Bars," for details and methods of reinforcement placement and supports and as specified.

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

3.3.2 Accurately position, support, and secure reinforcement against displacement. Locate and support reinforcing by metal chairs, runners, bolsters, spacers and hangers.

3.3.3 Place reinforcement to maintain minimum coverage as indicated for concrete protection. Arrange, space, and securely tie bars and bar supports to hold reinforcement in position during concrete placement operations. No bars, including dowels, are to be placed by shoving into already placed fresh concrete. Set wire ties so ends are directed into concrete, not toward exposed concrete surfaces.

3.4 PREPARING FORM SURFACES

Coat contact surfaces of forms with an approved, nonresidual, low VOC, form coating compound before placing reinforcement.

3.4.1 Do not allow excess form coating material to accumulate in forms or come into contact with in place concrete surfaces against which fresh concrete will be placed. Apply according to manufacturer's instructions.

Coat steel forms with a nonstaining, rust preventative material. Rust stained steel formwork is not acceptable.

3.5 CONCRETE PLACEMENT

3.5.1 Inspection: Before placing concrete, inspect and complete formwork installation, reinforcing steel, and items to be embedded or cast in. Notify other trades to permit installation of their work.

3.5.2 General: Comply with ACI 304, "Guide for Measuring, Mixing, Transporting, and Placing Concrete," and as specified.

3.5.3 Deposit concrete continuously or in layers of such thickness that no new concrete will be placed on concrete that has hardened sufficiently to cause seams or planes of weakness. Deposit concrete to avoid segregation at its final location.

3.5.4 Consolidate placed concrete by mechanical vibrating equipment supplemented by hand spading, rodding, or tamping. Use equipment and procedures for consolidation of concrete complying with ACI 309.

3.5.5 Cold Weather Placement: Comply with provisions of ACI 306 and as follows. Protect concrete work from physical damage or reduced strength that could be caused by frost, freezing actions, or low temperatures.

3.5.6 When air temperature has fallen to or is expected to fall below 40 deg F (4 deg C), uniformly heat water and aggregates before mixing to obtain a concrete mixture temperature of not less than 50 deg F (10 deg C) and not more than 80 deg F (27 deg C) at point of placement.

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

3.5.6.2 Do not use calcium chloride, salt, or other materials containing antifreeze agents or chemical accelerators.

3.5.7 Hot Weather Placement: When hot weather conditions exist that would impair quality and strength of concrete, place concrete complying with ACI 305 and as specified.

3.5.7.1 Cool ingredients before mixing to maintain concrete temperature at time of placement to below 90 deg F (32 deg C). Mixing water may be chilled or chopped ice may be used to control temperature, provided water equivalent of ice is calculated to total amount of mixing water. Using liquid nitrogen to cool concrete is Contractor's option.

3.5.7.2 Cover reinforcing steel with water soaked burlap if it becomes too hot, so that steel temperature will not exceed the ambient air temperature immediately before embedding in concrete.

3.5.7.3 Fog spray forms, reinforcing steel, and subgrade just before placing concrete. Keep subgrade moisture uniform without puddles or dry areas.

3.5.7.4 Use water reducing admixture when required by high temperatures, low humidity, or other adverse placing conditions, as acceptable to Contracting Officer.

3.6 FINISHING FORMED SURFACES

Smooth Formed Finish: Provide a smooth formed finish on formed concrete surfaces exposed to view.

3.7 CONCRETE CURING AND PROTECTION

Protect freshly placed concrete from premature drying and excessive cold or hot temperatures. In hot, dry, and windy weather protect concrete from rapid moisture loss before and during finishing operations with an evaporation control material. Apply according to manufacturer's instructions after screeding and bull floating, but before power floating and troweling.

3.7.1 Start initial curing as soon as free water has disappeared from concrete surface after placing and finishing. Weather permitting, keep continuously moist for not less than 7 days.

3.7.2 Curing Methods: Cure concrete by curing compound, by moist curing, by moisture retaining cover curing, or by combining these methods, as specified.

3.7.3 Provide moisture curing by the following methods:

3.7.3.1 Keep concrete surface continuously wet by covering with water.

3.7.3.2 Use continuous water fog spray.

3.7.3.3 Cover concrete surface with specified absorptive cover, thoroughly saturate cover with water, and keep continuously wet. Place absorptive cover to provide coverage of concrete surfaces and edges, with a 4 inch lap over adjacent absorptive covers.

3.7.4 Provide moisture retaining cover curing as follows:

3.7.4.1 Cover concrete surfaces with moisture retaining cover for curing concrete, placed in widest practicable width with sides and ends lapped at least 3 inches and sealed by waterproof tape or adhesive. Immediately repair any holes or tears during curing period using cover material and waterproof tape.

3.7.5 Apply curing compound on exposed interior slabs and on exterior slabs, walks, and curbs as follows:

3.7.5.1 Apply curing compound to concrete slabs as soon as final finishing operations are complete (within 2 hours and after surface water sheen has disappeared). Apply uniformly in continuous operation by power spray or roller according to manufacturer's directions. Recoat areas subjected to heavy rainfall within 3 hours after initial application. Maintain continuity of coating and repair damage during curing period.

3.7.5.2 Use membrane curing compounds that will not affect surfaces to be covered with finish materials applied directly to concrete.

3.7.6 Curing Formed Surfaces: Cure formed concrete surfaces, including underside of beams, supported slabs, and other similar surfaces, by moist curing with forms in place for the full curing period or until forms are removed. If forms are removed, continue curing by methods specified above, as applicable.

3.8 REMOVING FORMS

Formwork not supporting weight of concrete, such as sides of beams, walls, columns, and similar parts of the work, may be removed after cumulatively curing at not less than 50 deg F (10 deg C) for 24 hours after placing concrete, provided concrete is sufficiently hard to not be damaged by form removal operations, and provided curing and protection operations are maintained.

3.9 REUSING FORMS

3.9.1 Clean and repair surfaces of forms to be reused in the Work. Split, frayed, delaminated, or otherwise damaged form facing material will not be acceptable for exposed surfaces. Apply new form coating compound as specified for new formwork.

3.9.2 When forms are extended for successive concrete placement, thoroughly clean surfaces, remove fins and laitance, and tighten forms to close joints. Align and secure joint to avoid offsets. Do not use patched forms for exposed concrete surfaces except as acceptable to Contracting Officer.

3.10 CONCRETE SURFACE REPAIRS

3.10.1 Patching Defective Areas: Repair and patch defective areas with cement mortar immediately after removing forms, when acceptable to Contracting Officer.

3.10.2 Mix dry pack mortar, consisting of one part portland cement to 2 1/2 parts fine aggregate passing a No. 16 mesh sieve, using only enough water as required for handling and placing.

3.10.2.1 Cut out honeycombs, rock pockets, voids over 1/4 inch in any dimension, and holes left by tie rods and bolts down to solid concrete but in no case to a depth less than 1 inch. Make edges of cuts perpendicular to the concrete surface. Thoroughly clean, dampen with water, and brush coat the area to be patched with bonding agent. Place patching mortar before bonding agent has dried.

3.10.2.2 For surfaces exposed to view, blend white portland cement and standard portland cement so, when dry, patching mortar will match surrounding color. Provide test areas in inconspicuous places to verify mixture and color match before proceeding with patching. Compact mortar in place and strike off slightly higher than surrounding surface.

3.10.3 Repairing Formed Surfaces: Remove and replace concrete having defective surfaces if defects cannot be repaired to satisfaction of Contracting Officer. Surface defects include color and texture irregularities, cracks, spalls, air bubbles, honeycomb, rock pockets, fins and other projections on the surface, and stains and other discolorations that cannot be removed by cleaning. Flush out form tie holes and fill with dry pack mortar or precast cement cone plugs secured in place with bonding agent.

3.10.3.1 Repair concealed formed surfaces, where possible, containing defects that affect the concrete's durability. If defects cannot be repaired, remove and replace the concrete.

3.10.4 Perform structural repairs with prior approval of Contracting Officer for method and procedure, using specified epoxy adhesive and mortar.

3.10.5 Repair methods not specified above may be used, subject to acceptance of Contracting Officer.

END OF SECTION 03 30 53

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