Atch3_TechSpecs.pdf

FA4861-10-B-A029

Attachment #3

Repair Data Lab & FTI Facility, Bldg. 423, Nellis AFB RKMF09-0070

FOR CONSTRUCTION

SECTION TABLE OF CONTENTS

DIVISION 03 - CONCRETE

SECTION 03 30 53

CAST-IN-PLACE CONCRETE

PART 1 GENERAL

1.1 SUMMARY

1.2 REFERENCES

1.3 SYSTEM DESCRIPTION

1.3.1 Strength

1.3.2 Construction Tolerances

1.3.3 Concrete Mixture Proportions

1.4 SUBMITTALS

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Cementitious Materials

2.1.1.1 Portland Cement

2.1.1.2 Pozzolan

2.1.2 Aggregates

2.1.3 Admixtures

2.1.3.1 Air-Entraining Admixture

2.1.3.2 Accelerating Admixture

2.1.3.3 Water-Reducing or Retarding Admixture

2.1.4 Water

2.1.5 Reinforcing Steel

2.1.6 Expansion Joint Filler Strips, Premolded

2.1.7 Joint Sealants - Field Molded Sealants

2.1.8 Formwork

2.1.9 Form Coatings

2.1.10 Vapor Barrier

2.1.11 Curing Materials

2.1.11.1 Impervious Sheet Materials

2.1.11.2 Membrane-Forming Curing Compound

2.2 READY-MIX CONCRETE

2.3 STEEL REINFORCEMENT

2.3.1 Deformed Steel Bars

2.3.2 Welded Wire Fabric

2.4 FORMS

2.5 ACCESSORIES

2.5.1 Chemical Floor Hardener

2.5.2 Curing Compound

PART 3 EXECUTION

3.1 PREPARATION

3.1.1 Embedded Items

3.1.2 Formwork Installation

3.1.3 Vapor Barrier Installation

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3.1.4 Production of Concrete

3.1.4.1 Ready-Mixed Concrete

3.1.4.2 Concrete Made by Volumetric Batching and Continuous Mixing

3.2 CONVEYING AND PLACING CONCRETE

3.2.1 Consolidation

3.2.2 Cold-Weather Requirements

3.2.3 Hot-Weather Requirements

3.2.4 Lifts in Concrete

3.3 FORM REMOVAL

3.4 FINISHING

3.4.1 Temperature Requirement

3.4.2 Finishing Formed Surfaces

3.4.3 Finishing Unformed Surfaces

3.4.3.1 Float Finish

3.4.3.2 Trowel Finish

3.5 CURING AND PROTECTION

3.6 TESTS AND INSPECTIONS

3.6.1 Field Testing Technicians

3.6.2 Inspection Details and Frequency of Testing

3.6.2.1 Preparations for Placing

3.6.2.2 Air Content

3.6.2.3 Slump

3.6.2.4 Consolidation and Protection

3.6.3 Action Required

3.6.3.1 Placing

3.6.3.2 Air Content

3.6.3.3 Slump

3.6.4 Reports

3.7 FORM WORK

3.7.1 Preparation of Form Surfaces

3.7.2 Form Coating

3.8 STEEL REINFORCING

3.8.1 Fabrication

3.8.2 Splicing

3.8.3 Supports

3.9 EMBEDDED ITEMS

3.10 FIELD TESTING

-- End of Section Table of Contents --

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SECTION 03 30 53

CAST-IN-PLACE CONCRETE

PART 1 GENERAL

1.1 SUMMARY

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

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.

ACI INTERNATIONAL (ACI)

ACI MCP SET (2009) Manual of Concrete Practice

ASTM INTERNATIONAL (ASTM)

ASTM A 185 (2007) Standard Specification for Steel Welded Wire Reinforcement, Plain, for Concrete

ASTM A 615 (2009) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

ASTM C 1064 (2008) Standard Test Method for Temperature of Freshly Mixed Hydraulic-Cement Concrete

ASTM C 1260 (2007) Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar-Bar Method)

ASTM C 143 (2009) Standard Test Method for Slump of Hydraulic-Cement Concrete

ASTM C 150 (2009) Standard Specification for Portland Cement

ASTM C 1567 (2008) Standard Test Method for Potential Alkali-Silica Reactivity of Combinations of Cementitious Materials and Aggregate (Accelerated Mortar-Bar Method)

ASTM C 171 (2007) Standard Specification for Sheet Materials for Curing Concrete

ASTM C 172 (2008) Standard Practice for Sampling Freshly Mixed Concrete

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ASTM C 173 (2009) Standard Test Method for Air Content of Freshly Mixed Concrete by the Volumetric Method

ASTM C 231 (2009a) Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method

ASTM C 260 (2006) Standard Specification for Air-Entraining Admixtures for Concrete

ASTM C 309 (2007) Standard Specification for Liquid Membrane-Forming Compounds for Curing Concrete

ASTM C 31 (2009) Standard Practice for Making and Curing Concrete Test Specimens in the Field

ASTM C 33 (2008) Standard Specification for Concrete Aggregates

ASTM C 39 (2005e1e2) Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

ASTM C 494 (2008a) Standard Specification for Chemical Admixtures for Concrete

ASTM C 595 (2008a) Standard Specification for Blended Hydraulic Cements

ASTM C 618 (2008a) Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

ASTM C 685 (2007) Concrete Made by Volumetric Batching and Continuous Mixing

ASTM C 920 (2008) Standard Specification for Elastomeric Joint Sealants

ASTM C 94 (2009) Standard Specification for Ready-Mixed Concrete

ASTM C 989 (2009a) Standard Specification for Ground Granulated Blast-Furnace Slag for Use in Concrete and Mortars

ASTM C 990 (2009) Standard Specification for Joints for Concrete Pipe, Manholes and Precast Box Sections Using Preformed Flexible Joint Sealants

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

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Joint Seals for Concrete Pavements

ASTM D 75 (2009) Standard Practice for Sampling Aggregates

ASTM D 98 (2005) Calcium Chloride

ASTM E 1155 (1996; R 2008) Standard Test Method for Determining Floor Flatness and Floor Levelness Numbers

ASTM E 1155M (1996; R 2008) Standard Test Method for Determining Floor Flatness and Floor Levelness Numbers (Metric)

ASTM E 96 (2005) Standard Test Methods for Water Vapor Transmission of Materials

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

40 CFR 247 Comprehensive Procurement Guideline for Products Containing Recovered Materials

1.3 SYSTEM DESCRIPTION

The Government retains the option to sample and test joint sealer, joint filler material, waterstop, aggregates and concrete to determine compliance with the specifications. Provide facilities and labor as may be necessary to assist the Government in procurement of representative test samples.

Obtain samples of aggregates at the point of batching in accordance with ASTM D 75. Sample concrete in accordance with ASTM C 172. Determine slump and air content in accordance with ASTM C 143 and ASTM C 231, respectively, when cylinders are molded. Prepare, cure, and transport compression test specimens in accordance with ASTM C 31. Test compression test specimens in accordance with ASTM C 39. Take samples for strength tests not less than once each shift in which concrete is produced from each class of concrete required. Provide a minimum of three specimens from each sample; two to be tested at 28 days (90 days if pozzolan is used) for acceptance, and one will be tested at 7 days for information.

1.3.1 Strength

Acceptance test results are the average strengths of two specimens tested at 28 days (90 days if pozzolan is used). The strength of the concrete is considered satisfactory so long as the average of three consecutive acceptance test results equal or exceed the specified compressive strength, f'c, and no individual acceptance test result falls below f'c by more than 500 psi.

1.3.2 Construction Tolerances

Apply a Class "C" finish to all surfaces except those specified to receive a Class "D" finish. Apply a Class "D" finish to all post-construction surfaces which will be permanently concealed. Surface requirements for the classes of finish required are as specified in Part 4 of ACI MCP SET.

1.3.3 Concrete Mixture Proportions

Concrete mixture proportions are the responsibility of the Contractor.

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Mixture proportions shall include the dry weights of cementitious material(s); the nominal maximum size of the coarse aggregate; the specific gravities, absorptions, and saturated surface-dry weights of fine and coarse aggregates; the quantities, types, and names of admixtures; and quantity of water per cubic yard of concrete. Provide materials included in the mixture proportions of the same type and from the same source as will be used on the project. Specified compressive strength f'c shall be 4000 psi at 28 days (90 days if pozzolan is used). The maximum nominal size coarse aggregate is 3/4 inch, in accordance with ACI MCP SET Part 3.

The air content shall be between 4.5 and 7.5 percent with a slump between 2 and 5 inches. The maximum water cement ratio is 0.45 .

1.4 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-03 Product Data

Air-Entraining Admixture Accelerating Admixture Water-Reducing or Retarding Admixture Curing Materials Reinforcing Steel Expansion Joint Filler Strips, Premolded Joint Sealants - Field Molded Sealants Manufacturer's literature from suppliers which demonstrates compliance with applicable specifications for the above materials.

Batching and Mixing Equipment

Manufacturer's data for batching and mixing equipment which demonstrates compliance with the applicable specifications.

Conveying and Placing Concrete

Methods and equipment for transporting, handling, depositing, and consolidating the concrete prior to the first concrete placement.

Concrete Placement Ready-Mix Concrete Mix Design Data Air-Entraining Admixtures Fly Ash Steel ReinforcementCuring CompoundSD-06 Test Reports

Aggregates

Test reports for aggregates showing the material(s) meets the quality and grading requirements of the specifications.

Concrete Mixture Proportions

The mixture proportions that will produce concrete of the quality required, ten days prior to placement of concrete.

Applicable test reports to verify that the concrete mixture proportions selected will produce concrete of the quality

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specified.

Compressive Strength Testing SlumpSD-07 Certificates

Cementitious Materials CPG for recycled materials or appropriate Waiver Form

Manufacturer's certificates of compliance, accompanied by mill test reports, attesting that the concrete materials meet the requirements of the specifications in accordance with the Special Clause "CERTIFICATES OF COMPLIANCE". Certificates for all material conforming to EPA's Comprehensive Procurement Guidelines (CPG), in accordance with 40 CFR 247.

Aggregates

Certificates of compliance stating that the material(s) meet the quality and grading requirements of the specifications under which it is furnished.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Cementitious Materials

Provide cementitious materials that conform to the appropriate specifications listed:

2.1.1.1 Portland Cement

ASTM C 150, Type I or II

2.1.1.2 Pozzolan

Provide pozzolan that conforms to ASTM C 618, Class C or F, including requirements of Tables 1A and 2A.

2.1.2 Aggregates

Fine and coarse aggregates shall meet the quality and grading requirements of ASTM C 33"be tested and evaluated for alkali-aggregate reactivity in accordance with ASTM C 1260. Perform evaluation of fine and coarse aggregates separately and in combination, matching the proposed mix design proportioning. All results of the separate and combination testing shall have a measured expansion less than 0.10 (0.08) percent at 16 days after casting. If the test data indicates an expansion of 0.10 (0.08) percent or greater, reject the aggregate(s) or perform additional testing using ASTM C 1260 and ASTM C 1567. Perform the additional testing using ASTM C 1260 and ASTM C 1567 using the low alkali portland cement in combination with Class F fly ash.Use Class F fly ash in the range of 15 to 25 percent of the total cementitious material by mass".

2.1.3 Admixtures

Admixtures to be used, when required or approved, shall comply with the appropriate specification listed. Retest chemical admixtures that have been in storage at the project site, for longer than 6 months or that have

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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.

2.1.3.2 Accelerating Admixture

Accelerators shall not be used.2.1.3.3 Water-Reducing or Retarding Admixture

Provide water-reducing or retarding admixture meeting the requirements of ASTM C 494, Type A, B, or D.

2.1.4 Water

Use fresh, clean, potable water for mixing and curing, free from injurious amounts of oil, acid, salt, or alkali, except that unpotable water may be used if it meets the requirements of COE CRD-C 400.

2.1.5 Reinforcing Steel

Provide reinforcing bars conforming to the requirements of ASTM A 615, Grade 60. Welded reinforcing steel shall comply iwth requirements of ASTM A 706 Grade 60.Welded steel wire fabric shall conform to the requirements of ASTM A 185. Details of reinforcement not shown shall be in accordance with ACI MCP SET Part 3, Chapters 7 and 12.

2.1.6 Expansion Joint Filler Strips, Premolded

Expansion joint filler strips, premolded shall be sponge rubber conforming to ASTM D 1752, Type I.

2.1.7 Joint Sealants - Field Molded Sealants

Joint sealants - field molded sealants shall conform to ASTM C 920, Type M, Grade NS, Class 25, use NT for vertical joints and Type M, Grade P, Class 25, use T for horizontal joints. Provide polyethylene tape, coated paper, metal foil, or similar type bond breaker materials. The backup material needs to be compressible, nonshrink, nonreactive with the sealant, and a nonabsorptive material such as extruded butyl or polychloroprene foam rubber. Immediately prior to installation of field-molded sealants, clean the joint of all debris and further cleaned using water, chemical solvents, or other means as recommended by the sealant manufacturer or directed.

2.1.8 Formwork

The design and engineering of the formwork as well as its construction, will be the responsibility of the Contractor.

2.1.9 Form Coatings

Coat forms, for exposed surfaces, with a nonstaining form oil to be applied shortly before concrete is placed.

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2.1.10 Vapor Barrier

Provide polyethylene vapor barrier sheeting with a minimum thickness of 6 mils or other equivalent material having a vapor permeance rating not exceeding 0.5 perms as determined in accordance with ASTM E 96.

2.1.11 Curing Materials

Provide curing materials conforming to the following requirements.

2.1.11.1 Impervious Sheet Materials

Impervious sheet materials, ASTM C 171, type optional, except polyethylene film, if used, shall be white opaque.

2.1.11.2 Membrane-Forming Curing Compound

ASTM C 309, Type 1-D or 2.

2.2 READY-MIX CONCRETE

a. Concrete shall be ready-mix concrete with mix design data conforming to ACI MCP SET Part 2. Bill of Lading for each ready-mix concrete delivery shall be in accordance with ASTM C 94.

b. Concrete elements: 4000 psi minimum compressive strength.

c. Slump: 1 to 4 inch according to ASTM C 143 and ACI MCP SET Part 1.

d. Portland Cement conforming to ASTM C 150, Type I or II.

e. Air-Entraining Admixtures conforming to ASTM C 260. Concrete exposed to freezing needs to be air-entrained 4.5 to 7.5 percent by volume. f. Water-reducing admixtures, retarding admixtures, water-reducing and accelerating admixtures, and water-reducing and retarding admixtures shall conform to ASTM C 494.

g. Fly Ash used as an admixture shall conform to ASTM C 618, Class C or F with 4 percent maximum loss on ignition and 25 percent maximum cement replacement by weight.

2.3 STEEL REINFORCEMENT

2.3.1 Deformed Steel Bars

Provide steel bars conforming to ASTM A 615, Grade .60 ksi ACI MCP SET Parts 2 and 3.

2.3.2 Welded Wire Fabric

Provide welded wire fabric conforming to ASTM A 185.

2.4 FORMS

Forms shall be of wood, steel, or other approved material and conform to ACI MCP SET, Parts 2 and 3.

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Provide form release conforming to ACI MCP SET, Part 4.

2.5 ACCESSORIES

2.5.1 Chemical Floor Hardener

Provide hardener which is a colorless aqueous solution containing a blend of magnesium fluorosilicate and zinc fluorosilicate combined with a wetting agent. Provide solution that contains not less than 2 pounds of fluorosilicates per gallon. An approved proprietary chemical hardener may be used provided hardener is delivered ready for use in manufacturer's original containers.

2.5.2 Curing Compound

Provide curing compound conforming to ASTM C 309.

PART 3 EXECUTION

3.1 PREPARATION

Prepare construction joints to expose coarse aggregate. The surface shall be clean, damp, and free of laitance. Construct ramps and walkways, as necessary, to allow safe and expeditious access for concrete and workmen.

Remove snow, ice, standing or flowing water, loose particles, debris, and foreign matter. Earth foundations shall be satisfactorily compacted.

Ensure spare vibrators are available. The entire preparation shall be accepted by the Government prior to placing.

3.1.1 Embedded Items

Secure reinforcement in place after joints, anchors, and other embedded items have been positioned. Arrange internal ties so that when the forms are removed the metal part of the tie is not less than 2 inches from concrete surfaces permanently exposed to view or exposed to water on the finished structures. Embedded items shall be free of oil and other foreign matters such as loose coatings or rust, paint, and scale. The embedding of wood in concrete is permitted only when specifically authorized or directed. All equipment needed to place, consolidate, protect, and cure the concrete shall be at the placement site and in good operating condition.

3.1.2 Formwork Installation

Forms shall be properly aligned, adequately supported, and mortar-tight.

Provide smooth form surfaces, free from irregularities, dents, sags, or holes when used for permanently exposed faces. Chamfer all exposed joints and edges , unless otherwise indicated.

3.1.3 Vapor Barrier Installation

Apply vapor barriers over gravel fill. Lap edges not less than 6 inches.

Seal all joints with pressure-sensitive adhesive not less than 2 inches wide. Protect the vapor barrier at all times to prevent injury or displacement prior to and during concrete placement.

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3.1.4 Production of Concrete

3.1.4.1 Ready-Mixed Concrete

Provide ready-mixed concrete conforming to ASTM C 94 except as otherwise specified.

3.1.4.2 Concrete Made by Volumetric Batching and Continuous Mixing

Concrete made by volumetric batching and continuous mixing shall conform to

ASTM C 685.

3.2 CONVEYING AND PLACING CONCRETE

Concrete placement is not permitted when weather conditions prevent proper placement and consolidation without approval. When concrete is mixed and/or transported by a truck mixer, deliver the concrete to the site of the work completing the discharge within 1-1/2 hours or 45 minutes when the placing temperature is 86 degrees F or greater unless a retarding admixture is used. Convey concrete from the mixer to the forms as rapidly as practicable by methods which prevent segregation or loss of ingredients.

Concrete shall be in place and consolidated within 15 minutes after discharge from the mixer. Deposit concrete as close as possible to its final position in the forms and regulate it so that it may be effectively consolidated in horizontal layers 18 inches or less in thickness with a minimum of lateral movement. Carry on the placement at such a rate that the formation of cold joints will be prevented. Perform conveying and placing concrete in conformance with the following requirements.

3.2.1 Consolidation

Consolidate each layer of concrete by rodding, spading, or internal vibrating equipment. External vibrating equipment may be used when authorized. Systematically accomplish internal vibration by inserting the vibrator through the fresh concrete in the layer below at a uniform spacing over the entire area of placement. The distance between insertions shall be approximately 1.5 times the radius of action of the vibrator and overlay the adjacent, just-vibrated area by approximately 4 inches. Ensure that the vibrator penetrates rapidly to the bottom of the layer and at least 6 inches into the layer below, if such a layer exists. Hold vibrator stationary until the concrete is consolidated and then withdraw it slowly at the rate of about 3 inches per second.

3.2.2 Cold-Weather Requirements

No concrete is to be mixed or placed when the ambient temperature is below 36 degrees F or if the ambient temperature is below 41 degrees F and falling. Provide suitable covering and other means as approved for maintaining the concrete at a temperature of at least 50 degrees F for not less than 72 hours after placing and at a temperature above freezing for the remainder of the curing period. Do not mix salt, chemicals, or other foreign materials with the concrete to prevent freezing. Remove and replace concrete damaged by freezing at the expense of the Contractor.

3.2.3 Hot-Weather Requirements

When the rate of evaporation of surface moisture, as determined by use of Figure 1 of ACI MCP SET Part 2, is expected to exceed 0.2 psf per hour, provisions for windbreaks, shading, fog spraying, or covering with a

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light-colored material shall be made in advance of placement, and such protective measures taken as quickly as finishing operations will allow.

3.2.4 Lifts in Concrete

Deposit concrete in horizontal layers not to exceed 24 inches in thickness. Carry on placement at a rate that prevents the formation of cold joints. Place slabs in one lift.

3.3 FORM REMOVAL

Do not remove forms before 24 hours after concrete placement, except as otherwise specifically authorized. Do not remove supporting forms and shoring until the concrete has cured for at least 5 days. When conditions require longer curing periods, forms shall remain in place.

3.4 FINISHING

3.4.1 Temperature Requirement

Do not finish or repair concrete when either the concrete or the ambient temperature is below 50 degrees F.

3.4.2 Finishing Formed Surfaces

Remove all fins and loose materials , and surface defects including filling of tie holes. Repair all honeycomb areas and other defects. Remove all unsound concrete from areas to be repaired. Surface defects greater than 1/2 inch in diameter and holes left by removal of tie rods in all surfaces not to receive additional concrete shall be reamed or chipped and filled with dry-pack mortar. Brush-coat the prepared area with an approved epoxy resin or latex bonding compound or with a neat cement grout after dampening and filling with mortar or concrete. The cement used in mortar or concrete for repairs to all surfaces permanently exposed to view shall be a blend of portland cement and white cement so that the final color when cured is the same as adjacent concrete.

3.4.3 Finishing Unformed Surfaces

Float finish all unformed surfaces, that are not to be covered by additional concrete or backfill, to elevations shown, unless otherwise specified. Surfaces to receive additional concrete or backfill shall be brought to the elevations shown and left as a true and regular surface.

Slope exterior surfaces for drainage unless otherwise shown. Carefully make joints with a jointing tool. Finish unformed surfaces to a tolerance of 3/8 inch for a float finish and 5/16 inch for a trowel finish as determined by a 10 foot straightedge placed on surfaces shown on the drawings to be level or having a constant slope. Do not perform finishing while there is excess moisture or bleeding water on the surface. No water or cement is to be added to the surface during finishing.

3.4.3.1 Float Finish

Provide float finished surfaces, screeded and darbied or bullfloated to eliminate the ridges and to fill in the voids left by the screed. In addition, the darby or bullfloat shall fill all surface voids and only slightly embed the coarse aggregate below the surface of the fresh concrete. When the water sheen disappears and the concrete supports a person's weight without deep imprint, complete floating. Floating shall embed large aggregates just beneath the surface, remove slight

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imperfections, humps, and voids to produce a plane surface, compact the concrete, and consolidate mortar at the surface.

3.4.3.2 Trowel Finish

Trowelling shall be done immediately following floating to provide a smooth, even, dense finish free from blemishes including trowel marks.

Protect finished surfaces from damage during the construction period.

3.5 CURING AND PROTECTION

Beginning immediately after placement, and continuing for at least 7 days, cure and protect all concrete from premature drying, extremes in temperature, rapid temperature change, freezing, mechanical damage, and exposure to rain or flowing water. Provide all materials and equipment needed for adequate curing and protection at the site of the placement prior to the start of concrete placement. Accomplish moisture preservation of moisture for concrete surfaces not in contact with forms by one of the following methods:

a. Continuous sprinkling or ponding.

b. Application of absorptive mats or fabrics kept continuously wet.

c. Application of sand kept continuously wet.

d. Application of impervious sheet material conforming to ASTM C 171.

e. Application of membrane-forming curing compound conforming to ASTM C 309, Type 1-D, on surfaces permanently exposed to view.

Accomplish Type 2 on other surfaces in accordance with manufacturer's instructions.

Accomplish the preservation of moisture for concrete surfaces placed against wooden forms by keeping the forms continuously wet for 7 days. If forms are removed prior to end of the required curing period, use other curing methods for the balance of the curing period. Do not perform protection removal if the temperature of the air in contact with the cocrete may drop more than 60 degrees F within a 24 hour period.

3.6 TESTS AND INSPECTIONS

3.6.1 Field Testing Technicians

The individuals who sample and test concrete, as required in this specification, shall have demonstrated a knowledge and ability to perform the necessary test procedures equivalent to the ACI minimum guidelines for certification of Concrete Field Testing Technicians, Grade I.

3.6.2 Inspection Details and Frequency of Testing

3.6.2.1 Preparations for Placing

Inspect foundation or construction joints, forms, and embedded items in sufficient time prior to each concrete placement by the Contractor to certify that it is ready to receive concrete.

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3.6.2.2 Air Content

Check air content at least once during each shift that concrete is placed for each class of concrete required. Obtain samples in accordance with ASTM C 172 and tested in accordance with ASTM C 231.

3.6.2.3 Slump

Check slump once during each shift that concrete is produced for each class of concrete required. Obtain samples in accordance with ASTM C 172 and tested in accordance with ASTM C 143.

3.6.2.4 Consolidation and Protection

Ensure that the concrete is properly consolidated, finished, protected, and cured.

3.6.3 Action Required

3.6.3.1 Placing

Do not permit placing to begin until the availability of an adequate number of acceptable vibrators, which are in working order and have competent operators, has been verified. Do not continue placing if any pile is inadequately consolidated.

3.6.3.2 Air Content

Whenever an air content test result is outside the specification limits, adjust the dosage of the air-entrainment admixture prior to delivery of concrete to forms.

3.6.3.3 Slump

Whenever a slump test result is outside the specification limits, adjust the batch weights of water and fine aggregate prior to delivery of concrete to the forms. The adjustments are to be made so that the water-cement ratio does not exceed that specified in the submitted concrete mixture proportion.

3.6.4 Reports

Report the results of all tests and inspections conducted at the project site informally at the end of each shift. Submit written reports weekly.

Deliver within 3 days after the end of each weekly reporting period.

3.7 FORM WORK

Form work shall conform to ACI MCP SET Parts 2 through 5.

3.7.1 Preparation of Form Surfaces

Forms shall be true to line and grade, mortar-tight, and sufficiently rigid to prevent objectionable deformation under load. Form surfaces for permanently exposed faces shall be smooth, free from irregularities, dents, sags, or holes. Chamfer exposed joints and exposed edges. Arrange internal ties so that when the forms are removed, the form ties are not less than 2 inches from concrete surfaces permanently exposed to view or exposed to water on the finished structure.

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3.7.2 Form Coating

Coat forms, for exposed surfaces, with a nonstaining form release coating applied shortly before concrete is placed. Forms for unexposed surfaces may be wetted in lieu of coating immediately before the placing of concrete, except that in freezing weather form release coating shall be used.

3.8 STEEL REINFORCING

Reinforcement shall be free from loose, flaky rust and scale, and free from oil, grease, or other coating which might destroy or reduce the reinforcement's bond with the concrete.

3.8.1 Fabrication

Shop fabricate steel reinforcement in accordance with ACI MCP SET Parts 2 and 3. Shop details and bending shall be in accordance with ACI MCP SET Parts 2 and 3.

3.8.2 Splicing

Perform splices in accordance with ACI MCP SET Parts 2 and 3.

3.8.3 Supports

Secure reinforcement in place by the use of metal or concrete supports, spacers, or ties.

3.9 EMBEDDED ITEMS

Before placing concrete, take care to determine that all embedded items are firmly and securely fastened in place. Provide embedded items free of oil and other foreign matter, such as loose coatings of rust, paint and scale.

Embedding of wood in concrete is permitted only when specifically authorized or directed.

3.10 FIELD TESTING

a. Provide samples and test concrete for quality control during placement. Sampling of fresh concrete for testing shall be in accordance with ASTM C 172.

b. Test concrete for compressive strength at 7 and 28 days for each design mix. Concrete test specimens shall conform to ASTM C 31.

Perform Compressive strength testing conforming to ASTM C 39.

c. Test Slump at the site of discharge for each design mix in accordance with ASTM C 143.

d. Test air content for air-entrained concrete in accordance with ASTM C 231. Test concrete using lightweight or test extremely porous aggegates in accordance with ASTM C 173.

e. Determine temperature of concrete at time of placement in accordance with ASTM C 1064.

-- End of Section --

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SECTION TABLE OF CONTENTS

DIVISION 04 - MASONRY

SECTION 04 20 00

MASONRY

PART 1 GENERAL

1.1 REFERENCES

1.2 SYSTEM DESCIPTION

1.2.1 Design Requirements

1.2.1.1 Unit Strength Method

1.2.1.2 Seismic Requirement

1.2.1.3 Masonry Strength

1.2.2 Additional Requirements

1.3 SUBMITTALS

1.4 QUALITY ASSURANCE

1.4.1 Masonry Inspector Qualifications

1.5 DELIVERY, HANDLING, AND STORAGE

1.5.1 Masonry Units

1.5.2 Reinforcement, Anchors, and Ties

1.5.3 Cementitious Materials, Sand and Aggregates

1.6 PROJECT/SITE CONDITIONS

1.6.1 Hot Weather Installtion

PART 2 PRODUCTS

2.1 GENERAL REQUIREMENTS

2.2 CONCRETE MASONRY UNITS (CMU)

2.2.1 Aggregates

2.2.2 Kinds and Shapes

2.2.2.1 Architectural Units

2.3 PRECAST CONCRETE ITEMS

2.4 MASONRY MORTAR

2.4.1 Colored Mortar

2.4.2 Hydrated Lime and Alternates

2.4.3 Cement

2.4.4 Pre-Mixed Mortar

2.4.5 Sand and Water

2.5 WATER-REPELLANT ADMIXTURE

2.6 GROUT AND READY-MIXED GROUT

2.6.1 Grout Barriers

2.7 ANCHORS, TIES, AND BAR POSITIONERS

2.7.1 Bar Positioners

2.8 JOINT REINFORCEMENT

2.9 REINFORCING STEEL BARS AND RODS

2.10 CONTROL JOINT KEYS

2.11 EXPANSION-JOINT MATERIALS

PART 3 EXECUTION

3.1 PREPARATION

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3.1.1 Stains

3.1.2 Loads

3.1.3 Surfaces

3.2 LAYING MASONRY UNITS

3.2.1 Forms and Shores

3.2.2 Reinforced Concrete Masonry Units Walls

3.2.3 Concrete Masonry Units

3.2.4 Tolerances

3.2.5 Cutting and Fitting

3.2.6 Jointing

3.2.6.1 Flush Joints

3.2.6.2 Tooled Joints

3.2.7 Joint Widths

3.2.7.1 Concrete Masonry Units

3.2.8 Embedded Items

3.2.9 Unfinished Work

3.2.10 Masonry Wall Intersections

3.3 MORTAR MIX

3.4 REINFORCING STEEL

3.4.1 Positioning Bars

3.4.2 Splices

3.5 JOINT REINFORCEMENT INSTALLATION

3.6 PLACING GROUT

3.6.1 Vertical Grout Barriers for Fully Grouted Walls

3.6.2 Horizontal Grout Barriers

3.6.3 Grout Holes and Cleanouts

3.6.3.1 Cleanouts for Hollow Unit Masonry Construction

3.6.4 Grouting Equipment

3.6.4.1 Grout Pumps

3.6.4.2 Vibrators

3.6.5 Grout Placement

3.6.5.1 Low-Lift Method

3.7 BOND BEAMS

3.8 CONTROL JOINTS

3.9 LINTELS

3.9.1 Masonry Lintels

3.9.2 Precast Concrete and Steel Lintels

3.10 SILLS AND COPINGS

3.11 POINTING AND CLEANING

3.11.1 Dry-Brushing

3.12 BEARING PLATES

3.13 PROTECTION

3.14 WASTE MANAGEMENT

3.14.1 Separate and Recycle Waste

3.15 TEST REPORTS

3.15.1 Field Testing of Mortar

3.15.2 Field Testing of Grout

-- End of Section Table of Contents --

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SECTION 04 20 00

MASONRY

PART 1 GENERAL

1.1 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.

ACI INTERNATIONAL (ACI)

ACI 318 (2008; Errata 2008) Building Code Requirements for Structural Concrete and Commentary

ACI 530 (2008) Building Code Requirements and Specification for Masonry Structures;

Containing Building Code Requirements for Masonry Structures, Specification for Masonry Structures and Companion Commentaries

ACI SP-66 (2004) ACI Detailing Manual

ASTM INTERNATIONAL (ASTM)

ASTM A 153 (2005) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware

ASTM A 167 (1999; R 2004) Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip

ASTM A 615 (2008b) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

ASTM A 641 (2003) Standard Specification for Zinc-Coated (Galvanized) Carbon Steel Wire

ASTM A 82 (2007) Standard Specification for Steel Wire, Plain, for Concrete Reinforcement

ASTM C 1019 (2008a) Standard Test Method for Sampling and Testing Grout

ASTM C 1072 (2006) Standard Test Method for Measurement of Masonry Flexural Bond Strength

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ASTM C 1142 (1995; R 2007) Standard Specification for Extended Life Mortar for Unit Masonry

ASTM C 129 (2006) Standard Specification for Nonloadbearing Concrete Masonry Units

ASTM C 140 (2008a) Standard Test Methods for Sampling and Testing Concrete Masonry Units and Related Units

ASTM C 144 (2004) Standard Specification for Aggregate for Masonry Mortar

ASTM C 150 (2007) Standard Specification for Portland Cement

ASTM C 207 (2006) Standard Specification for Hydrated Lime for Masonry Purposes

ASTM C 270 (2008a) Standard Specification for Mortar for Unit Masonry

ASTM C 476 (2008) Standard Specification for Grout for Masonry

ASTM C 494 (2008a) Standard Specification for Chemical Admixtures for Concrete

ASTM C 593 (2006) Fly Ash and Other Pozzolans for Use with Lime

ASTM C 641 (2007) Staining Materials in Lightweight Concrete Aggregates

ASTM C 744 (2008) Prefaced Concrete and Calcium Silicate Masonry Units

ASTM C 780 (2008) Preconstruction and Construction Evaluation of Mortars for Plain and Reinforced Unit Masonry

ASTM C 90 (2008) Loadbearing Concrete Masonry Units

ASTM C 91 (2005) Masonry Cement

ASTM C 94 (2007) Standard Specification for Ready-Mixed Concrete

ASTM C 989 (2006) Standard Specification for Ground Granulated Blast-Furnace Slag for Use in Concrete and Mortars

ASTM D 1972 (1997; R 2005) Standard Practice for Generic Marking of Plastic Products

ASTM D 2000 (2008) Standard Classification System for Rubber Products in Automotive Applications

ASTM D 2240 (2005) Standard Test Method for Rubber

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Property - Durometer Hardness

ASTM D 2287 (1996; R 2001) Nonrigid Vinyl Chloride Polymer and Copolymer Molding and Extrusion Compounds

ASTM E 119 (2008a) Standard Test Methods for Fire Tests of Building Construction and Materials

ASTM E 2129 (2005) Standard Practice for Data Collection for Sustainability Assessment of Building Products

ASTM E 514 (2008) Water Penetration and Leakage Through Masonry

INTERNATIONAL CODE COUNCIL (ICC)

ICC IBC (2006; Errata 2006; Errata 2007;

Supplement 2007; Errata 2007) International Building Code

U.S. DEPARTMENT OF DEFENSE (DOD)

UFC 3-310-04 (2007) Seismic Design for Buildings

1.2 SYSTEM DESCIPTION

1.2.1 Design Requirements

1.2.1.1 Unit Strength Method

Compute compressive strength of masonry system "Unit Strength Method," ACI 530. Submit calculations and certifications of unit and mortar strength.

1.2.1.2 Seismic Requirement

In addition to design requirements of ICC IBC, provide additional seismic reinforcement as detailed on the drawings.

Bond beams are required at the top of footings, at the bottom and top of openings at roof level, and at the top of walls.

1.2.1.3 Masonry Strength

Determine masonry strength in accordance with ACI 530. The cost of testing shall be paid by the Contractor.

1.2.2 Additional Requirements

a. Maintain at least one spare vibrator on site at all times.

b. Provide bracing and scaffolding necessary for masonry work. Design bracing to resist wind pressure as required by local code.

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1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-05 Design Data

Pre-mixed mortar composition. Calculations and certifications of masonry unit and mortar strength.

SD-06 Test Reports

Test reports from an approved independent laboratory. Test reports on a previously tested material shall be certified as the same as that proposed for use in this project.

Masonry Inspector Qualifications; G

Copies of masonry inspector reports.

SD-07 Certificates

Certificates of compliance stating that the materials meet the specified requirements.

SD-08 Manufacturer's Instructions

Masonry Cement

When masonry cement is used, submit the manufacturer's printed instructions on proportions of water and aggregates and on mixing to obtain the type of mortar required.

1.4 QUALITY ASSURANCE

1.4.1 Masonry Inspector Qualifications

A qualified masonry inspector approved by the Contracting Officer shall perform inspection of the masonry work. Minimum qualifications for the masonry inspector shall be 5 years of reinforced masonry inspection experience or acceptance by a State, municipality, or other governmental body having a program of examining and certifying inspectors for reinforced masonry construction. The masonry inspector shall be present during sampling and placing of masonry units, placement of reinforcement (including placement of dowels in footings and foundation walls), inspection of grout space, immediately prior to closing of cleanouts, and during grouting operations. The masonry inspector shall assure compliance with the drawings and specifications. The masonry inspector shall keep a complete record of all inspections and shall submit daily written reports to the Quality Control Supervisory Representative reporting the quality of masonry construction.

1.5 DELIVERY, HANDLING, AND STORAGE

Materials shall be delivered, handled, stored, and protected to avoid

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chipping, breakage, and contact with soil or contaminating material. Store and prepare materials in already disturbed areas to minimize project site disturbance and size of project site.

1.5.1 Masonry Units

Cover and protect moisture-controlled concrete masonry units and cementitious materials from precipitation. Conform to all handling and storage requirements of ASTM C 90. Prefabricated lintels shall be marked on top sides to show either the lintel schedule number or the number and size of top and bottom bars.

1.5.2 Reinforcement, Anchors, and Ties

Steel reinforcing bars, coated anchors, ties, and joint reinforcement shall be stored above the ground. Steel reinforcing bars and uncoated ties shall be free of loose mill scale and rust.

1.5.3 Cementitious Materials, Sand and Aggregates

Cementitious and other packaged materials shall be delivered in unopened containers, plainly marked and labeled with manufacturers' names and brands. Cementitious material shall be stored in dry, weathertight enclosures or be completely covered. Cement shall be handled in a manner that will prevent the inclusion of foreign materials and damage by water or dampness. Sand and aggregates shall be stored in a manner to prevent contamination or segregation.

1.6 PROJECT/SITE CONDITIONS

Conform to ACI 530 for hot weather masonry erection.

1.6.1 Hot Weather Installtion

Take the following precautions if masonry is erected when the ambient air temperature is more than 99 degrees F in the shade and the relative humidity is less than 50 percent or the ambient air temperature exceeds 90 degrees F and the wind velocity is more than 8 mph. All masonry materials shall be shaded from direct sunlight; mortar beds shall be spread no more than 4 feet ahead of masonry; masonry units shall be set within one minute of spreading mortar; and after erection, masonry shall be protected from direct exposure to wind and sun for 48 hours.

PART 2 PRODUCTS

2.1 GENERAL REQUIREMENTS

The source of materials which will affect the appearance of the finished work shall not be changed after the work has started except with Contracting Officer's approval.

2.2 CONCRETE MASONRY UNITS (CMU)

Units shall be of modular dimensions and air, water, or steam cured.

Exterior concrete masonry units shall have water-repellant admixture added during manufacture.

a. Hollow Load-Bearing Units: ASTM C 90, made with normal weight aggregate. Provide load-bearing units for load-bearing walls.

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2.2.1 Aggregates

Lightweight aggregates and blends of lightweight and heavier aggregates in proportions used in producing the units, shall comply with the following requirements when tested for stain-producing iron compounds in accordance with ASTM C 641: by visual classification method, the iron stain deposited on the filter paper shall not exceed the "light stain" classification.

Use industrial waste by-products (air-cooled slag, cinders, or bottom ash), ground waste glass and concrete, granulated slag, and expanded slag in aggregates. Slag shall comply with ASTM C 989.

2.2.2 Kinds and Shapes

Units shall be modular in size and shall include closer, jamb, header, lintel, and bond beam units and special shapes and sizes to complete the work as indicated. In exposed interior masonry surfaces, units having a bullnose shall be used for vertical external corners except at door, window, and louver jambs. Radius of the bullnose shall be 1 inch. Units used in exposed masonry surfaces in any one building shall have a uniform fine to medium texture and a uniform color.

2.2.2.1 Architectural Units

Units in existing walls shall have patterned face shell to match existing adjacent masonry. Face shell pattern of new walls shall be split. Units shall be integrally colored during manufacture. Color shall match Nellis AFB Compatability Standards.

2.3 PRECAST CONCRETE ITEMS

Cap blocks shall be factory-made units from a plant regularly engaged in producing precast concrete units. Unless otherwise indicated, concrete shall be 4,000 psi minimum.

2.4 MASONRY MORTAR

TMortar Type S shall conform to the proportion specification of ASTM C 270 except Type S cement-lime mortar proportions shall be 1 part cement, 1/2 part lime and 4-1/2 parts aggregate; Type N cement-lime mortar proportions shall be 1 part cement, 1 part lime and 6 parts aggregate. Type N or S mortar shall be used for non-load-bearing, non-shear-wall interior masonry;

and Type S for remaining masonry work; except where higher compressive strength is indicated on structural drawings. When masonry cement ASTM C 91 is used the maximum air content shall be limited to 12 percent and performance equal to cement-lime mortar shall be verified. Verification of masonry cement performance shall be based on ASTM C 780 and ASTM C 1072.

Pointing mortar in showers and kitchens shall contain ammonium stearate, or aluminum tri-stearate, or calcium stearate in an amount equal to 3 percent by weight of cement used. Cement shall have a low alkali content and be of one brand. Aggregates shall be from one source.

2.4.1 Colored Mortar

Mortar coloring shall be added to the mortar used for exposed masonry surfaces to produce a uniform color matching existing building mortar.

Mortar coloring shall be chemically inert, of finely ground limeproof pigment, and furnished in accurately pre-measured and packaged units that can be added to a measured amount of cement.

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2.4.2 Hydrated Lime and Alternates

Hydrated lime shall conform to ASTM C 207, Type S.

2.4.3 Cement

Portland cement shall conform to ASTM C 150, Type I,or III. Masonry cement shall conform to ASTM C 91, Type S. Containers shall bear complete instructions for proportioning and mixing to obtain the required types of mortar. Incorporate to the maximum extent, without conflicting with other requirements of this section, up to 40 percent fly ash, up to 70 percent slag, up to 10 percent cenospheres, and up to 10 percent silica fume.

2.4.4 Pre-Mixed Mortar

Pre-mixed mortar shall conform to ASTM C 1142.

2.4.5 Sand and Water

Sand shall conform to ASTM C 144. Water shall be clean, potable, and free from substances which could adversely affect the mortar.

2.5 WATER-REPELLANT ADMIXTURE

Polymeric type formulated to reduce porosity and water transmission.

Construct panels of masonry units conforming to ASTM C 744 and mortar which contain the water-repellant admixture. When tested in accordance with ASTM C 1072, such panels shall have flexural strength not less than that specified or indicated. When tested in accordance with ASTM E 514, panels shall exhibit no water visible on back of test panel and no leaks through the panel after 24 hours, and not more than 25 percent of wall area shall be damp after 72 hours.

2.6 GROUT AND READY-MIXED GROUT

Grout shall conform to ASTM C 476, coarse. Cement used in grout shall have a low alkali content. Grout slump shall be between 8 and 10 inches.

Minimum grout strength shall be 2000 psi in 28 days, as tested by ASTM C 1019. Grout shall be used subject to the limitations of Table III.

Proportions shall not be changed and materials with different physical or chemical characteristics shall not be used in grout for the work unless additional evidence is furnished that the grout meets the specified requirements. Ready-Mixed grout shall conform to ASTM C 94.

2.6.1 Grout Barriers

Grout barriers for vertical cores shall consist of fine mesh wire, fiberglass, or expanded metal.

2.7 ANCHORS, TIES, AND BAR POSITIONERS

Anchors and ties shall be fabricated without drips or crimps and shall be zinc-coated in accordance with ASTM A 153, Class B-2. Steel wire used for anchors and ties shall be fabricated from steel wire conforming to ASTM A 82.

Wire ties or anchors in exterior walls shall conform to ASTM A 641. Joint reinforcement in interior walls, and in exterior or interior walls exposed to moist environment shall conform to ASTM A 641; coordinate with paragraph JOINT REINFORCEMENT below. Anchors and ties shall be sized to provide a

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minimum of 5/8 inch mortar cover from either face.

2.7.1 Bar Positioners

Bar positioners, used to prevent displacement of reinforcing bars during the course of construction, shall be factory fabricated from 9 gauge steel wire or equivalent, and coated with a hot-dip galvanized finish. Not more than one wire shall cross the cell.

2.8 JOINT REINFORCEMENT

Joint reinforcement shall be factory fabricated from steel wire conforming to ASTM A 82, welded construction. Tack welding will not be acceptable in reinforcement used for wall ties. Wire shall have zinc coating conforming to ASTM A 153, Class B-2. All wires shall be a minimum of 9 gauge.

Reinforcement shall be ladder type design, having one longitudinal wire in the mortar bed of each face shell for hollow units and one wire for solid units. Joint reinforcement shall be placed a minimum of 5/8 inch cover from either face. The distance between crosswires shall not exceed 16 inches. Joint reinforcement for straight runs shall be furnished in flat sections not less than 10 feet long. Joint reinforcement shall be provided with factory formed corners and intersections. If approved for use, joint reinforcement may be furnished with adjustable wall tie features.

2.9 REINFORCING STEEL BARS AND RODS

Reinforcing steel bars and rods shall conform to ASTM A 615, Grade 60.

2.10 CONTROL JOINT KEYS

Control joint keys shall be a factory fabricated solid section of natural or synthetic rubber (or combination thereof) conforming to ASTM D 2000 or polyvinyl chloride conforming to ASTM D 2287. The material shall be resistant to oils and solvents. The control joint key shall be provided with a solid shear section not less than 5/8 inch thick and 3/8 inch thick flanges, with a tolerance of plus or minus 1/16 inch. The control joint key shall fit neatly, but without forcing, in masonry unit jamb sash grooves. The control joint key shall be flexible at a temperature of minus 30 degrees F after five hours exposure, and shall have a durometer hardness of not less than 70 when tested in accordance with ASTM D 2240.

2.11 EXPANSION-JOINT MATERIALS

Backer rod and sealant shall be adequate to accommodate joint compression equal to 50 percent of the width of the joint. The backer rod shall be compressible rod stock of polyethylene foam, polyurethane foam, butyl rubber foam, or other flexible, nonabsorptive material as recommended by the sealant manufacturer.