Specs_Roofing.V2.3.doc

SPECIFICATIONS

for Homestead Air Reserve Base General Roof Repair and Replacement for Multiple Contracts V 2.3 March 2012 These specifications do not generally cover structural roofing elements or framing.

Table of Contents

SECTION 02 – EXISTING CONDITIONS

02 41 00

Demolition (05/10) Modified for roof items only.

SECTION 03 – CONCRETE

03 30 00

Cast-in-Place Concrete (05/10) Modified for small projects. Addition or reconstruction of parapets, curbs, or concrete drainage structures.

SECTION 05 – METALS

05 30 00

Steel Decks (05/10) Modified for Roof deck repair and replacement.

05 50 13

Metals: Miscellaneous and Fabrications (05/10). Modified for roof scuttles and downspout boots only.

05 51 33

Metal Ladders (05/10) Modified for roof ladders only.

SECTION 06 – WOOD

06 10 00

Rough Carpentry (11/09) Modified for roof sheathing, cant strips, blocking, curb extensions and nailers only.

SECTION 07 – THERMAL AND MOISTURE PROTECTION

07 13 53

Elastomeric Sheet Waterproofing (04/06) 07 19 00 X

Limestone Water Repellents (05/11) Modified for limestone block coping and sills.

07 22 00

Roof and Deck Insulation (08/10) Modified for built-up and single-ply roofs using polyisocyanurate insulation on plywood, steel, lightweight / gypsum, or structural concrete decks only, and for compliance with the Florida Building Code for High Velocity Hurricane Zones.

07 41 13

Metal Roof Panels (11/08)

07 52 00

Modified Bituminous Membrane Roofing (11/08) Modified for Base Roofing Standards and compliance with the Florida Building Code for High Velocity Hurricane Zones.

07 54 19

Single-Ply Roofing (11/08) Modified for PVC and EIP Membranes and for compliance with the South Florida Administrative Code.

07 60 00

Flashing and Sheet Metal (08/08) Modified for general purpose flat roof and SSMR flashing and accessories, trim, gutters and downspouts typical at HARB.

07 72 00

Roof Ventilators, Gravity-Type (08/09) Modified for compliance with the Florida Building Code for High Velocity Hurricane Zones.

07 92 00

Joint Sealants (01/07) Modified for external use only.

SECTION 09 – FINISHES

09 24 34

Stucco (05/09) Modified for small areas applied over masonry only.

09 90 00

Paints and Coatings (08/10) Modified for roof related painting: metal trim, concrete and masonry only.

SECTION 22 – PLUMBING

22 00 00

Plumbing, General Plumbing (08/10) Modified for roof drains and sleeves only.

SECTION 26 – ELECTRICAL

26 41 01.00 10

Lightning Protection Systems (11/08) Modified for typical roof-related repair or new installations only

SECTION 02 41 00

DEMOLITION

05/10

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.

AMERICAN SOCIETY OF SAFETY ENGINEERS (ASSE/SAFE)

· ASSE/SAFE A10.6 (2006) Safety Requirements for Demolition Operations

U.S. ARMY CORPS OF ENGINEERS (USACE)

· COE EM 385-1-1(2003) Safety –Safety and Health Requirements

1.2 GENERAL REQUIREMENTS

Do not begin demolition until authorization is received from the Contracting Officer. Remove rubbish and debris from the project site; do not allow accumulations inside or outside the buildings. Take special measures to prevent any debris from reaching airfield pavements such as covering dumpsters when not in use and while in transit.

1.3 SUBMITTALS

The following shall be submitted in accordance with the SCOPE OF WORK.

SD-11 Closeout Submittals

· Receipts or bills of laden, as specified, for disposal of hazardous wastes according to the ENVIRONMENTAL PROTECTION STATEMENT.

1.4 REGULATORY AND SAFETY REQUIREMENTS

Comply with federal, state, and local hauling and disposal regulations. In addition to the requirements of the "Contract Clauses," conform to the safety requirements contained in ASSE/SAFE A10.6.

1.5 DUST AND DEBRIS CONTROL

Prevent the spread of dust and debris to occupied portions of the building and on airfield pavements. Sweep pavements as often as necessary to control the spread of debris that may result in foreign object damage potential to aircraft.

1.6 PROTECTION

1.6.1 Weather Protection

For portions of the building to remain, protect building interior and materials and equipment from the weather at all times. Where removal of existing roofing is necessary to accomplish work, have materials and workmen ready to provide adequate and temporary covering of exposed areas.

1.6.2 Utility Service

Maintain existing utilities indicated to stay in service and protect against damage during demolition operations.

1.6.3 Protection of Personnel

Before, during and after the demolition work the Contractor shall continuously evaluate the condition of the structure being demolished and take immediate action to protect all personnel working in and around the demolition site. No area, section, or component of floors, roofs, walls, columns, pilasters, or other structural element will be allowed to be left standing without sufficient bracing, shoring, or lateral support to prevent collapse or failure while workmen remove debris or perform other work in the immediate area.

1.7 BURNING

The use of burning at the project site for the disposal of refuse and debris will not be permitted.

1.8 FOREIGN OBJECT DAMAGE (FOD)

Aircraft and aircraft engines are subject to FOD from debris and waste material lying on airfield pavements. Remove all such materials that may appear on operational aircraft pavements due to the Contractor's operations. If necessary, the Contracting Officer may require the Contractor to install a temporary barricade at the Contractor's expense to control the spread of FOD potential debris. The barricade must include a fence covered with a fabric designed to stop the spread of debris. Anchor the fence and fabric to prevent displacement by winds or jet/prop blasts. Remove barricade when no longer required.

1.9 RELOCATIONS

Perform the removal and reinstallation of relocated items as indicated with workmen skilled in the trades involved. Items to be relocated which are damaged by the Contractor shall be repaired or replaced with new undamaged items as approved by the Contracting Officer.

PART 2 PRODUCTS

N/A.

PART 3 EXECUTION

3.1 EXISTING FACILITIES TO BE REMOVED

3.1.1 Utilities and Related Equipment

3.1.1.1 General Requirements

Do not interrupt existing utilities serving occupied or used facilities, except when authorized in writing by the Contracting Officer. Do not interrupt existing utilities serving facilities occupied and used by the Government except when approved in writing and then only after temporary utility services have been approved and provided. Do not begin demolition work until all utility disconnections have been made. Shut off and cap utilities for future use, as indicated.

3.1.1.2 Disconnecting Existing Utilities

Remove existing utilities as required and terminate in a manner conforming to the nationally recognized code covering the specific utility and approved by the Contracting Officer. When utility lines are encountered that are not indicated on the drawings, the Contracting Officer shall be notified prior to further work in that area.

3.1.2 Roofing

Unless otherwise specified by the statement of work or in writing from the Contracting Officer, remove the roofing system and insulation without damaging the roof deck. Sequence the work to minimize building exposure between demolition and new roof materials installation.

3.1.2.1 Temporary Roofing

Install temporary roofing and flashing as necessary to maintain a watertight condition throughout the course of the work. Remove temporary work prior to installation of permanent roof system materials unless approved otherwise by the Contracting Officer. If the existing deck is deteriorated such that ability to support foot traffic and construction loads is unknown, then make provisions for worker safety during demolition and installation according to COE EM 385-1-1.

3.1.2.2 Reroofing

When removing the existing roofing system from the roof deck, remove only as much roofing as can be recovered by the end of the work day, unless approved otherwise by the Contracting Officer. Do not attempt to open the roof covering system in threatening weather. Reseal all openings prior to suspension of work the same day.

3.1.3 Miscellaneous Metal

Salvage shop-fabricated items such as access doors and frames, steel gratings, metal ladders, wire mesh partitions, metal railings, metal windows and similar items as whole units. Salvage light-gage and cold-formed metal framing, such as steel studs, steel trusses, metal gutters, roofing and siding and similar items.

3.1.4. Salvage and Disposal

Salvage and dispose of all materials as described in the ENVIRONMENTAL PROTECTION STATEMENT.

SECTION 03 30 00

CAST-IN-PLACE CONCRETE (SMALL PROJECTS)

05/10

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/MCP-1 (2010) Manual of Concrete Practice Part 1

· ACI/MCP-2 (2010) Manual of Concrete Practice Part 2

· ACI/MCP-3 (2010) Manual of Concrete Practice Part 3

· ACI/MCP-4 (2010) Manual of Concrete Practice Part 4

AMERICAN HARDBOARD ASSOCIATION (AHA)

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

ASTM INTERNATIONAL (ASTM)

· ASTM A 123/A 123M (2009) Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

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

· ASTM A 496 (2007) Steel Wire, Deformed, for Concrete Reinforcement

· ASTM A 497 (2007) Steel Welded Wire Reinforcement, Deformed, for Concrete

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

· ASTM A 706/A 706M (2009b) Standard Specification for Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement

· ASTM A 767/A 767M (2009) Zinc-Coated (Galvanized) Steel Bars for Concrete Reinforcement

· ASTM A 775/A 775M (2007b) Standard Specification for Epoxy-Coated Steel Reinforcing Bars

· ASTM A 780 (2009) Repair of Damaged and Uncoated Areas of Hot-Dipped Galvanized Coatings

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

· ASTM A 934/A 934M (2007) Standard Specification for Epoxy-Coated Prefabricated Steel Reinforcing Bars

· ASTM C 1017/C 1017M (2007) Chemical Admixtures for Use in Producing Flowing Concrete

· ASTM C 1107 (2008) Packaged Dry, Hydraulic-Cement Grout (Nonshrink)

· ASTM C 1116 (2009) Fiber-Reinforced Concrete and Shotcrete

· ASTM C 143/C 143M (2009) Slump of Hydraulic Cement Concrete

· ASTM C 150 (2009) Portland Cement

· ASTM C 172 (2008) Sampling Freshly Mixed Concrete

· ASTM C 173/C 173M (2009) Air Content of Freshly Mixed Concrete by the Volumetric Method

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

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

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

· ASTM C 31/C 31M(2009) Making and Curing Concrete Test Specimens in the Field

· ASTM C 33 (2008) Concrete Aggregates

· ASTM C 39 (2009a) Compressive Strength of Cylindrical Concrete Specimens

· ASTM C 494/C 494M (2008a) Chemical Admixtures for Concrete

· ASTM C 618 (2008a) Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use as a Mineral Admixture in Concrete

· ASTM C 881 (2002) Epoxy-Resin-Base Bonding Systems for Concrete

· ASTM C 920 (2008) Elastomeric Joint Sealants

· ASTM C 94/C 94M (2009a) Ready-Mixed Concrete

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

· ASTM D 1190 (1997) Concrete Joint Sealer, Hot-Applied Elastic Type

· ASTM D 1751 (2004; R 2008) Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types)

· ASTM D 1752 (2004a; R 2008) Preformed Sponge Rubber and Cork Expansion Joint Fillers for Concrete Paving and Structural Construction

NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY (NIST)

· NIST PS 1 (2007) DOC Voluntary Product Standard PS 1-07, Structural Plywood

U.S. DEPARTMENT OF COMMERCE (DOC)

· DOC NIST/PS 1 (1995) Construction and Industrial Plywood (APA V995)

1.2 DEFINITIONS

"Cementitious material" as used herein shall include all portland cement, pozzolan, fly ash and ground iron blast-furnace slag.

1.3 SUBMITTALS

The following shall be submitted in accordance with the SCOPE OF WORK.

SD-02 Shop Drawings

· Reinforcing steel and accessories SD-03 Product Data

· Materials for curing concrete

· Joint sealants

· Joint filler

· Reinforcement

SD-05 Design Data

· Concrete materials and mix design

· Admixtures

· Material Safety Data Sheets

PART 2 PRODUCTS

2.1 MATERIALS FOR FORMS

Provide wood, plywood, or steel. Use concrete form panels, plywood or steel forms where a smooth form finish is required. Concrete forms shall comply with NIST PS 1 B-B not less than 5/8” thick. Plywood shall comply with DOC/NIST PS 1 B-B or AHA A 135.4. Stell forms shall be free of irregularities, dents or sags.

Lumber shall be square edged or tongue-and-groove boards, free of raised grain, knotholes, or other surface defects.

2.2 FORM TIES AND ACCESSORIES

The use of wire alone is prohibited. Form ties and accessories shall not reduce the effective cover of the reinforcement. Polyvinylchloride Waterstops shall comply with COE CRD-C 572.

2.3 CONCRETE MIX DESIGN

Comply with ACI/MCP-1, ACI/MCP-2 and ACI/MCP-3. Structural Concrete for Buildings, except as otherwise specified or approved by the Contracting Officer.

· Normal weight concrete, compressive strength (f'c) of 3,500 psi at 28 days.

· Maximum nominal aggregate size: 57.

· Maximum water-cement ratio by weight: 0.50.

· Maximum Air Entrainment: 6%

2.3.1 Cement

ASTM C 150, Type IS cement blended with one of the following materials: ASTM C 618, Type F or C pozzolan or fly ash, or ASTM C 989 Grade 120 ground iron blast-furnace slag. The pozzolan or fly ash content shall not exceed 25% by weight of the total cementitious material. The ground iron blast-furnace slag shall not exceed 40% by weight of total cementitious material. Use one manufacturer for each type of cement, ground slag, fly ash, and pozzolan.

2.3.2 Water

Water shall be fresh, clean, and potable; free from injurious amounts of oils, acids, alkalis, salts, organic materials, or other substances deleterious to concrete.

2.3.3 Aggregates

ASTM C 33.

2.3.4 Nonshrink Grout

ASTM C 1107.

2.3.5 Admixtures

ASTM C 494/C 494M: Type A, water reducing; Type B, retarding; Type C, accelerating; Type D, water-reducing and retarding; and Type E, water-reducing and accelerating admixture. Do not use calcium chloride admixtures.

2.3.5.1 Air-Entraining

ASTM C 260.

2.3.5.2 High Range Water Reducer (HRWR) (Superplasticizers)

ASTM C 494/C 494M, Type F and ASTM C 1017/C 1017M.

2.3.6 Vapor Retarder / Barrier

Polyethylene sheeting, minimum 6 mil thickness, or waterproof kraft paper as recommended by the manufacturer.

2.3.7 Liquid Membrane-Forming Compound

ASTM C 309, white-pigmented, Type 2, Class B.

2.3.8 Liquid Chemical Sealer-Hardener Compound

Compound shall be magnesium fluosilicate which when mixed with water seals and hardens the surface of the concrete. Compound shall not reduce the adhesion of resilient flooring, tile, paint, roofing, waterproofing, or other material applied to concrete.

2.3.9 Expansion/Contraction Joint Filler

ASTM D 1751, ASTM D 1752, or 100% recycled material meeting ASTM D 1752 (subparagraphs 5.1 to 5.4). Material shall be 1/2 inch thick unless otherwise indicated or approved by submittal. Preformed joint filler strips as recommended by roof membrane manufacturer.

2.3.10 Joint Sealants

2.3.10.1 Horizontal Surfaces, 3% Slope Maximum

ASTM D 1190 or ASTM C 920, Type M, Class 25, Use T.

2.3.10.2 Vertical Surfaces Greater Than 3% Slope

ASTM C 920, Type M, Grade NS, Class 25, Use T.

2.3.11 Epoxy Bonding Compound

ASTM C 881. Provide Type I for bonding hardened concrete to hardened concrete; Type II for bonding freshly mixed concrete to hardened concrete; and Type III as a binder in epoxy mortar or concrete, or for use in bonding skid-resistant materials to hardened concrete. Provide Grade 1 or 2 for horizontal surfaces and Grade 3 for vertical surfaces. Provide Class A if placement temperature is below 40°F; Class B if placement temperature is between 40 and 60°F; or Class C if placement temperature is above 60°F.

2.4 REINFORCEMENT

Bars, fabrics, connectors, and chairs shall be galvanized, zinc-coated.

2.4.1 Reinforcing Bars

Galvanized, ASTM A 123/A 123M or Zinc-coated bars, ASTM A 767/A 767M and ASTM A 780. Epoxy-coated reinforcing steel bars, ASTM A 775/A 775M Grade 40 or 60. Epoxy-coated prefabricated steel reinforcing bars, ASTM A 934/A 934M.

Weldable reinforcing bars shall conform to ASTM A 706/A 706M and ASTM A 615/A 615M and Supplement S1, Grade 60, except that the maximum carbon content must be 0.55 percent.

2.4.2 Mechanical Reinforcing Bar Connectors

ACI/MCP-2. Provide 125% minimum yield strength of the reinforcement bar.

2.4.3 Welded Wire Fabric

ASTM A 185 or ASTM A 497. Provide flat sheets of welded wire fabric for slabs and toppings.

2.4.4 Wire

ASTM A 82 or ASTM A 496.

2.4.5 Reinforcing Bar Supports

Provide bar ties and supports of coated or non corrodible material.

2.4.6 Fiber-Reinforced Concrete

In addition to the requirements specified above, fiber reinforced concrete shall be provided in accordance with ASTM C 1116 Type III, synthetic fiber reinforced concrete, and as follows. Synthetic reinforcing fibers shall be 100 percent virgin polypropylene fibrillated fibers containing no reprocessed olefin materials. Fibers shall have a specific gravity of 0.9, a minimum tensile strength of 70 ksi, graded per manufacturer, and specifically manufactured to an optimum gradation for use as concrete secondary reinforcement. A minimum of 1.5 pounds of fibers per cubic yard of concrete shall be used.

PART 3 EXECUTION

3.1 FORMS

ACI/MCP-2. Provide forms, shoring, and scaffolding for concrete placement. Set forms mortar-tight and true to line and grade. Chamfer above grade exposed joints, edges, and external corners of concrete 0.75 inch unless otherwise indicated. Provide formwork with clean-out openings to permit inspection and removal of debris. Material with raised grain, torn surfaces, worn edges, patches, dents, or other defects which will impair the texture of the concrete surface shall not be used.

3.1.1 Coating

Before concrete placement, coat the contact surfaces of forms with a nonstaining mineral oil, nonstaining form coating compound, or two coats of nitrocellulose lacquer. Do not use mineral oil on forms for surfaces to which adhesive, paint, or other finish material is to be applied.

3.1.2 Removal of Forms and Supports

After placing concrete, forms shall remain in place for the time periods specified in ACI/MCP-4. Prevent concrete damage during form removal. Clean all forms immediately after removal.

3.2 PLACING REINFORCEMENT AND MISCELLANEOUS MATERIALS

ACI/MCP-2, ACI/MCP-3 and ACI/MCP-4. Provide bars, wire fabric, wire ties, supports, and other devices necessary to install and secure reinforcement. Reinforcement shall not have rust, scale, oil, grease, clay, or foreign substances that would reduce the bond. Rusting of reinforcement is a basis of rejection if the effective cross-sectional area or the nominal weight per unit length has been reduced. Remove loose rust prior to placing steel. Tack welding is prohibited.

Epoxy Coated Reinforcing must meet the requirements of ASTM A 934.

3.2.1 Setting Miscellaneous Material

Place and secure anchors and bolts, pipe sleeves, conduits, and other such items in position before concrete placement. Plumb anchor bolts and check location and elevation. Temporarily fill voids in sleeves with readily removable material to prevent the entry of concrete.

3.2.2 Construction Joints

Locate joints to least impair strength. Continue reinforcement across joints unless otherwise indicated.

3.2.3 Expansion Joints and Contraction Joints

Make expansion joints 1/2 inch wide unless indicated otherwise. Fill expansion joints not exposed to weather with preformed joint filler material. Completely fill joints exposed to weather with joint filler material and joint sealant. Do not extend reinforcement or other embedded metal items bonded to the concrete through any expansion joint unless an expansion sleeve is used. Provide contraction joints, either formed or saw cut or cut with a jointing tool, to the indicated depth after the surface has been finished. Sawed joints shall be completed within 4 to 12 hours after concrete placement. Protect joints from intrusion of foreign matter.

3.2.4 Welding

Welding must be in accordance with AWS D1.4/

3.3 BATCHING, MEASURING, MIXING, AND TRANSPORTING CONCRETE

ASTM C 94/C 94M, ACI/MCP-2. Furnish mandatory batch ticket information for each load of ready mix concrete.

3.3.1 Mixing

ASTM C 94/C 94M and ACI/MCP-2. Machine mix concrete. Begin mixing within 30 minutes after the cement has been added to the aggregates. Place concrete within 90 minutes of either addition of mixing water to cement and aggregates or addition of cement to aggregates if the air temperature is less than 85 degrees F. Reduce mixing time and place concrete within 60 minutes if the air temperature is greater than 85°F except as follows: if set retarding admixture is used and slump requirements can be met, limit for placing concrete may remain at 90 minutes. Additional water may be added, provided that both the specified maximum slump and water-cement ratio are not exceeded. When additional water is added, an additional 30 revolutions of the mixer at mixing speed is required. Dissolve admixtures in the mixing water and mix in the drum to uniformly distribute the admixture throughout the batch.

3.3.2 Transporting

Transport concrete from the mixer to the forms as rapidly as practicable. Prevent segregation or loss of ingredients. Clean transporting equipment thoroughly before each batch. Do not use aluminum pipe or chutes. Remove concrete which has segregated in transporting and dispose of as directed.

3.4 PLACING CONCRETE

Place concrete as soon as practicable after the forms and the reinforcement have been inspected and approved. Do not place concrete when weather conditions prevent proper placement and consolidation; in uncovered areas during periods of precipitation; or in standing water. Prior to placing concrete, remove dirt, and construction debris from within the forms. Deposit concrete as close as practicable to the final position in the forms. Do not exceed a free vertical drop of 3 feet from the point of discharge. Place concrete in one continuous operation from one end of the structure towards the other. Position grade stakes on 10 foot centers maximum in each direction when pouring interior slabs and on 20 foot centers maximum for exterior slabs.

3.4.1 Vibration

ACI MCP-2 and ASTM A 934. Furnish a spare, working, vibrator on the job site whenever concrete is placed. Consolidate concrete slabs greater than 4 inches in depth with high frequency mechanical vibrating equipment supplemented by hand spading and tamping. Consolidate concrete slabs 4 inches or less in depth by wood tampers, spading, and settling with a heavy leveling straightedge. Operate internal vibrators with vibratory element submerged in the concrete, with a minimum frequency of not less than 6000 impulses per minute when submerged. Do not use vibrators to transport the concrete in the forms. Insert and withdraw vibrators approximately 18 inches apart. Penetrate the previously placed lift with the vibrator when more than one lift is required. Place concrete in 18 inch maximum vertical lifts. External vibrators shall be used on the exterior surface of the forms when internal vibrators do not provide adequate consolidation of the concrete.

3.4.2 Pumping

ACI/MCP-2. Pumping shall not result in separation or loss of materials nor cause interruptions sufficient to permit loss of plasticity between successive increments. Loss of slump in pumping equipment shall not exceed 2 inches. Concrete shall not be conveyed through pipe made of aluminum or aluminum alloy. Rapid changes in pipe sizes shall be avoided. Maximum size of course aggregate shall be limited to 33 percent of the diameter of the pipe. Maximum size of well rounded aggregate shall be limited to 40 percent of the pipe diameter. Samples for testing shall be taken at both the point of delivery to the pump and at the discharge end.

3.4.2.1 Pumping Lightweight Concrete

ACI MCP-1. Aggregates shall be presoaked or presaturated. Cement content shall be minimum of 564 pounds per cubic yard and shall be sufficient to accommodate a 4 to 6 inch slump. Field trial run shall be made in accordance with ACI/MCP-1.

3.4.3 Hot Weather

Maintain required concrete temperature using Figure 2.1.5 in ACI/MCP-2 to prevent the evaporation rate from exceeding 0.2 pound of water per square foot of exposed concrete per hour. Cool ingredients before mixing or use other suitable means to control concrete temperature and prevent rapid drying of newly placed concrete. Shade the fresh concrete as soon as possible after placing. Start curing when the surface of the fresh concrete is sufficiently hard to permit curing without damage. Provide water hoses, pipes, spraying equipment, and water hauling equipment, where job site is remote to water source, to maintain a moist concrete surface throughout the curing period. Provide burlap cover or other suitable, permeable material with fog spray or continuous wetting of the concrete when weather conditions prevent the use of either liquid membrane curing compound or impervious sheets. For vertical surfaces, protect forms from direct sunlight and add water to top of structure once concrete is set.

3.5 SURFACE FINISHES

3.5.1 Surfaces Against Forms

Repair formed surfaces by removing minor honeycombs, pits greater than 1 square inch surface area or 0.25 inch maximum depth, or otherwise defective areas. Provide edges perpendicular to the surface and patch with nonshrink grout. Patch tie holes and defects when the forms are removed. Concrete with extensive honeycomb including exposed steel reinforcement, cold joints, entrapped debris, separated aggregate, or other defects which affect the serviceability or structural strength will be rejected, unless correction of defects is approved. Obtain approval of corrective action prior to repair. The surface of the concrete shall not vary more than the allowable tolerances of ACI/MCP-4. Exposed surfaces shall be uniform in appearance and finished to a smooth form finish unless otherwise specified.

3.5.2 Surfaces Not Exposed to Public View

Rough. Patch holes and defects and level abrupt irregularities. Remove or rub off fins and other projections exceeding 0.25 inch in height.

3.5.3 Surfaces to Receive Roofing

Floated. After the concrete has been placed, consolidated, struck off, and leveled, do not work the concrete further, until ready for floating. Whether floating with a wood, magnesium, or composite hand float, with a bladed power trowel equipped with float shoes, or with a powered disc, float shall begin when the surface has stiffened sufficiently to permit the operation. During or after the first floating, surface shall be checked with a 10 foot straightedge applied at no less than two different angles, one of which is perpendicular to the direction of strike off. High spots shall be cut down and low spots filled during this procedure to produce a surface level within ¼ inch in 10 feet.

3.5.4 All Other Surfaces.

Use a broomed finish on all other surfaces not to receive roofing unless otherwise approved. Perform a floated finish, then draw a broom or burlap belt across the surface to produce a coarse scored texture. Permit surface to harden sufficiently to retain the scoring or ridges. Broom transverse to traffic or at right angles to the slope of the slab.

3.5.5 Splash Blocks

Provide at outlets of downspouts emptying at grade. Splash blocks may be precast concrete, and shall be 24 inches long, 12 inches wide, and 4 inches thick, unless otherwise indicated, with smooth-finished countersunk dishes sloped to drain away from the building.

3.6 CURING AND PROTECTION

ACI/MCP-2 unless otherwise specified. Protect concrete from injurious action by sun, rain, flowing water, mechanical injury, tire marks, and oil stains. Do not allow concrete to dry out from time of placement until the expiration of the specified curing period. Do not use membrane-forming compound on surfaces where appearance would be objectionable, on any surface to be painted, where coverings are to be bonded to the concrete, or on concrete to which other concrete is to be bonded. If forms are removed prior to the expiration of the curing period, provide another curing procedure specified herein for the remaining portion of the curing period. Provide moist curing for those areas receiving liquid chemical sealer-hardener or epoxy coating.

3.6.1 General

Protect freshly placed concrete from premature drying or hot temperature and maintain without drying at a relatively constant temperature for the period of time necessary for hydration of cement and proper hardening of concrete.

Start initial curing as soon as free water has disappeared from surface of concrete after placing and finishing. Keep concrete moist for minimum 72 hours.

Final curing must immediately follow initial curing and before concrete has dried. Continue final curing until cumulative number of hours or fraction thereof (not necessarily consecutive) during which temperature of air in contact with the concrete is above 50°F has totaled 168 hours. Alternatively, if tests are made of cylinders kept adjacent to the structure and cured by the same methods, final curing may be terminated when the average compressive strength has reached 70 percent of the 28-day design compressive strength. Prevent rapid drying at end of final curing period.

3.6.2 Moist Curing

Remove water without erosion or damage to the structure.

3.6.2.1 Ponding or Immersion

Continually immerse the concrete throughout the curing period. Water shall not be more than 20 degrees F less than the temperature of the concrete. For temperatures between 40 and 50°F, increase the curing period by 50%.

3.6.2.2 Fog Spraying or Sprinkling

Apply water uniformly and continuously throughout the curing period. For temperatures between 40 and 50°F, increase the curing period by 50%.

3.6.2.3 Pervious Sheeting

Completely cover surface and edges of the concrete with two thicknesses of wet sheeting. Overlap sheeting 6 inches over adjacent sheeting. Sheeting shall be at least as long as the width of the surface to be cured. During application, do not drag the sheeting over the finished concrete nor over sheeting already placed. Wet sheeting thoroughly and keep continuously wet throughout the curing period.

3.6.2.4 Impervious Sheeting

Wet the entire exposed surface of the concrete thoroughly with a fine spray of water and cover with impervious sheeting throughout the curing period. Lay sheeting directly on the concrete surface and overlap edges 12 inches minimum. Provide sheeting not less than 18 inches wider than the concrete surface to be cured. Secure edges and transverse laps to form closed joints. Repair torn or damaged sheeting or provide new sheeting. Cover or wrap columns, walls, and other vertical structural elements from the top down with impervious sheeting; overlap and continuously tape sheeting joints; and introduce sufficient water to soak the entire surface prior to completely enclosing.

3.6.3 Liquid Membrane-Forming Curing Compound

Seal or cover joint openings prior to application of curing compound. Prevent curing compound from entering the joint. Apply in accordance with the recommendations of the manufacturer immediately after any water sheen which may develop after finishing has disappeared from the concrete surface. Provide and maintain compound on the concrete surface throughout the curing period. Do not use this method of curing where the use of Figure 2.1.5 in ACI/MCP-2 indicates that hot weather conditions will cause an evaporation rate exceeding 0.2 pound of water per square foot per hour.

3.6.3.1 Application

Unless the manufacturer recommends otherwise, apply compound immediately after the surface loses its water sheen and has a dull appearance, and before joints are sawed. Mechanically agitate curing compound thoroughly during use. Use approved power-spraying equipment to uniformly apply two coats of compound in a continuous operation. The total coverage for the two coats shall be 200 square feet maximum per gallon of undiluted compound unless otherwise recommended by the manufacturer's written instructions. The compound shall form a uniform, continuous, coherent film that will not check, crack, or peel. Immediately apply an additional coat of compound to areas where the film is defective. Re-spray concrete surfaces subjected to rainfall within 3 hours after the curing compound application.

3.6.3.2 Protection of Treated Surfaces

Prohibit pedestrian and vehicular traffic and other sources of abrasion at least 72 hours after compound application. Maintain continuity of the coating for the entire curing period and immediately repair any damage.

3.6.4 Liquid Chemical Sealer-Hardener

Apply sealer-hardener to interior floors not receiving floor covering and floors located under access flooring. Apply the sealer-hardener in accordance with manufacturer's recommendations. Seal or cover joints and openings in which joint sealant is to be applied as required by the joint sealant manufacturer. The sealer-hardener shall not be applied until the concrete has been moist cured and has aged for a minimum of 30 days. Apply a minimum of two coats of sealer-hardener.

3.6.5 Curing Periods

ACI/MCP-2 except 10 days for retaining walls, pavement or chimneys. Begin curing immediately after placement. Protect concrete from premature drying, excessively hot temperatures, and mechanical injury; and maintain minimal moisture loss at a relatively constant temperature for the period necessary for hydration of the cement and hardening of the concrete. The materials and methods of curing shall be subject to approval by the Contracting Officer.

3.6.6 Requirements for Type III, High-Early-Strength Portland Cement

The curing periods shall be not less than one-fourth of those specified for portland cement, but in no case less than 72 hours.

3.7 FIELD QUALITY CONTROL

No less than one week before pouring, consult with the Contracting Officer as to the extent of testing necessary depending on job size.

3.7.1 Sampling

ASTM C 172. Collect samples of fresh concrete to perform tests specified. ASTM C 31/C 31M for making test specimens.

3.7.2 Testing

3.7.2.1 Slump Tests

ASTM C 143/C 143M. The contractor shall take concrete samples during concrete placement. The maximum slump may be increased as specified with the addition of an approved admixture provided that the water-cement ratio is not exceeded. Perform tests at commencement of concrete placement, when test cylinders are made, and for each batch (minimum) or every 20 cubic yards (maximum) of concrete.

3.7.2.2 Temperature Tests

Test the concrete delivered and the concrete in the forms. Perform tests in hot or cold weather conditions (below 50°F and above 80°F) for each batch (minimum) or every 20 cubic yards (maximum) of concrete, until the specified temperature is obtained, and whenever test cylinders and slump tests are made.

3.7.2.3 Compressive Strength Tests

ASTM C 39. Make five test cylinders for each set of tests in accordance with ASTM C 31/C 31M. Precautions shall be taken to prevent evaporation and loss of water from the specimen. Test two cylinders at 7 days, two cylinders at 28 days, and hold one cylinder in reserve. Samples for strength tests of each mix design shall be taken not less than once a day, nor less than once for each 100 cubic yards of concrete. Each strength test result shall be the average of two cylinders from the same concrete sample tested at 28 days. Remove concrete not meeting strength criteria and provide new acceptable concrete.

3.7.2.4 Air Content

ASTM C 173/C 173M or ASTM C 231 for normal weight concrete and ASTM C 173/C 173M for lightweight concrete. Test air-entrained concrete for air content at the same frequency as specified for slump tests.

SECTION 05 30 00

STEEL DECKS

05/10

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.

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

· AISC 360 (2005) Specification for Structural Steel Buildings, with Commentary

AMERICAN IRON AND STEEL INSTITUTE (AISI)

· AISI SG03-3 (2002; Suppl 2001-2004; R 2008) Cold-Formed Steel Design Manual

AMERICAN WELDING SOCIETY (AWS)

· AWS D1.1/D1.1M (2010) Structural Welding Code - Steel

· AWS D1.3 (2008) Structural Welding Code - Sheet Steel

ASTM INTERNATIONAL (ASTM)

· ASTM A 1008/A 1008M (2009a) Steel, Sheet, Cold-Rolled, Carbon, Structural, High-Strength Low-Alloy and High-Strength Low-Alloy with Improved Formability, Solution Hardened, and Bake Hardened

· ASTM A 108 (2007) Steel Bars, Carbon, Cold-Finished

· ASTM A 653/A 653M (2009a) Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process

· ASTM A 780 (2009) Repair of Damaged and Uncoated Areas of Hot-Dipped Galvanized Coatings

· ASTM A 792/A 792M (2009a) Steel Sheet, 55% Aluminum-Zinc Alloy-Coated by the Hot-Dip Process

· ASTM C 423 (2009a) Sound Absorption and Sound Absorption Coefficients by the Reverberation Room Method

FM GLOBAL (FM)

· FM DS 1-28 (2002) Design Wind Loads

· FM APP GUIDE (Updated on-line http://www.approvalguide.com/CC_host/pages/public/custom) Approval Guide

STEEL DECK INSTITUTE (SDI)

· SDI 31 (2007) Design Manual for Composite Decks, Form Decks, and Roof Decks

· SDI DDM03 (2004; Errata 2006; Add 2006) Diaphragm Design Manual

· SDI DDP (1987; R 2000) Deck Damage and Penetrations

· SDI MOC2 (2006) Manual of Construction with Steel Deck

U.S. DEPARTMENT OF DEFENSE (DOD)

· UFC 3-310-01 (2010) Load Assumptions for Buildings

UNDERWRITERS LABORATORIES (UL)

· UL 580 (2006; R 2009) Tests for Uplift Resistance of Roof Assemblies

· UL Bld Mat Dir (2010) Building Materials Directory

1.2 SUBMITTALS

The following shall be submitted in accordance with the SCOPE OF WORK:

SD-02 Shop Drawings

· Fabrication Drawings

· Cant Strips

· Ridge Valley Plates

· Metal Closure Strips SD-03 Product Data

· Roof Deck Units

· Accessories

· Galvanizing Repair Paint

· Mechanical Fasteners SD-05 Design Data

· Deck Units

SD-07 Certificates

· Welders Qualifications

· Roof Deck Units

· Wind Storm Resistance

1.3 QUALITY ASSURANCE

1.3.1 Deck Units

Deck units and accessories shall be products of a manufacturer regularly engaged in manufacture of steel decking. Provide manufacturer's certificates attesting that the decking material meets the specified requirements.

1.3.2 Qualification of Welders

Provide welder qualification procedures, welder qualifications, and duration of qualification period in accordance with AWS D1.1/D1.1M.

1.3.3 Regulatory Requirements

1.3.3.1 Fire Safety

Roof deck shall have been tested as a part of a roof deck construction assembly of the type used for this project, shall be listed as fire classified in the UL Bld Mat Dir, or listed as Class I construction in the FM APP GUIDE, and so labeled.

1.3.3.2 Wind Storm Resistance

Provide roof construction assembly capable of withstanding the uplift pressure resulting from a 150 mph wind speed, or 90 pounds per square foot, whichever is greater, when tested in accordance with the uplift pressure test described in the FM DS 1-28 or as described in UL 580 and in general compliance with UFC 3-310-01.

1.3.4 Fabrication Drawings

Show type and location of units, location and sequence of connections, bearing on supports, methods of anchoring, attachment of accessories, adjusting plate details, size and location of holes to be cut and reinforcement to be provided, the manufacturer's erection instructions and other pertinent details.

1.4 DELIVERY, STORAGE, AND HANDLING

Deliver deck units to the site in a dry and undamaged condition. Store and handle steel deck in a manner to protect it from corrosion, deformation, and other types of damage. Do not use decking for storage or as working platform until units have been fastened into position. Exercise care not to damage material or overload decking during construction. The maximum uniform distributed storage load shall not exceed the design live load. Stack decking on platforms or pallets and cover with weathertight ventilated covering. Elevate one end during storage to provide drainage. Maintain deck finish at all times to prevent formation of rust. Repair deck finish using touch-up paint. Replace damaged material.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Steel Sheet

Flat rolled carbon steel sheets of structural quality, thickness not less than 0.034 inches (before coating), meeting the requirements of AISI SG03-3, except as modified herein.

2.1.2 Steel Coating

ASTM A 653/A 653M designation G90 galvanized, or galvalume ASTM A 792/A 792M designation AZ55, aluminum-zinc alloy. Apply coating to both sides of sheet.

2.1.3 Galvanized Steel Angles for Roof Decks

Provide hot-rolled carbon steel angles conforming to ASTM A 36/A 36M, merchant quality, Grade Designation SAE/AISI 1023 or SAE/AISI 1025, and hot-dip galvanized in accordance with ASTM A 123/A 123M.

2.1.4 Joint Sealant Material for Roof Decks

Provide a nonskinning, gun-grade, bulk compound material as recommended by the manufacturer.

2.1.5 Galvanizing Repair Paint

Provide a high zinc-dust content paint for regalvanizing welds in galvanized steel and shall conform to ASTM A 780.

2.2 ACCESSORIES

Provide accessories of same material as deck, unless specified otherwise. Provide manufacturer's standard type accessories, as specified.

2.2.1 Adjusting Plates

Provide adjusting plates, or segments of deck units, of same thickness and configuration as deck units in locations too narrow to accommodate full size units. Provide factory cut plates of predetermined size where possible.

2.2.2 End Closures

Fabricated of sheet metal by the deck manufacturer. Provide end closures minimum 0.024 inch thick to close open ends at parapets, end walls, eaves, and openings through deck.

2.2.3 Partition Closures

Provide closures for closing voids above interior walls and partitions that are perpendicular to the direction of the configurations. Provide rubber, plastic, or sheet steel closures above typical partitions. Provide minimum one inch thick soft composition rubber closures above walls and partitions contiguous to acoustical steel deck. Provide sheet steel closures above fire-resistant interior walls and partitions located on both sides of wall or partition.

2.2.4 Closure Plates for Composite Deck

The concrete shall be supported and retained at each floor level. Provide edge closures at all edges of the slab of sufficient strength and stiffness to support the wet concrete. Metal closures shall be provided for all openings in composite steel deck 1/4 inch and over.

2.2.5 Sheet Metal Collar

Where deck is cut for passage of pipes, ducts, columns, etc., and deck is to remain exposed, provide a neatly cut sheet metal collar to cover edges of deck. Do not cut deck until after installation of supplemental supports.

2.2.6 Cover Plates

Sheet metal to close panel edge and end conditions, and where panels change direction or butt. Polyethylene-coated, self-adhesive, 2 inch wide joint tape may be provided in lieu of cover plates on flat-surfaced decking butt joints.

2.2.7 Sump Roof Pans

Sump pans shall be provided for roof drains and shall be minimum 0.075 inch thick steel, flat or recessed type. Sump pans shall be shaped to meet roof slope by the supplier or by a sheet metal specialist. Bearing flanges of sump pans shall overlap steel deck a minimum of 3 inches. Opening in bottom of pan shall be shaped, sized, and reinforced to receive roof drain.

2.2.8 Column Closures

Sheet metal minimum 0.0358 inch thick or metal rib lath.

2.2.9 Access Hole Covers

Sheet metal minimum 0.0474 inch thick.

2.2.10 Hanger

Provide clips or loops for utility systems and suspended ceilings of one or more of the following types:

a. Lip tabs or integral tabs where noncellular decking or flat plate of cellular section is 0.0474 inch thick or more, and a structural concrete fill is used over deck.

b. Slots or holes punched in decking for installation of pigtails.

c. Tabs driven from top side of decking and arranged so as not to pierce electrical cells.

d. Decking manufacturer's standard as approved by the Contracting Officer.

2.2.11 Shear Connectors

Shear connectors shall be headed stud type, ASTM A 108, Grade 1015 or 1020, cold finished carbon steel with dimensions complying with AISC 360 or strap type, ASTM A 570/A 570M, Grade D, hot-rolled carbon steel.

2.2.12 Mechanical Fasteners

Provide mechanical fasteners, such as powder actuated or pneumatically driven fasteners, for anchoring the deck to structural supports and adjoining units that are designed to meet the loads indicated. Provide positive locking-type fasteners standard with the Steel Deck Institute and the steel deck manufacturer, as approved by the Contracting Officer.

2.2.13 Miscellaneous Accessories

The manufacturer's standard accessories shall be furnished as necessary to complete the deck installation. Metal accessories shall be of the same material as the deck and have minimum design thickness as follows: saddles, 0.0474 inch; welding washers, 0.0598 inch; cant strip, 0.0295 inch; other metal accessories, 0.0358 inch; unless otherwise indicated. Accessories shall include but not be limited to saddles, welding washers, fasteners, cant strips, butt cover plates, underlapping sleeves, and ridge and valley plates.

2.3 FABRICATION

2.3.1 Roof Deck

Deck used in conjunction with insulation and built-up roofing shall conform to ASTM A 792/A 792M or ASTM A 1008/A 1008M. Roof deck units shall be fabricated of 0.034 inch design thickness or thicker steel and shall be zinc-coated in conformance with ASTM A 653/A 653M, G90 coating class or aluminum-zinc coated in accordance with ASTM A 792/A 792M Coating Designation AZ55.

2.3.1.1 Cant Strips for Roof Decks

Fabricate cant strips from the specified commercial-quality steel sheets not less than nominal 0.0359 inch thick before galvanizing. Bend strips to form a 45-degree cant not less than 5 inch wide, with top and bottom flanges a minimum 3 inch wide. Provide a minimum length of strips of 10 feet.

2.3.1.2 Ridge and Valley Plates for Roof Decks

Fabricate plates from the specified structural-quality steel sheets, not less than nominal 0.0359 inch thick before galvanizing. Provide plates of minimum 4-1/2 inch wide and bent to provide tight fitting closures at ridges and valleys. Provide a minimum length of ridge and valley plates of 10 feet.

2.3.1.3 Metal Closure Strips for Roof Decks

Fabricate strips from the specified commercial-quality steel sheets not less than nominal 0.0359 inch thick before galvanizing. Provide strips from the configuration required to provide tight-fitting closures at open ends and sides of steel roof decking.

2.3.3 Form Deck

Deck used as formwork for concrete shall conform to ASTM A 653/A 653M or ASTM A 1008. Form deck shall be fabricated of 0.015 inch design thickness or thicker steel. Zinc-coat in conformance with ASTM A 653/A 653M, G90 coating class.

2.3.4 Composite Deck

Composite deck assembly shall conform to ASTM A 653/A 653M or ASTM A 1008/A 1008M. Deck used as the tension reinforcing in composite deck shall be fabricated if 0.0295 inch design thickness or thicker steel. Zinc-coat in conformance with ASTM A 653/A 653M, G90 coating class.

In addition to resisting shear, devices shall provide resistance to vertical separation between the steel deck and the concrete. Provide one of the following types of shear devices:

a. Mechanically fixed shear devices such as embossments, holes, or welded buttons.

b. Mechanically fixed shear devices such as inverted, triangular-shaped ribs.

2.3.6 Venting

For decks using cast-in-place lightweight insulating concrete, provide slotted or perforated steel deck to receive concrete fill, overlay, or a poured concrete deck.

PART 3 EXECUTION

3.1 EXAMINATION

Prior to installation of decking units and accessories, examine worksite to verify that as-built structure will permit installation of decking system without modification.

3.2 INSTALLATION

Install steel deck units in accordance with SDI 31 approved shop drawings. Place units on structural supports, properly adjusted, leveled, and aligned at right angles to supports before permanently securing in place. Damaged deck and accessories including material which is permanently stained or contaminated, deformed, or with burned holes shall not be installed. Extend deck units over three or more supports unless absolutely impractical. Report inaccuracies in alignment or leveling to the Contracting Officer and make necessary corrections before permanently anchoring deck units. Locate deck ends over supports only. Ends of floor deck may be lapped or butted. Do not use unanchored deck units as a work or storage platform. Do not fill unanchored deck with concrete. Permanently anchor units placed by the end of each working day. Do not support suspended ceilings, light fixtures, ducts, utilities, or other loads by steel deck unless indicated. Loads shall be distributed by appropriate means to prevent damage. Shoring shall be in position before concrete placement begins in composite or form deck. Acoustical material shall be neatly fitted into the rib voids.

3.2.1 Attachment

Immediately after placement and alignment, and after correcting inaccuracies, permanently fasten steel deck units to structural supports and to adjacent deck units by welding with normal 5/8 inch diameter puddle welds or fastened with screws, powder-actuated fasteners, or pneumatically driven fasteners in accordance with manufacturer's recommended procedure and SDI 31.