03 30 00.pdf

AFRL, RENOVATE H8 LABORATORY, B3 ULDF200308AE

SECTION 03 30 00

CAST-IN-PLACE CONCRETE

02/19, CHG 9: 08/24

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 CONCRETE INSTITUTE (ACI)

ACI 117 (2010; R 2015) Specifications for Tolerances for Concrete Construction and Materials and Commentary

ACI 121R (2008) Guide for Concrete Construction Quality Systems in Conformance with ISO

ACI 213R (2014; E2017) Guide for Structural Lightweight-Aggregate Concrete

ACI 301 (2020) Specifications for Structural Concrete

ACI 302.1R (2015) Guide for Concrete Floor and Slab Construction

ACI 304.2R (2017) Guide to Placing Concrete by Pumping Methods

ACI 304R (2000; R 2009) Guide for Measuring, Mixing, Transporting, and Placing Concrete

ACI 305.1 (2014) Specification for Hot Weather Concreting

ACI 305R (2020) Guide to Hot Weather Concreting

ACI 306.1 (1990; R 2002) Standard Specification for Cold Weather Concreting

ACI 306R (2016) Guide to Cold Weather Concreting

ACI 308.1 (2023) Specification for Curing Concrete

ACI MNL-2 (2019; 11th Edition) ACI Manual of Concrete Inspection

ACI MNL-15 (2020) Field Reference Manual:

Specifications for Concrete Construction ACI 301-20 with Selected ACI References

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ASTM INTERNATIONAL (ASTM)

ASTM A184/A184M (2024) Standard Specification for Welded Deformed Steel Bar Mats for Concrete Reinforcement

ASTM A615/A615M (2024) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

ASTM A934/A934M (2022) Standard Specification for Epoxy-Coated Prefabricated Steel Reinforcing Bars

ASTM A1044/A1044M (2016a; Errata 1) Standard Specification for Steel Stud Assemblies for Shear Reinforcement of Concrete

ASTM A1064/A1064M (2024) Standard Specification for Carbon-Steel Wire and Welded Wire Reinforcement, Plain and Deformed, for Concrete

ASTM C31/C31M (2024c) Standard Practice for Making and Curing Concrete Test Specimens in the Field

ASTM C33/C33M (2024a) Standard Specification for Concrete Aggregates

ASTM C39/C39M (2024) Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

ASTM C42/C42M (2020) Standard Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete

ASTM C78/C78M (2022) Standard Test Method for Flexural Strength of Concrete (Using Simple Beam with Third-Point Loading)

ASTM C94/C94M (2024c) Standard Specification for Ready-Mixed Concrete

ASTM C136/C136M (2019) Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates

ASTM C138/C138M (2024a) Standard Test Method for Density (Unit Weight), Yield, and Air Content (Gravimetric) of Concrete

ASTM C143/C143M (2020) Standard Test Method for Slump of Hydraulic-Cement Concrete

ASTM C150/C150M (2024) Standard Specification for Portland Cement

ASTM C172/C172M (2017) Standard Practice for Sampling Freshly Mixed Concrete

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ASTM C173/C173M (2024a) Standard Test Method for Air Content of Freshly Mixed Concrete by the Volumetric Method

ASTM C231/C231M (2024) Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method

ASTM C260/C260M (2010a; R 2016) Standard Specification for Air-Entraining Admixtures for Concrete

ASTM C311/C311M (2024) Standard Test Methods for Sampling and Testing Fly Ash or Natural Pozzolans for Use in Portland-Cement Concrete

ASTM C330/C330M (2017a) Standard Specification for Lightweight Aggregates for Structural Concrete

ASTM C494/C494M (2024) Standard Specification for Chemical Admixtures for Concrete

ASTM C567/C567M (2019) Determining Density of Structural Lightweight Concrete

ASTM C595/C595M (2024) Standard Specification for Blended Hydraulic Cements

ASTM C618 (2023; E 2023) Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

ASTM C803/C803M (2023) Standard Test Method for Penetration Resistance of Hardened Concrete

ASTM C873/C873M (2015) Standard Test Method for Compressive Strength of Concrete Cylinders Cast in Place in Cylindrical Molds

ASTM C900 (2015) Standard Test Method for Pullout Strength of Hardened Concrete

ASTM C920 (2018; R 2024) Standard Specification for Elastomeric Joint Sealants

ASTM C989/C989M (2024) Standard Specification for Slag Cement for Use in Concrete and Mortars

ASTM C1074 (2019; E 2021) Standard Practice for Estimating Concrete Strength by the Maturity Method

ASTM C1077 (2024) Standard Practice for Agencies Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Testing Agency Evaluation

ASTM C1107/C1107M (2020) Standard Specification for Packaged

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Dry, Hydraulic-Cement Grout (Nonshrink)

ASTM C1157/C1157M (2023) Standard Performance Specification for Hydraulic Cement

ASTM C1218/C1218M (2020c) Standard Test Method for Water-Soluble Chloride in Mortar and Concrete

ASTM C1260 (2023) Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar-Bar Method)

ASTM C1293 (2008; R 2015) Standard Test Method for Determination of Length Change of Concrete Due to Alkali-Silica Reaction

ASTM C1567 (2023) Standard Test Method for Potential Alkali-Silica Reactivity of Combinations of Cementitious Materials and Aggregate (Accelerated Mortar-Bar Method)

ASTM C1602/C1602M (2022) Standard Specification for Mixing Water Used in Production of Hydraulic Cement Concrete

ASTM D1751 (2018) Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types)

ASTM D2628 (1991; R 2016) Standard Specification for Preformed Polychloroprene Elastomeric Joint Seals for Concrete Pavements

ASTM D2835 (1989; R 2017) Standard Specification for Lubricant for Installation of Preformed Compression Seals in Concrete Pavements

ASTM D5759 (2012; R 2020) Characterization of Coal Fly Ash and Clean Coal Combustion Fly Ash for Potential Uses

ASTM D6690 (2021) Standard Specification for Joint and Crack Sealants, Hot Applied, for Concrete and Asphalt Pavements

ASTM E96/E96M (2024) Standard Test Methods for Gravimetric Determination of Water Vapor Transmission Rate of Materials

ASTM E329 (2023) Standard Specification for Agencies Engaged in Construction Inspection, Testing, or Special Inspection

ASTM E1155 (2020) Standard Test Method for Determining Floor Flatness and Floor Levelness Numbers

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ASTM E1643 (2018a) Standard Practice for Selection, Design, Installation, and Inspection of Water Vapor Retarders Used in Contact with Earth or Granular Fill Under Concrete Slabs

ASTM E1745 (2017; R 2023) Standard Specification for Water Vapor Retarders Used in Contact with Soil or Granular Fill under Concrete Slabs

COMPOSITE PANEL ASSOCIATION (CPA)

ANSI/CPA A135.4 (2012; R2020) Basic Hardboard

CONCRETE REINFORCING STEEL INSTITUTE (CRSI)

CRSI 10MSP (2018; Errata 2019) Manual of Standard Practice

CRSI RB4.1 (2016) Supports for Reinforcement Used in Concrete

FOREST STEWARDSHIP COUNCIL (FSC)

FSC STD 01 001 (2015) Principles and Criteria for Forest Stewardship

NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY (NIST)

NIST PS 1 (2009) DOC Voluntary Product Standard PS 1-07, Structural Plywood

U.S. ARMY CORPS OF ENGINEERS (USACE)

COE CRD-C 104 (1980) Method of Calculation of the Fineness Modulus of Aggregate

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FS SS-S-200 (Rev E; Notice 1; Notice 2) Sealant, Joint, Two-Component, Jet-Blast-Resistant, Cold-Applied, for Portland Cement Concrete Pavement

1.2 DEFINITIONS

a. "Cementitious material" as used herein includes all portland cement, pozzolan, fly ash, slag cement, and silica fume.

b. "Exposed to public view" means situated so that it can be seen from eye level from a public location after completion of the building. A public location is accessible to persons not responsible for operation or maintenance of the building.

c. "Chemical admixtures" are materials in the form of powder or fluids that are added to the concrete to give it certain characteristics not obtainable with plain concrete mixes.

d. "Supplementary cementing materials" (SCM) include coal fly ash and

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slag cement when used in such proportions to replace the portland cement that result in improvement to sustainability and durability and reduced cost.

e. "Design strength" (f'c) is the specified compressive strength of concrete at time(s) specified in this section to meet structural design criteria.

f. "Mass Concrete" is any concrete system that approaches a maximum temperature of 158 degrees F within the first 72 hours of placement.

In addition, it includes all concrete elements with a section thickness of 3 feet or more regardless of temperature.

g. "Mixture proportioning" is the process of designing concrete mixture proportions to enable it to meet the strength, service life and constructability requirements of the project while minimizing the initial and life-cycle cost.

h. "Mixture proportions" are the masses or volumes of individual ingredients used to make a unit measure (cubic meter or cubic yard) of concrete.

i. "Pozzolan" is a siliceous or siliceous and aluminous material, which in itself possesses little or no cementitious value but will, in finely divided form and in the presence of moisture, chemically react with calcium hydroxide at ordinary temperatures to form compounds possessing cementitious properties.

j. "Workability (or consistence)" is the ability of a fresh (plastic) concrete mix to fill the form/mould properly with the desired work (vibration) and without reducing the concrete's quality. Workability depends on water content, chemical admixtures, aggregate (shape and size distribution), cementitious content and age (level of hydration).

1.3 SUBMITTALS

Government approval is required for submittals with a "G" or "S" classification. Submittals not having a "G" or "S" classification are for Contractor Quality Control approval. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Quality Control Program ; G

Quality Control Personnel Certifications ; G

Quality Control Organizational Chart

Laboratory Accreditation ; G

Maturity Method Data

SD-02 Shop Drawings

Reinforcing Steel ; G

SD-03 Product Data

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Joint Sealants ; S

Joint Filler ; S

Formwork Materials

Cementitious Materials ; S

Vapor Retarder

Concrete Curing Materials

Reinforcement ; S

Liquid Chemical Floor Hardeners and Sealers

Admixtures

Local/Regional Materials ; S

Biodegradable Form Release Agent

Nonshrink Grout

SD-04 Samples

SD-05 Design Data

Concrete Mix Design ; G

SD-06 Test Reports

Concrete Mix Design ; G

Fly Ash

Slag Cement

Aggregates

Compressive Strength Tests ; G

Unit Weight of Structural Concrete

Slump Tests

Water

SD-07 Certificates

Reinforcing Bars

VOC Content for Form Release Agents, Curing Compounds, and Concrete Penetrating Sealers

Safety Data Sheets

Forest Stewardship Council (FSC) Certification

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Field Testing Technician and Testing Agency

SD-08 Manufacturer's Instructions

Liquid Chemical Floor Hardeners and Sealers

Joint Sealants ; S

Curing Compound

1.4 MODIFICATION OF REFERENCES

Accomplish work in accordance with ACI publications except as modified herein. Consider the advisory or recommended provisions to be mandatory.

Interpret reference to the "Building Official," the "Structural Engineer," and the "Architect/Engineer" to mean the Contracting Officer.

1.5 DELIVERY, STORAGE, AND HANDLING

Follow ACI 301 , ACI 304R and ASTM A934/A934M requirements and recommendations. Do not deliver concrete until vapor retarder, forms, reinforcement, embedded items, and chamfer strips are in place and ready for concrete placement. Do not store concrete curing compounds or sealers with materials that have a high capacity to adsorb volatile organic compound (VOC) emissions. Do not store concrete curing compounds or sealers in occupied spaces.

1.5.1 Reinforcement

Store reinforcement of different sizes and shapes in separate piles or racks raised above the ground to avoid excessive rusting. Protect from contaminants such as grease, oil, and dirt. Ensure bar sizes can be accurately identified after bundles are broken and tags removed.

1.6 QUALITY ASSURANCE

1.6.1 Design Data

1.6.1.1 Concrete Mix Design

Sixty days minimum prior to concrete placement, submit a mix design for each strength and type of concrete. Submit all documentation required in ACI 301 Section 4 and as specified in this section. Submit a complete list of materials including type; brand; source and amount of cement, supplementary cementitious materials, and admixtures; and applicable reference specifications. Submit mill test and all other test for cement, supplementary cementitious materials, aggregates, and admixtures. Provide documentation of maximum nominal aggregate size, gradation analysis, percentage retained and passing sieve, and a graph of percentage retained verses sieve size. Provide mix proportion data using at least three different water-cementitious material ratios for each type of mixture, which produce a range of strength encompassing those required for each type of concrete required. If source material changes, resubmit mix proportion data using revised source material. Provide only materials that have been proven by trial mix studies to meet the requirements of this specification, unless otherwise approved in writing by the Contracting Officer. Indicate clearly in the submittal where each mix design is used when more than one mix design is submitted. Resubmit data

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on concrete components if the qualities or source of components changes.

Required average strength can be documented by field experience if field strength test data are available and represent a single group of at least 10 consecutive strength tests for one mixture, using materials and conditions similar to those expected for work, and encompassing a period of not less than 45 days. The average of field strength tests must equal or exceed fcr'. Changes in materials, conditions, and proportions within the test record must not have been more closely restricted than those for the proposed work. Test records must not be more than 24 months old.

Obtain mix design approval from the contracting officer prior to concrete placement.

1.6.2 Shop Drawings

1.6.2.1 Reinforcing Steel

Indicate bending diagrams, assembly diagrams, splicing and laps of bars, shapes, dimensions, and details of bar reinforcing, accessories, and concrete cover. Do not scale dimensions from structural drawings to determine lengths of reinforcing bars. Reproductions of contract drawings are unacceptable.

1.6.3 Control Submittals

1.6.3.1 VOC Content for form release agents, curing compounds, and concrete penetrating sealers

Submit certification for the form release agent, curing compounds, and concrete penetrating sealers that indicate the VOC content of each product.

1.6.3.2 Safety Data Sheets

Submit Safety Data Sheets (SDS) for all materials that are regulated for hazardous health effects. SDS must be readily accessible during each work shift to employees when they are at the construction site.

1.6.4 Test Reports

1.6.4.1 Fly Ash

Submit test results in accordance with ASTM C618 for fly ash. Submit test results performed within 6 months of submittal date.

1.6.4.2 Slag Cement

Submit test results in accordance with ASTM C989/C989M for slag cement.

Submit test results performed within 6 months of submittal date.

1.6.4.3 Aggregates

Submit test results in accordance with ASTM C33/C33M, or ASTM C330/C330M for lightweight aggregate, and ASTM C1293 or ASTM C1567 as required in the paragraph titled ALKALI-AGGREGATE REACTION.

1.6.5 Quality Control Program

Develop and submit for approval a concrete quality control program in accordance with the guidelines of ACI 121R and as specified herein.

Include approved laboratories. Provide direct oversight for the concrete

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qualification program inclusive of associated sampling and testing.

Provide all quality control reports to the Contracting Officer, Quality Manager and Concrete Supplier. Maintain a copy of ACI MNL-15 and CRSI 10MSP at project site.

1.6.6 Quality Control Personnel Certifications

Submit for approval the responsibilities of the various quality control personnel, including the names and qualifications of the individuals in those positions and a quality control organizational chart defining the quality control hierarchy and the responsibility of the various positions. Quality control personnel must be employed by the Contractor.

Submit American Concrete Institute certification for the following:

a. CQC personnel responsible for inspection of concrete operations.

b. Lead Foreman or Journeyman of the Concrete Placing, Finishing, and Curing Crews.

c. Field Testing Technicians: ACI Concrete Field Testing Technician, Grade I.

1.6.6.1 Quality Manager Qualifications

Holds a current license as a professional engineer in a U.S. state or territory with experience on at least five similar projects. Evidence of extraordinary proven experience may be considered by the Contracting Officer as sufficient to act as the Quality Manager.

1.6.6.2 Field Testing Technician and Testing Agency

Submit data on qualifications of proposed testing agency and technicians for approval by the Contracting Officer prior to performing testing on concrete.

a. Work on concrete under this contract must be performed by an ACI Concrete Field Testing Technician Grade 1 qualified in accordance with ACI MNL-2 or equivalent. Equivalent certification programs must include requirements for written and performance examinations as stipulated in ACI MNL-2 .

b. Testing agencies that perform testing services on reinforcing steel must meet the requirements of ASTM E329.

c. Testing agencies that perform testing services on concrete materials must meet the requirements of ASTM C1077.

1.6.7 Laboratory Qualifications for Concrete Qualification Testing

The concrete testing laboratory must have the necessary equipment and experience to accomplish required testing. The laboratory must meet the requirements of ASTM C1077 and be Cement and Concrete Reference Laboratory (CCRL) inspected.

1.6.8 Laboratory Accreditation

Laboratory and testing facilities are provided by and at the expense of the Contractor. The laboratories performing the tests must be accredited

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in accordance with ASTM C1077, including ASTM C78/C78M and ASTM C1260.

The accreditation must be current and must include the required test methods, as specified. Furthermore, comply with the following requirements:

a. Aggregate Testing and Mix Proportioning: Studies performed by an accredited laboratory and under the direction of a registered professional engineer in a U.S. state or territory competent in concrete materials who is competent in concrete materials and must sign all reports and designs.

b. Acceptance Testing: Furnish all materials, labor, and facilities required for molding, curing, testing, and protecting test specimens at the site and in the laboratory. Furnish and maintain boxes or other facilities suitable for storing and curing the specimens at the site while in the mold within the temperature range stipulated by

ASTM C31/C31M.

c. Contractor Quality Control: All sampling and testing must be performed by an approved, onsite, independent, accredited laboratory.

1.7 ENVIRONMENTAL REQUIREMENTS

Provide space ventilation according to material manufacturer recommendations, at a minimum, during and following installation of concrete curing compound and sealer. Maintain one of the following ventilation conditions during the curing period or for 72 hours after installation:

a. Supply 100 percent outside air 24 hours a day.

b. Supply airflow at a rate of 6 air changes per hour, when outside temperatures are between 55 degrees F and 84 degrees F and humidity is between 30 percent and 60 percent.

c. Supply airflow at a rate of 1.5 air changes per hour, when outside air conditions are not within the range stipulated above.

1.7.1 Submittals for Environmental Performance

a. Provide data indication the percentage of post-industrial pozzolan (fly ash, slag cement) cement substitution as a percentage of the full product composite by weight.

b. Provide data indicating the percentage of post-industrial and post-consumer recycled content aggregate.

c. Provide product data indicating the percentage of post-consumer recycled steel content in each type of steel reinforcement as a percentage of the full product composite by weight.

d. Provide product data stating the location where all products were manufactured

e. For projects using FSC certified formwork, provide chain-of-custody documentation for all certified wood products.

f. For projects using reusable formwork, provide data showing how formwork is reused.

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g. Provide SDS product information data showing that form release agents meet any environmental performance goals such as using vegetable and soy based products.

h. Provide SDS product information data showing that concrete adhesives meet any environmental performance goals including low emitting, low volatile organic compound products.

1.8 SUSTAINABLE DESIGN REQUIREMENTS

1.8.1 Local/Regional Materials

Use materials or products extracted, harvested, or recovered, as well as manufactured, within a 500 mile radius from the project site, if available from a minimum of three sources. Submit documentation indicating distance between manufacturing facility and the project site. Indicate distance of raw material origin from the project site. Indicate relative dollar value of local/regional materials to total dollar value of products included in project.

1.8.2 Forest Stewardship Council (FSC) Certification

Use FSC-certified wood where specified. Provide letter of certification signed by lumber supplier. Indicate compliance with FSC STD 01 001 and identify certifying organization. Submit FSC certification numbers;

identify each certified product on a line-item basis. Submit copies of invoices bearing the FSC certification numbers.

PART 2 PRODUCTS

2.1 FORMWORK MATERIALS

a. Form-facing material in contact with concrete must be lumber, plywood, or tempered concrete-form-grade hardboard. Submit product information on proposed form-facing materials if different from that specified herein.

b. Design formwork, shores, reshores, and backshores to support loads transmitted to them and to comply with applicable building code requirements.

c. Design formwork and shoring for load redistribution resulting from stressing of post-tensioned reinforcement. Ensure that formwork allows movement resulting from application of prestressing force.

d. Design formwork to withstand pressure resulting from placement and vibration of concrete and to maintain specified tolerances.

e. Design formwork to accommodate waterstop materials in joints at locations indicated in Contract Documents.

f. Provide temporary openings in formwork if needed to facilitate cleaning and inspection.

g. Design formwork joints to inhibit leakage of mortar.

h. Limit deflection of facing materials for concrete surfaces exposed to view to 1/400 of center-to-center spacing of facing supports.

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i. Do not use earth cuts as forms for vertical or sloping surfaces.

j. Submit product information on proposed form-facing materials if different from that specified herein.

k. Submit manufacturer's product data on form liner proposed for use with each formed surface.

2.1.1 Wood Forms

Use lumber as specified in Section 06 10 00 ROUGH CARPENTRY and as follows. Provide lumber that is square edged or tongue-and-groove boards, free of raised grain, knotholes, or other surface defects. Provide plywood that complies with NIST PS 1 , B-B concrete form panels or better or ANSI/CPA A135.4 , hardboard for smooth form lining. Submit data verifying that composite wood products contain no urea formaldehyde resins.

2.1.1.1 Concrete Form Plywood (Standard Rough)

Provide plywood that conforms to NIST PS 1 , B-B, concrete form, not less than 5/8-inch thick.

2.1.1.2 Overlaid Concrete Form Plywood (Standard Smooth)

Provide plywood that conforms to NIST PS 1 , B-B, high density form overlay, not less than 5/8-inch thick.

2.2 FORMWORK ACCESSORIES

a. Use commercially manufactured formwork accessories, including ties and hangers.

b. Form ties and accessories must not reduce the effective cover of the reinforcement.

2.2.1 Form Ties

a. Use form ties with ends or end fasteners that can be removed without damage to concrete.

b. Where indicated in Contract Documents, use form ties with integral water barrier plates or other acceptable positive water barriers in walls.

c. The breakback distance for ferrous ties must be at least 2 in. for Surface Finish-2.0 or Surface Finish-3.0, as defined in ACI 301 .

d. If the breakback distance is less than 3/4 in. , use coated or corrosion-resistant ties.

e. Submit manufacturer's data sheet on form ties.

2.2.2 Biodegradable Form Release Agent

a. Provide form release agent that is colorless, biodegradable, and water-based, with a zero VOC content.

b. Provide product that does not bond with, stain, or adversely affect

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concrete surfaces and does not impair subsequent treatments of concrete surfaces.

c. Provide form release agent that reduces formwork moisture absorption, and does not contain diesel fuel, petroleum-based lubricating oils, waxes, or kerosene. Submit documentation indicating type of biobased material in product and biobased content. Indicate relative dollar value of biobased content products to total dollar value of products included in project.

d. Submit manufacturer's product data on formwork release agent for use on each form-facing material.

2.2.3 Chamfer Materials

Use lumber materials with dimensions of 3/4 x 3/4 in .

2.2.4 Construction and Movement Joints

a. Submit details and locations of construction joints in accordance with the requirements herein.

b. Locate construction joints within middle one-third of spans of slabs, beams, and girders. If a beam intersects a girder within the middle one-third of girder span, the distance between the construction joint in the girder and the edge of the beam must be at least twice the width of the larger member.

c. Locate construction joints in walls and columns at underside of slabs, beams, or girders and at tops of footings or slabs.

d. Make construction joints perpendicular to main reinforcement.

e. Provide movement joints where indicated in Contract Documents or in accepted alternate locations.

f. Submit location and detail of movement joints if different from those indicated in Contract Documents.

g. Submit manufacturer's data sheet on expansion joint materials.

h. Provide keyways where indicated in Contract Documents.

2.2.5 Other Embedded items

Use sleeves, inserts, anchors, and other embedded items of material and design indicated in Contract Documents.

2.3 CONCRETE MATERIALS

2.3.1 Cementitious Materials

2.3.1.1 Portland Cement

a. Unless otherwise specified, provide cement that conforms to ASTM C150/C150M Type I , II , III.

b. Use one brand and type of cement for formed concrete having

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exposed-to-view finished surfaces.

c. Submit information along with evidence demonstrating compliance with referenced standards. Include types of cementitious materials, manufacturing locations, shipping locations, and certificates showing compliance.

d. Store cementitious materials and keep dry and free from contaminants.

2.3.1.2 Blended Cements

a. Conform to ASTM C595/C595M Type IL or ASTM C1157/C1157M Type GU , HE.

2.3.1.3 Fly Ash

a. ASTM C618, Class F , Class C, except that the maximum allowable loss on ignition must not exceed 6 percent.

b. If fly ash is used it must range from 15 to 20 percent by weight of cementitious material, provided the fly ash does not reduce the amount of cement in the concrete mix below the minimum requirements of local building codes. Do not use fly ash when it cannot meet the minimum level. Report the chemical analysis of the fly ash in accordance with ASTM C311/C311M. Evaluate and classify fly ash in accordance with

ASTM D5759.

2.3.1.4 Slag Cement

ASTM C989/C989M, Grade 100 , 120.

2.3.2 Water

a. Water or ice must comply with the requirements of ASTM C1602/C1602M .

b. Minimize the amount of water in the mix. Improve workability by adjusting the grading of the aggregate and using admixture rather than by adding water.

c. Provide water potable; free from injurious amounts of oils, acids, alkalis, salts, organic materials, or other substances deleterious to concrete.

d. Protect mixing water and ice from contamination during storage and delivery.

e. Submit test report showing water complies with ASTM C1602/C1602M .

2.3.3 Aggregate

2.3.3.1 Normal-Weight Aggregate

a. Conform to ASTM C33/C33M.

b. Obtain aggregates used in concrete from the same sources and have the same size range as aggregates used in concrete represented by submitted field test records or used in trial mixtures.

c. Provide sand that is at least 50 percent natural sand.

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d. Store and handle aggregate in a manner that will avoid segregation and prevents contamination by other materials or other sizes of aggregates. Store aggregates in locations that will permit them to drain freely. Do not use aggregates that contain frozen lumps.

e. Submit types, pit or quarry locations, producers' names, aggregate supplier statement of compliance with ASTM C33/C33M, and ASTM C1293 expansion data not more than 18 months old.

2.3.3.2 Lightweight Aggregate

Lightweight aggregate in accordance with ASTM C330/C330M.

2.3.4 Admixtures

a. Chemical admixtures must conform to ASTM C494/C494M.

b. Air-entraining admixtures must conform to ASTM C260/C260M.

c. Do not use calcium chloride admixtures.

d. Admixtures used in concrete must be the same as those used in the concrete represented by submitted field test records or used in trial mixtures.

e. Protect stored admixtures against contamination, evaporation, or damage.

f. To ensure uniform distribution of constituents, provide agitating equipment for admixtures used in the form of suspensions or unstable solutions. Protect liquid admixtures from freezing and from temperature changes that would adversely affect their characteristics.

g. Submit types, brand names, producers' names, manufacturer's technical data sheets, and certificates showing compliance with standards required herein.

2.4 MISCELLANEOUS MATERIALS

2.4.1 Concrete Curing Materials

Provide concrete curing material in accordance with ACI 301 Section 5 and ACI 308.1 Section 2. Submit product data for concrete curing compound s.

Submit manufactures instructions for placement of curing compound.

2.4.2 Nonshrink Grout

Nonshrink grout in accordance with ASTM C1107/C1107M .

2.4.3 Floor Finish Materials

2.4.3.1 Liquid Chemical Floor Hardeners and Sealers

a. Hardener must be a colorless aqueous solution containing a blend of inorganic silicate or siliconate material and proprietary components combined with a wetting agent; that penetrates, hardens, and densifies concrete surfaces. Submit manufactures instructions for placement of liquid chemical floor hardener.

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b. Use concrete penetrating sealers with a low (maximum 100 grams/liter, less water and less exempt compounds) VOC content. Submit manufactures instructions for placement of sealers.

2.4.4 Expansion/Contraction Joint Filler

ASTM D1751. Provide material 1/2 inch thick, unless otherwise indicated.

2.4.5 Joint Sealants

Submit manufacturer's product data, indicating VOC content.

2.4.5.1 Horizontal Surfaces, 3 Percent Slope, Maximum

ASTM D6690 or ASTM C920, Type M, Class 25, Use T.

2.4.5.2 Vertical Surfaces Greater Than 3 Percent Slope

ASTM C920, Type M, Grade NS, Class 25, Use T. FS SS-S-200 , no sag.

2.4.5.3 Preformed Polychloroprene Elastomeric Type

ASTM D2628.

2.4.5.4 Lubricant for Preformed Compression Seals

ASTM D2835.

2.4.6 Vapor Retarder

ASTM E1745 Class A polyethylene sheeting, minimum 10 mil thickness or other equivalent material with a maximum permeance rating of 0.04 perms per ASTM E96/E96M.

Consider plastic vapor retarders and adhesives with a high recycled content, low toxicity low VOC (Volatile Organic Compounds) levels.

2.5 CONCRETE MIX DESIGN

2.5.1 Properties and Requirements

a. Use materials and material combinations listed in this section and the contract documents.

b. Cementitious material content must be adequate for concrete to satisfy the specified requirements for strength, w/cm, durability, and finishability described in this section and the contract documents.

c. Selected target slump must meet the requirements of this section, the contract documents, and must not exceed 9 in . Concrete must not show visible signs of segregation.

d. Enforce the target slump for the duration of the project. Determine the slump by ASTM C143/C143M. Slump tolerances must meet the requirements of ACI 117 .

e. The nominal maximum size of coarse aggregate for a mixture must not exceed three-fourths of the minimum clear spacing between

SECTION 03 30 00 PAGE 17

reinforcement, one-fifth of the narrowest dimension between sides of forms, or one-third of the thickness of slabs or toppings.

f. Concrete must be air entrained for members assigned to Exposure Class F1, F2, or F3, with the total air content in accordance with the requirements of the paragraph titled DURABILITY.

g. Measure air content at the point of delivery in accordance with ASTM C173/C173M or ASTM C231/C231M.

h. Concrete for slabs to receive a hard-troweled finish must not contain an air-entraining admixture or have a total air content greater than 3 percent.

i. Use fly ash or slag cement as needed to reduce the total amount of Portland cement or blended hydraulic cement, which would otherwise be used, by not less than 20 percent. .

j. Concrete properties and requirements for each portion of the structure are specified in the table below. Refer to the paragraph titled DURABILITY for more details on exposure categories and their requirements.

Minimum f'c psi Exposure Categories^

Miscellaneous Requirements

Footings at 28 days

S0;

C0;

W0;

F0

Max. slump: 6 in.

Nominal maximum aggregate size must be 1- 1/2 in.

Columns / walls Piers and Pedestals

28 days

S0;

C0;

W0;

F0

Nominal maximum aggregate size must be 1- 1/2 in.

Slabs-on-ground 3000 at 28 days

S0;

C0;

W0;

F0

Nominal maximum aggregate size must be 3/4 in.

Lightweight concrete suspended slab at 28 days

S0;

C0;

W0;

F0

Max. density of 11 0 (pounds per cubic foot)

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2.5.2 Durability

2.5.2.1 Alkali-Aggregate Reaction

Do not use any aggregate susceptible to alkali-carbonate reaction (ACR).

Use one of the three options below for qualifying concrete mixtures to reduce the potential of alkali-silica reaction (ASR):

a. For each aggregate used in concrete, the expansion result determined in accordance with ASTM C1293 must not exceed 0.04 percent at one year.

b. For each aggregate used in concrete, the expansion result of the aggregate and cementitious materials combination determined in accordance with ASTM C1567 must not exceed 0.10 percent at an age of 16 days.

2.5.2.2 Freezing and Thawing Resistance

a. Provide concrete meeting the following requirements based on exposure class assigned to members for freezing-and-thawing exposure in Contract Documents:

Exposure class Maximum w/cm* Minimum f'c, psi Air content Additional Requirements

F0 N/A 2500 N/A

*The maximum w/cm limits do not apply to lightweight concrete.

2.5.2.3 Corrosion and Chloride Content

a. Provide concrete meeting the requirements of the following table based on the exposure class assigned to members requiring protection against reinforcement corrosion in Contract Documents.

b. Submit documentation verifying compliance with specified requirements.

c. Determine water-soluble chloride ion content contributed from constituents including water, aggregates, cementitious materials, and admixtures for the concrete mixture by ASTM C1218/C1218M at age between 28 and 42 days.

d. The maximum water-soluble chloride ion (Cl-) content in concrete, percent by mass of cement is as follows:

Exposure class

Maximum w/cm*

Minimum f'c, psi

Maximum water-soluble chloride ion (CL-) content in concrete, percent by mass of cement

Reinforced concrete

C0 N/A 2500 1.00

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*The maximum w/cm limits do not apply to lightweight concrete.

2.5.2.4 Sulfate Resistance

a. Provide concrete meeting the requirements of the following table based on the exposure class assigned to members for sulfate exposure.

Exposure class

Maximum w/cm

Minimum f'c, psi

Required cementitious materials-types Calcium chloride admixture

ASTM

C150/C150M

ASTM

C595/C595M

ASTM

C1157/C1157M

S0 N/A 2500 N/A N/A N/A No restrictions

b. The maximum w/cm limits for sulfate exposure do not apply to lightweight concrete.

2.5.2.5 Concrete Temperature

The temperature of concrete as delivered must not exceed 95 degrees F .

2.5.2.6 Concrete Permeability

a. Provide concrete meeting the requirements of the following table based on exposure class assigned to members requiring low permeability in the Contract Documents.

Exposure class

Maximum w/cm*

Minimum f'c, psi

Additional minimum requirements

W0 N/A 2500 None

*The maximum w/cm limits do not apply to lightweight concrete.

b. Submit documentation verifying compliance with specified requirements.

2.5.3 Trial Mixtures

In accordance with ACI 301 .

2.5.4 Ready-Mix Concrete

Provide concrete that meets the requirements of ASTM C94/C94M.

Ready-mixed concrete manufacturer must provide duplicate delivery tickets with each load of concrete delivered. Provide delivery tickets with the following information in addition to that required by ASTM C94/C94M:

a. Type and brand cement

b. Cement and supplementary cementitious materials content in 94-pound bags per cubic yard of concrete

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c. Maximum size of aggregate

d. Amount and brand name of admixtures

e. Total water content expressed by water cementitious material ratio

2.6 REINFORCEMENT

Shop Fabricate reinforcing bars to conform to shapes and dimensions indicated for reinforcement, and as follows:

a. Bend reinforcement cold. Reinforcement must be bent cold in the shop to shapes as indicated. Rebending of a reinforcing bar that has been bent incorrectly is not permitted. Bending must be in accordance with the standard approved practice and by approved machine methods.

Provide hooks and bends that are in accordance with the Contract Documents. Fabricate reinforcement in accordance with fabricating tolerances of ACI 117 .

b. Submit manufacturer's certified test report for reinforcement.

c. Submit placing drawings showing fabrication dimensions and placement locations of reinforcement and reinforcement supports. Indicate locations of splices, lengths of lap splices, and details of mechanical and welded splices.

d. Submit request with locations and details of splices not indicated in Contract Documents.

e. Submit request to place column dowels without using templates.

Deliver reinforcing bars bundled, tagged, and marked. Tags must be metal with bar size, length, mark, and other information pressed in by machine.

Marks must correspond with those used on the placing drawings.

2.6.1 Reinforcing Bars

a. Deformed, except spirals, load-transfer dowels, and welded wire reinforcement, which may be plain.

b. ASTM A615/A615M with the bars marked S, Grade 60 .

c. Submit mill certificates for reinforcing bars.

2.6.1.1 Bar Mats

a. Conform to ASTM A184/A184M .

2.6.1.2 Headed Shear Stud Reinforcement

Headed studs and headed stud assemblies must conform to ASTM A1044/A1044M .

2.6.2 Welded Wire Reinforcement

a. Use welded wire reinforcement specified in Contract Documents and conforming to one or more of the specifications given herein.

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b. Plain welded wire reinforcement must conform to ASTM A1064/A1064M , with welded intersections spaced no greater than 12 in. apart in direction of principal reinforcement.

c. Deformed welded wire reinforcement must conform to ASTM A1064/A1064M , with welded intersections spaced no greater than 16 in. apart in direction of principal reinforcement.

2.6.3 Reinforcing Bar Supports

a. Provide reinforcement support types within structure as required by Contract Documents. Conform to CRSI RB4.1 . Submit description of reinforcement supports and materials for fastening coated reinforcement if not in conformance with CRSI RB4.1 .

b. Legs of supports in contact with formwork may be hot-dip galvanized, or plastic coated after fabrication, or stainless-steel bar supports.

PART 3 EXECUTION

3.1 EXAMINATION

a. Do not begin installation until substrates have been properly constructed; verify that substrates are level.

b. If substrate preparation is the responsibility of another installer, notify Contracting Officer of unsatisfactory preparation before processing.

c. Check field dimensions before beginning installation. If dimensions vary too much from design dimensions for proper installation, notify Contracting Officer and wait for instructions before beginning installation.

3.2 PREPARATION

Determine quantity of concrete needed and minimize the production of excess concrete. Designate locations or uses for potential excess concrete before the concrete is poured.

3.2.1 General

a. Surfaces against which concrete is to be placed must be free of debris, loose material, standing water, snow, ice, and other deleterious substances before start of concrete placing.

b. Remove standing water without washing over freshly deposited concrete.

Divert flow of water through side drains provided for such purpose.

3.2.2 Subgrade Under Foundations and Footings

a. When subgrade material is semi-porous and dry, sprinkle subgrade surface with water as required to eliminate suction at the time concrete is deposited, or seal subgrade surface by covering surface with specified vapor retarder.

b. When subgrade material is porous, seal subgrade surface by covering

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surface with specified vapor retarder.

3.2.3 Subgrade Under Slabs on Ground

a. Before construction of slabs on ground, have underground work on pipes and conduits completed and approved.

b. Clean previously constructed subgrade or fill of foreign materials.

c. Finish surface of capillary water barrier under interior slabs on ground must not show deviation in excess of 1/4 inch when tested with a 10-foot straightedge parallel with and at right angles to building lines.

d. Finished surface of subgrade or fill under exterior slabs on ground must not be more than 0.02-foot above or 0.10-foot below elevation indicated.

3.2.4 Edge Forms and Screed Strips for Slabs

a. Set edge forms or bulkheads and intermediate screed strips for slabs to obtain indicated elevations and contours in finished slab surface, strong enough to support vibrating bridge screeds or roller pipe screeds if nature of specified slab finish requires use of such equipment.

b. Align concrete surface to elevation of screed strips by use of strike-off templates or approved compacting-type screeds.

3.2.5 Reinforcement and Other Embedded Items

a. Secure reinforcement, joint materials, and other embedded materials in position, inspected, and approved before start of concrete placing.

b. When concrete is placed, reinforcement must be free of materials deleterious to bond. Reinforcement with rust, mill scale, or a combination of both will be considered satisfactory, provided minimum nominal dimensions, nominal weight, and minimum average height of deformations of a hand-wire-brushed test specimen are not less than applicable ASTM specification requirements.

3.3 FORMS

a. Provide forms, shoring, and scaffolding for concrete placement. Set forms mortar-tight and true to line and grade.

b. Chamfer above grade exposed joints, edges, and external corners of concrete 0.75 inch . Place chamfer strips in corners of formwork to produce beveled edges on permanently exposed surfaces.

c. Provide formwork with clean-out openings to permit inspection and removal of debris.

d. Inspect formwork and remove foreign material before concrete is placed.

e. At construction joints, lap form-facing materials over the concrete of previous placement. Ensure formwork is placed against hardened concrete so offsets at construction joints conform to specified tolerances.

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f. Provide positive means of adjustment (such as wedges or jacks) of shores and struts. Do not make adjustments in formwork after concrete has reached initial setting. Brace formwork to resist lateral deflection and lateral instability.

g. Fasten form wedges in place after final adjustment of forms and before concrete placement.

h. Provide anchoring and bracing to control upward and lateral movement of formwork system.

i. Construct formwork for openings to facilitate removal and to produce opening dimensions as specified and within tolerances.

j. Provide runways for moving equipment. Support runways directly on formwork or structural members. Do not support runways on reinforcement. Loading applied by runways must not exceed capacity of formwork or structural members.

k. Position and support expansion joint materials and other embedded items to prevent displacement. Fill voids in sleeves, inserts, and anchor slots temporarily with removable material to prevent concrete entry into voids.

l. Clean surfaces of formwork and embedded materials of mortar, grout, and foreign materials before concrete placement.

3.3.1 Coating

a. Cover formwork surfaces with an acceptable material that inhibits bond with concrete.

b. If formwork release agent is used, apply to formwork surfaces in accordance with manufacturer's recommendations before placing reinforcement. Remove excess release agent on formwork prior to concrete placement.

c. Do not allow formwork release agent to contact reinforcement or hardened concrete against which fresh concrete is to be placed.

3.3.2 Reshoring

a. Do not allow structural members to be loaded with combined dead and construction loads in excess of loads indicated in the accepted procedure.

b. Install and remove reshores or backshores in accordance with accepted procedure.

c. For floors supporting shores under newly placed concrete, either leave original supporting shores in place, or install reshores or backshores. Shoring system and supporting slabs must resist anticipated loads. Locate reshores and backshores directly under a shore position or as indicated on formwork shop drawings.

d. In multistory buildings, place reshoring or backshoring over a sufficient number of stories to distribute weight of newly placed concrete, forms, and construction live loads.

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3.3.3 Reuse

a. Reuse forms providing the structural integrity of concrete and the aesthetics of exposed concrete are not compromised.

b. Wood forms must not be clogged with paste and must be capable of absorbing high water-cementitious material ratio paste.

c. Remove leaked mortar from formwork joints before reuse.

3.3.4 Forms for Standard Rough Form Finish

Provide formwork in accordance with ACI 301 Section 5 with a surface finish, SF-1.0, for formed surfaces that are to be concealed by other construction.

3.3.5 Forms for Standard Smooth Form Finish

Provide formwork in accordance with ACI 301 Section 5 with a surface finish, SF-3.0, for formed surfaces that are exposed to view.

3.3.6 Form Ties

a. For post-tensioned structures, do not remove formwork supports until stressing records have been accepted by the Contracting Officer.

b. After ends or end fasteners of form ties have been removed, repair tie holes in accordance with ACI 301 Section 5 requirements.

3.3.7 Tolerances for Form Construction

a. Construct formwork so concrete surfaces conform to tolerances in

ACI 117 .

b. Position and secure sleeves, inserts, anchors, and other embedded items such that embedded items are positioned within ACI 117 tolerances.

c. To maintain specified elevation and thickness within tolerances, install formwork to compensate for deflection and anticipated settlement in formwork during concrete placement. Set formwork and intermediate screed strips for slabs to produce designated elevation, camber, and contour of finished surface before formwork removal. If specified finish requires use of vibrating screeds or roller pipe screeds, ensure that edge forms and screed strips are strong enough to support such equipment.

3.3.8 Removal of Forms and Supports

a. If vertical formed surfaces require finishing, remove forms as soon as removal operations will not damage concrete.

b. Remove top forms on sloping surfaces of concrete as soon as removal will not allow concrete to sag. Perform repairs and finishing operations required. If forms are removed before end of specified curing period, provide curing and protection.

c. Do not damage concrete during removal of vertical formwork for

SECTION 03 30 00 PAGE 25

columns, walls, and sides of beams. Perform needed repair and finishing operations required on vertical surfaces. If forms are removed before end of specified curing period, provide curing and protection.

d. Leave formwork and shoring in place to support construction loads and weight of concrete in beams, slabs, and other structural members until in-place required strength of concrete is reached.

e. Form-facing material and horizontal facing support members may be removed before in-place concrete reaches specified compressive strength if shores and other supports are designed to allow facing removal without deflection of supported slab or member.

3.3.9 Strength of Concrete Required for Removal of Formwork

If removal of formwork, reshoring, or backshoring is based on concrete reaching a specified in-place strength, mold and field-cure cylinders in accordance with ASTM C31/C31M. Test cylinders in accordance with ASTM C39/C39M. Alternatively, use one or more of the methods listed herein to evaluate in-place concrete strength for formwork removal.

a. Tests of cast-in-place cylinders in accordance with ASTM C873/C873M.

This option is limited to slabs with concrete depths from 5 to 12 in .

b. Penetration resistance in accordance with ASTM C803/C803M.

c. Pullout strength in accordance with ASTM C900.

d. Maturity method in accordance with ASTM C1074.