FIO W912HV-21-R-0002-am0005 Revised Specifications.pdf

FY21 DLA DESC1904 UPGRADE FUEL WHARF 19SF0005

Tsurumi, Japan

SECTION 03 30 00

CAST-IN-PLACE CONCRETE

02/19

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 INTERNATIONAL (ACI)

ACI 301 (2016) Specifications for Structural Concrete

ACI 305R (2010) Guide to Hot Weather Concreting

ACI SP-2 (2007; Abstract: 10th Edition) ACI Manual of Concrete Inspection

ASTM INTERNATIONAL (ASTM)

ASTM A970/A970M (2018) Standard Specification for Headed Steel Bars for Concrete Reinforcement

ASTM C494/C494M (2017) Standard Specification for Chemical Admixtures for Concrete

ASTM C595/C595M (2018) Standard Specification for Blended Hydraulic Cements

ASTM C618 (2019) Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

ASTM C881/C881M (2015) Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete

ASTM C1012/C1012M (2018b) Standard Test Method for Length Change of Hydraulic-Cement Mortars Exposed to a Sulfate Solution

ASTM C1116/C1116M (2010a; R 2015) Standard Specification for Fiber-Reinforced Concrete

ASTM C1399/C1399M (2010; R 2015) Standard Test Method for Obtaining Average Residual-Strength of Fiber-Reinforced Concrete

JAPANESE ARCHITECTURAL STANDARDS SPECIFICAITONS (JASS)

JASS 5 (2015) Reinforced Concrete Work

JASS 6 (2015) Structural Steelwork Specification

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JAPANESE INDUSTRIAL STANDARDS (JIS)

JIS A 1101 (2014) Method of Test for Slump of Concrete

JIS A 1107 (2014) Method of Sampling and Testing for Compressive Strength of Drilled Cores of Concrete

JIS A 1108 (2018) Method of Test for Compressive Strength of Concrete

JIS A 1115 (2014) Method of Sampling Fresh Concrete

JIS A 1116 (2005) Method of Test for Unit Mass and Air Content of Fresh Concrete by Mass Method

JIS A 1118 (2017) Method of Test for Air Content of Fresh Concrete by Volumetric Method

JIS A 1128 (2014) Method of Test for Air Content of Fresh Concrete by Pressure Method

JIS A 1132 (2014) Method of Making and Curing Concrete Specimens

JIS A 1146 (2017) Method of Test for Alkali-Silica Reactivity of Aggregates by Mortar-bar Method

JIS A 1154 (2012) Method of Test for Chloride Ion Content in Hardened Concrete

JIS A 1804 (2009) Methods of Test for Production Control of Concrete - Method of Rapid Test for Identification of Alkali-Silica Reactivity of Aggregate

JIS A 5005 (2009) Crushed Stone and Manufactured Sand for Concrete

JIS A 5011 (2013) Slag Aggregate for Concrete

JIS A 5308 (2014) Ready-Mixed Concrete

JIS A 5758 (2016) Sealants for Sealing and Glazing in Buildings

JIS A 6201 (2015) Fly Ash for Use in Concrete

JIS A 6204 (2011) Chemical Admixtures for Concrete

JIS A 8652 (1995) Metal Panels for Concrete Form

JIS G 3112 (2010) Steel Bars for Concrete Reinforcement

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JIS G 3551 (2005) Welded Wire Mesh and Rebar Grid

JIS K 6258 (2016) Rubber, Vulcanized or Thermoplastic

- Determination of the Effect of Liquids

JIS Q 1011 (2009) Conformity Assessment – Conformity Assessment for Japanese Industrial Standards – Guidance on Third-party Certification System for Ready-mixed Concrete Products

JIS Q 17011 (2005) Conformity Assessment - General Requirements for Accreditation Bodies Accrediting Conformity Assessment Bodies

JIS Q 17025 (2005) General Requirements for the Competence of Testing and Calibration Laboratories

JIS R 5210 (2009) Portland Cement

JIS R 5211 (2019) Portland Blast-Furnace Slag Cement

JIS R 5212 (2019) Portland Pozzolan Cement

JIS Z 3881 (2014) Standard Qualification Procedure for Gas Pressure Welding Technique of Steel Bars for Concrete Reinforcement

MINISTRY OF LAND, INFRASTRUCTURE, TRANSPORT AND TOURISM,

GOVERNMENT OF JAPAN (MLIT)

MLIT-SS Chapter 6 MLIT Architectural Standard Specifications, Chapter 6 Concrete

U.S. GREEN BUILDING COUNCIL (USGBC)

LEED NC (2009) Leadership in Energy and Environmental Design(tm) New Construction Rating System

1.2 DEFINITIONS

a. "Cementitious material" as used herein must include all portland cement, pozzolan, fly ash, and slag cement.

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, slag cement, natural or calcined pozzolans, and ultra-fine coal ash when used in such proportions to replace the portland cement that result in improvement to sustainability and durability and reduced cost.

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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 70 degrees C within the first 72 hours of placement.

In addition, it includes all concrete elements with a section thickness of 1 meter 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" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Concrete Curing Plan

Quality Control Plan; G

Laboratory Accreditation; G

SD-02 Shop Drawings

Formwork

Reinforcing Steel; G

SD-03 Product Data

Formwork Materials

Reinforcement

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Liquid Chemical Hardeners and Sealers

Mechanical Reinforcing Bar Connectors

Pumping Concrete

Admixtures; G

Fiber Reinforcement

SD-04 Samples

SD-05 Design Data

Concrete Mix Design; G

SD-06 Test Reports

Concrete Mix Design; G

Fly Ash

Pozzolan

Slag Cement

Aggregates

Compressive Strength Tests; G

Unit Weight of Structural Concrete

Air Content

Slump Tests

Water

SD-07 Certificates

Reinforcing Bars

Welder Qualifications

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

Safety Data Sheets

Field Testing Technician and Testing Agency

SD-08 Manufacturer's Instructions

Liquid Chemical Hardeners and Sealers

Joint Sealants; ( LEED NC)

Curing Compound

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1.4 MODIFICATION OF REFERENCES

Accomplish work in accordance with JASS 5 and MLIT-SS Chapter 6 or 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 JASS 5 and MLIT-SS Chapter 6 , requirements and recommendations. Do not deliver concrete until 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 a complete list of materials including type; brand; source and amount of cement, supplementary cementitious materials, fibers, 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 on concrete components if the qualities or source of components changes.

For previously approved concrete mix designs used within the past twelve months, the previous mix design may be re-submitted without further trial batch testing if accompanied by material test data conducted within the last six months. 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, W912HV-21-R-0002 SECTION 03 30 00 Page 6 (AM-0005)

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1.6.3 Control Submittals

1.6.3.1 Concrete Curing Plan

Submit proposed materials, methods and duration for curing concrete elements in accordance with JASS 5 and MLIT-SS Chapter 6 .

1.6.3.2 Pumping Concrete

Submit proposed materials and methods for pumping concrete. Submittal must include mix designs, pumping equipment including type of pump and size and material for pipe, and maximum length and height concrete is to be pumped.

1.6.3.3 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.

1.6.3.4 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 and Pozzolan

Submit test results in accordance with JIS A 6201 for fly ash and pozzolan. Submit test results performed within 6 months of submittal date.

1.6.4.2 Slag Cement

Submit test results in accordance with JIS R 5211 for slag cement. Submit test results performed within 6 months of submittal date.

1.6.4.3 Aggregates

Submit test results in accordance with JIS A 5005 , JIS A 1146 and JIS A 1804 as required in the paragraph titled ALKALI-AGGREGATE REACTION.

1.6.5 Field Samples

1.6.6 Quality Control Plan

Develop and submit for approval a concrete quality control program in accordance with the guidelines of JASS 5 and MLIT-SS Chapter 6 and as specified herein. The plan must include approved laboratories. Provide direct oversight for the concrete qualification program inclusive of associated sampling and testing. All quality control reports must be provided to the Contracting Officer, Quality Manager and Concrete Supplier.

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1.6.7 Quality Control Personnel Certifications

The Contractor must 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 Japan Concrete Institute (JCI) or American Concrete Institute (ACI) 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 or equivalent Japan Concrete Institute (JCI) Concrete Field Testing Technician.

1.6.7.1 Quality Manager Qualifications

The quality manager must hold a current license as a First Class Kenchikushi architect registered under standard law of Japan 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.

1.6.7.2 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 SP-2 or equivalent JCI Concrete Field Testing Technician.

Equivalent certification programs must include requirements for written and performance examinations as stipulated in ACI SP-2 .

b. Testing agencies that perform testing services on concrete materials including reinforcing steel must meet the requirements of JASS 5 , JIS Q 1011 , JIS Q 17011 and JIS Q 17025 .

1.6.8 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 JASS 5 , JIS Q 1011 , JIS Q 17011 and JIS Q 17025 .

1.6.9 Laboratory Accreditation

Laboratory and testing facilities must be provided by and at the expense of the Contractor. The laboratories performing the tests must be accredited in accordance with JIS Q 17011 and JIS Q 17025 . The accreditation must be current and must include the required test methods, as specified. Furthermore, the testing must comply with the following requirements:

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a. Aggregate Testing and Mix Proportioning: Aggregate testing and mixture proportioning studies must be performed by an accredited laboratory and under the direction of a Chief Concrete Engineer or Concrete Engineer authorized by the Japan Concrete Institute or First Class Kenchikushi 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

JIS A 1132 .

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 13 degrees C and 29 degrees C 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.

1.8 QUALIFICATIONS FOR WELDING WORK

Welding procedures must be in accordance with JASS 6 .

Verify that Welder qualifications are in accordance with JIS Z 3881 for welding of reinforcement or under an equivalent qualification test approved in advance. Welders are permitted to do only the type of welding for which each is specifically qualified.

PART 2 PRODUCTS

2.1 FORMWORK MATERIALS

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

b. Design formwork, shores, reshores, and backshores to support all vertical and lateral 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

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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.

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 shop drawings for formwork, shoring, reshoring, and backshoring. Shop drawings must be signed and sealed by a licensed design engineer or First Class Kenchikushi.

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

2.1.1 Wood Forms

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 Japan Agricultural Standard concrete form panels or better or 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 Japan Agricultural Standard concrete form, not less than 16 mm thick.

2.1.1.2 Overlaid Concrete Form Plywood (Standard Smooth)

Provide plywood that conforms to Japan Agricultural Standard high density form overlay, not less than 16 mm thick.

2.1.2 Steel Forms

Provide JIS A 8652 steel form surfaces that do not contain irregularities, dents, or sags.

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.

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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. Submit manufacturer's data sheet on form ties.

2.2.2 Waterstops

Submit manufacturer's data sheet on waterstop materials and splices.

2.2.2.1 Thermoplastic Elastomeric Rubber Waterstop

Thermoplastic elastomeric rubber waterstops must be fuel resistant andconform to JIS K 6258 .

2.2.3 Biodegradable Form Release Agent

a. Provide form release agent that is colorless, biodegradable, and water-based, with a low (maximum of 55 grams/liter (g/l)) VOC content.

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

2.2.4 Chamfer Materials

Use lumber materials with dimensions of 20 x 20 mm.

2.2.5 Construction and movement joints

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

b. Locate construction joints in walls at underside of slabs, and at tops of footings or slabs.

c. Make construction joints perpendicular to main reinforcement.

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

e. Provide keyways where indicated in Contract Documents. Longitudinal keyways indicated in Contract Documents must be at least 40 mm deep, measured perpendicular to the plane of the joint.

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2.2.6 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

Cementitious materials shall be Portland cement or cement blended with supplementary cementing materials. New submittals are required when the cementitious materials change sources or types. The Contractor shall provide cementitious materials meeting the requirements of the applicable specification, and as modified herein. Provide a single manufacturer of cementitious material for each type of cement and supplementary cementing materials supplied to the project.

2.3.1.1 Portland Cement

a. Unless otherwise specified, provide cement that conforms to JIS R 5210 , Sulfate-resistant Portland Cement .

b. Use one brand and type of cement for formed concrete having exposed-to-view finished surfaces.

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

d. Cementitious materials must be stored and kept dry and free from contaminants.

2.3.1.2 Blended Cements

Blended cement shall conform to ASTM C595/C595M, Type IP or IS, or JIS R 5212 or JIS R 5211 , including the optional requirement for mortar expansion and sulfate soundness and consist of a mixture of JIS R 5210 portland cement and a supplementary cementing material. The slag added to the Type IS blend shall be JIS A 5011 ground granulated blast-furnace slag. The pozzolan added to the Type IP blend shall be JIS A 6201 fly ash and shall be interground with the cement clinker. The manufacturer shall state in writing that the amount of pozzolan in the finished cement will not vary more than plus or minus 5 mass percent of the finished cement from lot-to-lot or within a lot. The percentage and type of mineral admixture used in the blend shall not change from that submitted for the aggregate evaluation and mixture proportioning.

2.3.1.3 Pozzolan

a. Fly ash shall conform to JIS A 6201 or ASTM C618, Class F. Fly ash shall have a Calcium Oxide (CaO) content of less than 8 percent and a total equivalent alkali content less than 1.5 percent. Add with cement. Fly ash per ASTM C618, Class C is not permitted.

b. Raw or Calcined Natural Pozzolan shall conform to ASTM C618, Class N, including the optional requirements for uniformity and effectiveness in controlling Alkali-Silica reaction and shall have an on ignition loss not exceeding 3 percent. Class N pozzolan for use in mitigating

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Alkali-Silica Reactivity shall have a Calcium Oxide (CaO) content of less than 13 percent and total equivalent alkali content less than 3 percent.

2.3.1.4 Ground Granulated Blast-Furnace (GGBF) Slag

Ground granulated blast-furnace slag shall conform to JIS A 5011 , Part 1.

Add with cement.

2.3.1.5 Silica Fume

Silica fume is not allowed.

2.3.1.6 Supplementary Cementitious Materials (SCM) Content

The concrete mix shall always contain supplementary cementing materials whether or not the aggregates are found to be reactive in accordance with the paragraph AGGREGATES. Concrete mixtures shall be designed and proportioned to meet the requirements for strength, constructability, shrinkage, and service life.

2.3.2 Water

a. Water or ice must comply with the requirements of JIS A 5308 , Annex C.

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. Water must be 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 JIS A 5308 , Annex C.

2.3.3 Aggregate

2.3.3.1 Normal-Weight Aggregate

a. Aggregates must conform to JIS A 5005 unless otherwise specified in the Contract Documents or approved by the contracting officer.

b. Aggregates used in concrete must be obtained 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. 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.

d. Submit types, pit or quarry locations, producers' names, aggregate supplier statement of compliance with JIS A 5005 and JIS A 1804 expansion data not more than 18 months old.

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2.3.4 Admixtures

a. Chemical admixtures must conform to JIS A 6204 .

b. Air-entraining admixtures must conform to JIS A 6204 .

c. Chemical admixtures for use in producing flowing concrete must conform to JIS A 6204 .

d. Provide complex catalyzed hydrous silicate, water vapor proofing liquid admixture per ASTM C494/C494M Type S.

e. Provide crystalline waterproofing admixture. Admixture must be tested by an independent laboratory meeting the requirements of the recognized specifying body of Japan. Tests must be performed according to the "Input Method" of the Technical Institiute Concrete Guide 11-Physics of Concrete. Test results must meet or exceed following performance results: Dosed at 1% by weight, the crystalline admixture treated concrete must have shown an improved permeability diffusion coefficient of at least 60% in comparison with the untreated concrete.

Submit test results. Admixture must be registered under the New Technology Information System (NETIS).

f. Do not use calcium chloride admixtures

g. 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.

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

i. 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.

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

2.3.5 Fiber Reinforcement

Fiber reinforcement shall conform to ASTM C1116/C1116M Type III, 2 times the length of largest aggregate, with minimum tensile strength of 572 MPa.

Provide fibers that are fibrillated or monofilaments polypropylene fibers engineered and designed for use in concrete. Uniformly disperse fibers into concrete at manufacturer's recommended rate. The dosage must be sufficient enough to provide resistance to temperature and shrinkage cracks as well as minimize plastic shrinkage crack formation. Consult manufacturer for correct dosage and type as it relates to usage, concrete properties, joint spacing/details and construction means and methods. The manufacturer or contractor must prepare a plan indicating propose joint spacing and detail if not indicated on plan or if required to be modified by the type and dosage of fiber reinforcement. Average Residual Strength as tested per ASTM C1399/C1399M must not be less than 1.72 MPa. The manufacturer must submit a letter attesting to the correct dosage and type based on the aforementioned parameters. Maximum Water-Cementitious Material Ratio of concrete used shall not be greater than 0.50.

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2.4 MISCELLANEOUS MATERIALS

2.4.1 Concrete Curing Materials

Provide concrete curing material in accordance with JASS 5 and MLIT-SS Chapter 6 . Submit product data for concrete curing compounds.

Submit manufactures instructions for placement of curing compound.

2.4.2 Nonshrink Grout

Packaged dry, hydraulic cement non-shrink grout, that is non-metallic, non-corrosive, non-bleed, with the following performance requirements when prepared using the highest water-to-solids ratio, maximum flow, or most fluid consistency at 23.0 plus or minus 2.0 degrees C:

a. Minimum compressive strengths: 7.0 MPa at 1 day; 17.0 MPa at 3 day;

24.0 MPa at 7 day; and 34.0 MPa at 28 day.

b. Early height change (maximum percent at time of final setting): plus

4.0 percent.

c. Height change of moist cured hardened grout: 0.0 to plus or minus 0.3 percent at 1-day, 3-day, 14-day and 28-day.

2.4.3 Finish Materials

2.4.3.1 Liquid Chemical 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 hardener.

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 Joint Sealants and Seals

2.4.4.1 Horizontal Surfaces, 3 Percent Slope, Maximum

JIS A 5758 , multi-component sealant, Class 25, traffic.

2.4.4.2 Vertical Surfaces Greater Than 3 Percent Slope

JIS A 5758 , multi-component sealant, non-sag, Class 25, traffic.

2.4.5 Epoxy Materials

2.4.5.1 Epoxy Bonding Adhesive

ASTM C881/C881M two-component epoxy resin, Type IV or V.

2.4.5.2 Marine Epoxy Grout

Three component 100 percent solids, moisture insensitive, high strength, impact resistant epoxy grout designed for underwater use.

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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 this section, the contract documents, and must not exceed 230 mm. Concrete must not show visible signs of segregation.

d. The target slump must be enforced for the duration of the project.

Determine the slump by JIS A 1101 . Slump tolerances must meet the requirements of JASS 5 and MLIT-SS Chapter 6 .

e. The nominal maximum size of coarse aggregate for a mixture must not exceed three-fourths of the minimum clear spacing between 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. The total air content must be in accordance with the requirements of the paragraph titled DURABILITY.

g. Measure air content at the point of delivery in accordance with JIS A 1118 or JIS A 1128 .

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. 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 MPa Exposure Categories^

All Concrete 36 at 28 days

S3;

C2;

W1;

F2

2.5.2 Durability

2.5.2.1 Alkali-Aggregate Reaction

Do not use any aggregate susceptible to alkali-carbonate reaction (ACR) to reduce the potential of alkali-silica reaction (ASR). For each aggregate used in qualifying concrete mixtures, the expansion result of the aggregate and cementitious materials combination determined in accordance

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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, MPa Air content

Additional Requirements

F0 N/A 18 N/A

F1 0.55 24 Depends on aggregate size

N/A

F2 0.45 30 Depends on aggregate size

See limits on maximum cementitious material by mass

F3 0.40 36 Depends on aggregate size

See limits on maximum cementitious material by mass

F3 plain concrete

0.45 30 Depends on aggregate size

See limits on maximum cementitious material by mass

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

b. Concrete must be air entrained for members assigned to Exposure Class F1, F2, or F3. The total air content must meet the requirements of the following table:

Nominal maximum aggregate size, mm

Total air content, percent*^

Exposure Class F2 and F3

Exposure Class F1

9.5 7.5 6.0

12.5 7.0 5.5

19.0 6.0 5.0

25.0 6.0 4.5

37.5 5.5 4.5

50 5.0 4.0

75 5.5 3.5

*Tolerance on air content as delivered must be plus/minus 1.5 percent.

^For f'c greater than 36 MPa psi, reducing air content by 1.0 percentage point is acceptable.

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c. Submit documentation verifying compliance with specified requirements.

d. For sections of the structure that are assigned Exposure Class F3, submit certification on cement composition verifying that concrete mixture meets the requirements of the following table:

Cementitious material Maximum percent of total cementiti ous material by mass*

Fly ash or other pozzolans conforming to

JIS A 6201

Slag cement conforming to JIS A 5011 50

*Total cementitious material also includes JIS R 5210 , fly ash, other pozzolans, and slag cement. The maximum percentages above must include:

i. Fly ash or other pozzolans present in Type IP JIS R 5212 blended cement.

ii. Slag cement present in Type IS JIS R 5211 blended cement.

^Fly ash or other pozzolans must constitute no more than 25 percent of the total mass of the cementitious materials.

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. Water-soluble chloride ion content contributed from constituents including water, aggregates, cementitious materials, and admixtures must be determined for the concrete mixture by JIS A 1154 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, MPa

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

Reinforced concrete

C0 N/A 18 1.00

C1 N/A 18 0.30

C2 0.4 36 0.15

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Exposure class

Maximum w/cm*

Minimum f'c, MPa

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

Prestressed concrete

C0 N/A 18 0.06

C1 N/A 18 0.06

C2 0.4 36 0.06

*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 MPa

Required cementitious materials-t ypes

Calcium chloride admixtureJIS R 5210

JIS R 5211,

JIS R 5212

S0 N/A 17 N/A N/A No restrictions

S1 0.50 28 II (moderate sulfate resistant)*^

IP, portland pozzolan cement

(moderate sulfate resistant); IS, portland blast furnace slag cement (<70) (moderate sulfate resistant)

No restrictions

S2 0.45 31 IV (low heat of hydration)*^

IP, portland pozzolan cement

(high sulfate resistant); IS, portland blast furnace slag cement (<70) (high sulfate resistant)

Not permitted

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Exposure class

Maximum w/cm*

Minimum f'c MPa

Required cementitious materials-types

Calcium chloride admixtureJIS R 5210

JIS R 5211,

JIS R 5212

S3 0.45 31 V (high sulfate resistant) + pozzolan or slag cement **

IP, portland pozzolan cement

(high sulfate resistant) + pozzolan or slag cement^; IS, portland blast furnace slag cement (<70) (high sulfate resistant) + pozzolan or slag cement *

Not permitted

* For seawater exposure, other types of portland cements with tricalcium aluminate (C3A) contents up to 10 percent are acceptable if the w/cm does not exceed 0.40.

** The amount of the specific source of the pozzolan or slag cement to be used shall be at least the amount determined by test or service record to improve sulfate resistance when used in concrete containing Type V cement. Alternatively, the amount of the specific source of the pozzolan or slag used shall not be less than the amount tested in accordance with ASTM C1012/C1012M and meeting the requirements maximum expansion requirements listed herein.

^ Other available types of cement, such as Type III or Type I, are acceptable in exposure classes S1 or S2 if the C3A contents are less than 8 or 5 percent, respectively.

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

c. Alternative combinations of cementitious materials of those listed in this paragraph are acceptable if they meet the maximum expansion requirements listed in the following table:

Exposure class

Maximum expansion when tested using ASTM C1012/C1012M

At 6 months At 6 months At 18 months

S1 0.10 percent N/A N/A

S2 0.05 percent 0.10 percent^ N/A

S3 N/A N/A 0.10 percent

^The 12-month expansion limit applies only when the measured expansion exceeds the 6-month maximum expansion limit.

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2.5.2.5 Concrete Temperature

The temperature of concrete as delivered must not exceed 35 degrees C .

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, MPa

Additional minimum requirements

W0 N/A 18 None

W1 0.5 27 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

Trial mixtures must be in accordance to JASS 5 and MLIT-SS Chapter 6 .

2.5.4 Ready-Mix Concrete

Provide concrete that meets the requirements of JIS A 5308 .

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 JIS A 5308 :

a. Type and brand cement

b. Cement and supplementary cementitious materials content in 43-kilogram bags per cubic meter of concrete

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

a. Bend reinforcement cold. Fabricate reinforcement in accordance with fabricating tolerances of JASS 5 and MLIT-SS Chapter 6 .

b. When handling and storing coated reinforcement, use equipment and methods that do not damage the coating. If stored outdoors for more than 2 months, cover coated reinforcement with opaque protective material.

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

d. Submit placing drawings showing fabrication dimensions and placement

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For Inf orm ati on locations of reinforcement and reinforcement supports. Placing drawings must indicate locations of splices, lengths of lap splices, and details of mechanical and welded splices.

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

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

g. Submit request and procedure to field-bend or straighten reinforcing bars partially embedded in concrete at locations not indicated in Contract Documents. Field bending or straightening of reinforcing bars is permitted where indicated in the Contract Documents

h. Submit request for field cutting, including location and type of bar to be cut and reason field cutting is required.

2.6.1 Reinforcing Bars

a. Reinforcing bars must be deformed, except spirals, load-transfer dowels, and welded wire reinforcement, which may be plain.

b. JIS G 3112 , grades and sizes as indicated. Cold drawn wire used for spiral reinforcement must conform to JIS G 3551 .

c. Submit mill certificates for reinforcing bars.

2.6.1.1 Headed Reinforcing Bars

Headed reinforcing bars must conform to ASTM A970/A970M including Annex A1, and other specified requirements.

2.6.2 Mechanical Reinforcing Bar Connectors

a. Provide 125 percent minimum yield strength of the reinforcement bar.

b. Mechanical splices for galvanized reinforcing bars must be galvanized or coated with dielectric material.

c. Mechanical splices used with epoxy-coated or dual-coated reinforcing bars must be coated with dielectric material.

d. Submit data on mechanical splices demonstrating compliance with this paragraph.

2.6.3 Wire

a. Plain or deformed steel wire must conform to JIS G 3551 .

2.6.4 Reinforcing Bar Supports

a. Provide reinforcement support types within structure as required by Contract Documents. Reinforcement supports must conform to JASS 5 and MLIT-SS Chapter 6 .

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

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2.6.5 Welding

a. Provide weldable reinforcing bars that conform to JIS G 3112 , grades and sizes as indicated. The maximum carbon equivalent content shall not exceed 0.55 percent with carbon not exceeding 0.30 percent and manganese not exceeding 1.5 percent.

b. Comply with JIS Z 3881 unless otherwise specified. Do not tack weld reinforcing bars.

c. Welded assemblies of steel reinforcement produced under factory conditions, such as welded wire reinforcement, bar mats, and deformed bar anchors, are allowed.

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 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.

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b. Previously constructed subgrade or fill must be cleaned of foreign materials

c. Finish surface of capillary water barrier under interior slabs on ground must not show deviation in excess of 6 mm when tested with a 3000 mm 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 6 mm above or 30 mm 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 and must be 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 20 mm. Place chamfer strips in corners of formwork to produce beveled edges on permanently exposed surfaces. Do not bevel reentrant corners or edges of formed joints of concrete.

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.

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.

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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, waterstops, 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.

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…