S02. Cast-In-Place Concrete - Revised 23 Jul 2025.pdf

Columbus VAMC Specification

VA Project 757-24-204 100% Bid Documents Submission

Columbus OH Parking Garage Tendon Repair Design 18 Jul 2025

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SECTION 03 30 53

(SHORT FORM) CAST-IN-PLACE CONCRETE

PART 1 - GENERAL

1.1 SUMMARY

A. Section Includes:

1. Cast-in-place structural concrete.

2. Preparation of existing surfaces to receive concrete.

1.2 RELATED WORK

A. Section 01 45 29, TESTING LABORATORY SERVICES: Materials Testing and

Inspection During Construction.

B. Section 01 81 13, SUSTAINABLE CONSTRUCTION REQUIREMENTS

C. Section 32 05 23, CEMENT AND CONCRETE FOR EXTERIOR IMPROVEMENTS:

Concrete Roads, Walks, and Similar Exterior Site Work.

1.3 QUALITY ASSURANCE

A. Work shall conform to requirements of ACI 301 as applicable except where more stringent requirements are shown on Drawings or specified in this Section.

B. Testing Agency:

1. Independent testing laboratory employed by Engineer and acceptable to the Owner.

2. Accredited by AASHTO under ASTM C1077. Testing laboratory shall submit documented proof of ability to perform required tests.

C. Sampling and testing of mortar shall be performed by ACI certified

Concrete Field Technicians Grade I. Certification shall be no more than three years old.

D. Testing Agency is responsible for conducting, monitoring, and reporting results of all tests required under this Section. Testing Agency has authority to reject mortar not meeting Specifications. Testing Agency does not have the authority to accept mortar that does not meet specifications.

E. Testing Agency shall submit the following information for Field Testing of Concrete unless modified in writing by Engineer:

1. Project name and location.

2. Contractor's name.

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3. Testing Agency's name, address, and phone number.

4. Mortar manufacturer.

5. Date of report.

6. Testing Agency technician's name (sampling and testing).

7. Placement location within structure.

8. Weather data:

A. Air temperatures.

B. Weather.

C. Wind speed.

9. Date, time, and place of test.

10. Compressive test data:

A. Cube or cylinder number.

B. Age of sample when tested.

C. Date and time of test.

D. Compressive strength.

1.4 APPLICABLE PUBLICATIONS

A. Comply with references to the extent specified in this Section.

B. American Concrete Institute (ACI):

117-10(R2015)...........Specification for Tolerances for Concrete

Construction and Materials and Commentary

211.1-91(R2009).........Standard Practice for Selecting Proportions for

Normal, Heavyweight, and Mass Concrete.

211.2-98(R2004).........Standard Practice for Selecting Proportions for

Structural Lightweight Concrete.

301/301M-16.............Specifications for Structural Concrete.

305.1-14 - .............Hot Weather Concreting.

306.1-90(R2002).........Cold Weather Concreting.

308.1 ..................Standard Specification for Curing Concrete

318/318M-19.............Building Code Requirements for Structural

Concrete and Commentary

347R-14 - ..............Guide to Formwork for Concrete.

SP-66-04-...............ACI Detailing Manual.

C. ASTM International (ASTM):

A615/A615M-20...........Standard Specification for Deformed and Plain

Carbon Steel Bars for Concrete Reinforcement

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A996/A996M-16...........Standard Specification for Rail Steel and Axle

Steel Deformed Bars for Concrete Reinforcement

A1064/A1064M-18a........Standard Specification for Carbon-Steel Wire and Welded Wire Reinforcement, Plain and

Deformed, for Concrete

C31.....................Test Method for Compressive Strength of

Cylindrical Concrete Specimens.

C33/C33M-18.............Standard Specification for Concrete Aggregates.

C39/C39M-20.............Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens.

C94/C94M-20.............Standard Specification for Ready-Mixed

Concrete.

C109....................Test Method for Compressive Strength of

Hydraulic Cement Mortars (Using 2-in. or 50-mm

Cube Specimens).

C143/C143M-20...........Standard Test Method for Slump of Hydraulic

Cement Concrete.

C150/C150M-20...........Standard Specification for Portland Cement.

C171-16.................Standard Specification for Sheet Materials for

Curing Concrete.

C192/C192M-19...........Standard practice for Making and Curing

Concrete Test Specimens in the Laboratory.

C219-20a................Standard Terminology Relating to Hydraulic and

Other Inorganic Cements.

C260/C260M-10a (2016)...Standard Specification for Air-Entraining

Admixtures for Concrete.

C330/C330M-17a..........Standard Specification for Lightweight

Aggregates for Structural Concrete.

C494/C494M-19...........Standard Specification for Chemical Admixtures for Concrete.

C618-19 ................Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in

Concrete.

C881/C881M-20 ..........Standard Specification for Epoxy-Resin-Base

Bonding Systems for Concrete.

C989/C989M-18a .........Standard Specification for Slag Cement for Use in Concrete and Mortars.

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C1240-20 ..............Standard Specification for Silica Fume Used in

Cementitious Mixtures.

C1583...................Standard Test Method for the Tensile Strength of Concrete Surfaces and the Bond Strength or

Tensile Strength of Concrete Repair and Overlay

Materials by Direct Tension (Pull-off Method)

D1751-18 ...............Standard Specification for Preformed Expansion

Joint Fillers for Concrete Paving and

Structural Construction (Non-extruding and

Resilient Bituminous Types).

E1155-20................Determining FF Floor Flatness and FL Floor

Levelness Numbers.

E1745-17 ...............Standard Specification for Water Vapor

Retarders Used in Contact with Soil or Granular

Fill under Concrete Slabs.

D. International Concrete Repair Institute:

310.2R-2013 -...........Selecting and Specifying Concrete Surface

Preparation for Sealers, Coatings, Polymer

Overlays, and Concrete Repair.

1.5 SUBMITTALS

A. Submittal Procedures: Refer to Section 01 33 23, SHOP DRAWINGS, PRODUCT

DATA, AND SAMPLES. All items indicated below are required submittals requiring Contracting Officer’s Representative (COR) review and approval.

B. Submittal Drawings:

1. Submit large scale drawings of reinforcing steel, including all reinforcing bend diagrams, and reinforcing details, to the COR for review and approval.

C. Manufacturer's Literature and Data:

1. Data sheets for prepacked repair materials.

2. Indicate manufacturer's recommendation for each application.

D. Contractor: At preconstruction meeting, submit procedures for demolition, surface preparation, material batching, placement, finishing, and curing of application. Provide procedure to protect fresh patches from severe weather conditions.

E. Sustainable Construction Submittals:

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1. Recycled Content: Identify post-consumer and pre-consumer recycled content percentage by weight.

F. Certificates: Certify products comply with specifications.

G. Testing Agency: Promptly report all mortar test results to Engineer and

Contractor. Include the following information:

1. See Article "Quality Assurance," paragraph "Testing Agency shall submit...."

2. Strength determined in accordance with ASTM C109.

1.6 WARRANTY

A. Construction Warranty: FAR clause 52.246-21, "Warranty of

Construction."

PART 2 - PRODUCTS

2.1 MATERIALS

A. Portland Cement: ASTM C150/C150M, Type I or II.

B. Pozzolans:

1. Fly Ash: ASTM International (ASTM) C618, Class C or F including supplementary optional physical requirements. Pozzolans shall not exceed 25 percent of total cementitious materials by weight.

2. Slag: ASTM International (ASTM) C989/C989M; Grade 100 .

3. Silica Fume: ASTM International (ASTM) C1240.

C. Coarse Aggregate: ASTM International (ASTM) C33/C33M.

1. Size 467 for footings and walls over 300 mm (12 inches) thick.

2. Size 7 for coarse aggregate for applied topping and metal pan stair fill.

3. Size 67 for other applications.

D. Fine Aggregate: ASTM International (ASTM) C33/C33M.

E. Mixing Water: Fresh, clean, and potable.

F. Air-Entraining Admixture: ASTM International (ASTM) C260/C260M.

G. Chemical Admixtures: ASTM International (ASTM) C494/C494M.

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H. Reinforcing Steel: ASTM International (ASTM) A615/A615M or

ASTM International (ASTM) A996/A996M, deformed. See Structural Drawings for grade.

I. Forms: Wood, plywood, metal, or other materials, approved by

Contracting Officer, of grade or type suitable to obtain type of finish specified.

1. Plywood: Exterior grade, free of defects and patches on contact surface.

2. Lumber: Sound, grade-marked, S4S stress graded softwood.

3. Form coating: As recommended by Contractor.

J. Welded Wire Fabric: ASTM International (ASTM) A1064/A1064M, sized as indicated.

K. Expansion Joint Filler: ASTM International (ASTM) D1751.

L. Sheet Materials for Curing Concrete: ASTM International (ASTM) C171.

M. Abrasive Aggregates: Aluminum oxide grains or emery grits.

N. Grout, Non-Shrinking: Premixed ferrous or non-ferrous. Grout to show no settlement or vertical drying shrinkage at 3 days. Compressive strength for grout, at least 18 MPa (2500 psi) at 3 days and 35 MPa (5000 psi) at 28 days.

O. Horizontal Repair and Form and Pour Mortar: Shall be prepackaged cementitious repair mortar capable of horizontal and form and pour partial depth applications, achieving a minimum 3,000 psi compressive strength at 7 days and 5,000 psi compressive strength at 28 days per

ASTM C39 as certified by manufacturer with maximum lineal shrinkage of

0.10% at 28 days. Extend per manufacturer’s instructions as required for deeper placements.

1. Acceptable cementitious repair materials for this Work are as follows:

A. “MasterEmaco S440/SikaEmaco 440,” by MBS/Sika.

B. “Eucocrete,” by Euclid.

C. “FA-S10 Concrete,” by King.

D. “Planitop 11,” by MAPEI.

E. “Sikacrete 211 SCC+,” by Sika.

P. Rapid Strength Repair Mortar: Shall be prepackaged, cementitious repair mortar. Repair mortar shall be capable of application achieving a minimum 3,500 psi compressive strength at 1 day and 5,000 psi compressive strength at 28 days per ASTM C39 as certified by

03 30 53 - 7 manufacturer. Extend per manufacturer’s instructions as required for deeper placements.

1. Acceptable materials for this Work are as follows:

A. “MasterEmaco T430/SikaEmaco 430 Arctic,” by MBS/Sika.

B. “Speedcrete 2028,” by Euclid.

C. “HP-S10 Concrete,” by King.

D. “Planitop 18 ES” by MAPEI.

E. “Sikaquick 1000,” by Sika.

F. “Aprisa P-80,” by Tomes.

Q. Trowel Applied Repair Mortar: Shall be prepackaged, cementitious repair mortar capable of vertical/overhead application by trowel achieving a minimum 3,000 psi compressive strength at 7 days and 4,500 psi compressive strength at 28 days per ASTM C 109 as certified by manufacturer.

1. Acceptable materials for this Work are as follows:

A. “MasterEmaco N425/SikaEmaco 425 Gel Patch,” by MBS/Sika.

B. “Verticoat Supreme,” by Euclid.

C. “Super-Top,” by King.

D. “Planitop XS,” by MAPEI

E. “Sikaquick VOH,” by Sika.

F. “CT-40 Do All Mortar,” by Tomes.

2.2 ACCESSORIES

A. Bonding Agent: ASTM International (ASTM) C 1059/C 1059M, Type II.

B. Structural Adhesive: ASTM International (ASTM) C881, 2-component material suitable for use on dry or damp surfaces. Provide material

Type, Grade, and Class to suit Project requirements.

C. Water Stops: Rubber base with self-healing properties. Expanding clay-based products is not acceptable.

D. Extended Open Time Epoxy Bonding Agent: Three component, water based, epoxy modified portland cement bonding agent and corrosion inhibitor coating providing the recommended Manufacturer’s open time in which to apply repair mortar.

1. Acceptable materials for this Work are:

A. “MasterEmaco P124,” by MBS.

B. “Duralprep A.C.,” by Euclid.

C. “Planibond 3C,” by MAPEI.

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D. “Armatec 110 EpoCem”, by Sika.

E. “B-1 Rebar Coating,” by Tomes.

E. Clear, Membrane-Forming Curing Compound: ASTM C 309, Type 1, Class B.

F. Clear, Solvent-Borne, Membrane-Forming Curing and Sealing Compound:

ASTM C 1315, Type 1, Class A.

G. Clear, Waterborne, Membrane-Forming Curing and Sealing Compound:

ASTM C 1315, Type 1, Class A.

2.3 BATCHING AND MIXING

A. Store, batch, and mix materials according to ASTM C94/C94M.

1. Job-Mixed: Batch mix concrete in stationary mixers as specified in

ASTM International (ASTM) C94/C94M.

2. When aggregate producer's instructions deviate from specifications, submit proposed resolution for Contracting Officer's Representative consideration.

PART 3 - EXECUTION

3.1 FORMWORK

A. Installation: Conform to ACI 347. Construct forms to obtain concrete shapes, dimensions and profiles indicated, with tight joints.

B. Design and construct forms to prevent bowing-out of forms between supports and to be removable without prying against or otherwise damaging fresh concrete.

C. When patching formed concrete, seal form edges against existing surface to prevent leakage; set forms so that patch is flush with adjacent surfaces.

D. Treating and Wetting: Treat or wet concrete contact surfaces:

1. Coat plywood and lumber forms with non-staining form sealer.

2. Prevent water from accumulating and remaining within forms.

3. Clean and coat removable metal forms with light form oil before reinforcement is placed.

4. In hot weather, cool metal forms by thoroughly wetting with water just before placing concrete.

5. Prevent water from accumulating and remaining within forms.

E. Inserts, Sleeves, and Similar Items: Install flashing reglets, masonry ties, anchors, inserts, wires, hangers, sleeves, boxes for floor

03 30 53 - 9 hinges, and other cast-in items specified in other Sections. Place where indicated, square, flush, and secured to formwork.

F. Construction Tolerances - General: Install and maintain concrete formwork to assure completion of work within specified tolerances.

G. Adjust or replace completed work exceeding specified tolerances before placing concrete.

3.2 REINFORCEMENT

A. Install concrete reinforcement according to ACI 318 and ACI SP-66.

B. Support and securely tie reinforcing steel to prevent displacement during placing of concrete.

C. Drilling for Dowels in Existing Concrete: Use sharp bits, drill hole slightly oversize, fill with epoxy grout, insert the dowel, and remove excess epoxy.

3.3 PLACING CONCRETE

A. Remove water from excavations before concrete is placed. Remove hardened concrete, debris, and other foreign materials from the interior of forms, and from inside of mixing and conveying equipment.

Obtain approval from Contracting Officer's Representative before placing concrete.

B. Install screeds at required elevations for concrete slabs.

C. Roughen and clean free from laitance, foreign matter, and loose particles before placing new concrete on existing concrete.

1. Blow-out areas with compressed air and immediately coat contact areas with adhesives in compliance with manufacturer's instructions.

D. Place structural concrete according to ACI 301 and ACI 318.

E. Convey concrete from mixer to final place of deposit by method that will prevent segregation or loss of ingredients. Do not deposit, in

Work, concrete that has attained its initial set or has contained its water or cement for more than 1 1/2 hours. Do not allow concrete to drop freely more than 1500 mm (5 feet) in unexposed work nor more than

900 mm (3 feet) in exposed work.

F. Place and consolidate concrete in horizontal layers not exceeding

300 mm (12 inches) in thickness. Consolidate concrete by spading, rodding, and mechanical vibrator. Do not secure vibrator to forms or reinforcement. Continuously vibrate during placement of concrete.

G. Hot Weather Concrete Placement: As recommended by ACI 305.1 to prevent adversely affecting properties and serviceability of hardened concrete.

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H. Cold Weather Concrete Placement: As recommended by ACI 306.1, to prevent freezing of thin sections less than 300 mm (12 inches) and to permit concrete to gain strength properly.

1. Do not use calcium chloride without written approval from

Contracting Officer's Representative.

I. Installation requirements where prepackaged repair mortar is specified:

1. Extended Open Time Epoxy Bonding Agent:

A. In strict accordance with manufacturer’s recommendations, mix and apply epoxy bonding agent to all areas as indicated on Drawings.

B. Allow epoxy bonding agent to dry a minimum 2 hours, but no more than the Manufacturer’s recommended open time prior to placing repair mortar.

2. Mortar Placement: Mortar materials shall be placed in strict accordance with the manufacturer’s instructions. Properly proportioned and mixed mortar material shall be placed using tools to consolidate mortar so that no voids exist within new material and continuous contact with base concrete is achieved.

3. Form and Pour Repair Mortar Placement: Mix and apply in strict accordance with manufacturer’s written instructions, to achieve a maximum 9” slump. Consolidate mortar so that no voids exist and continuous contact with base concrete is achieved.

4. Vertical and Overhead Repairs: Mortar materials shall be placed in strict accordance with the manufacturer’s instructions. Properly proportioned and mixed mortar material shall be placed using tools to consolidate mortar so that no voids exist within new material and continuous contact with base concrete is achieved. Supplemental wire mesh shall be required for delamination and spall repairs greater than two inches in depth.

3.4 PROTECTION AND CURING

A. Protect exposed surfaces of concrete from premature drying, wash by rain or running water, wind, mechanical damage, and excessive hot or cold temperatures. Comply with ACI 306.1 for cold-weather protection and ACI 305R for hot-weather protection during placement. Keep concrete continually moist prior to final curing by evaporation retarder, misting, sprinkling, or using absorptive mat or fabric covering kept continually moist.

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B. Immediate upon conclusion of finishing operation cure concrete in accordance with ACI 308.1 for duration of at least seven days by curing methods listed below. Provide additional curing immediately following initial curing and before concrete has dried.

1. During initial and final curing periods maintain concrete above 50°.

2. Prevent rapid drying at end of curing period.

C. Curing Methods: Cure formed and non-formed concrete moisture curing, moisture-retaining-cover curing, curing compound, or a combination of these as follows:

1. Moisture Curing: Keep surfaces continuously moist for not less than seven days with the following materials:

A. Water.

B. Continuous water-fog spray.

C. Absorptive cover, water saturated and kept continuously wet.

Cover concrete surfaces and edges with 12-inch (300-mm) lap over adjacent absorptive covers.

2. Moisture-Retaining-Cover Curing: Cover concrete surfaces with moisture-retaining cover for curing concrete, placed in widest practicable width, with sides and ends lapped at least 12 inches, and sealed by waterproof tape or adhesive. Immediately repair any holes or tears during curing period using cover material and waterproof tape.

D. Curing Methods: Cure concrete with curing compound using wet method with sheets.

E. Formed Concrete Curing: Wet the tops and exposed portions of formed concrete and keep moist until forms are removed.

1. If forms are removed before 14 days after concrete is cast, install sheet curing materials as specified above.

F. Concrete Flatwork Curing:

1. Install sheet materials according to the manufacturer's instructions.

A. When manufacturer's instructions deviate from specifications, submit proposed resolution for Contracting Officer's

Representative consideration.

3.5 FORM REMOVAL

A. Maintain forms in place until concrete is self-supporting, with construction operation loads.

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B. Remove fins, laitance, and loose material from concrete surfaces when forms are removed. Repair honeycombs, rock pockets, sand runs, spalls, or otherwise damaged surfaces by patching with the same mix as concrete minus the coarse aggregates.

C. Finish to match adjacent surfaces.

3.6 FINISHES

A. Vertical and Overhead Surface Finishes:

1. Provide a surface finish similar to adjacent surfaces for vertical and overhead partial depth repairs.

2. Finish formed surfaces similar to adjacent surfaces.

3. Surfaces Concealed in Completed Construction: As-cast; no additional finishing required.

4. Surfaces Exposed in Unfinished Areas: As-cast; no additional finishing required.

A. Mechanical rooms.

B. Electrical rooms.

5. Surfaces Exposed to View Scheduled for Paint Finish: Remove fins, burrs and similar projections by mechanical means approved by

Contracting Officer's Representative flush with adjacent surface.

Lightly rub with fine abrasive stone or hone. Use ample amount of water during rubbing without working up a lather of mortar or changing the texture of concrete.

6. Surfaces Exposed to View in Finished Areas: Grout finish, unless otherwise shown, for uniform color and smooth finish treated.

A. Remove laitance, fins, and burrs.

B. Scrub concrete with wire brushes. Clean stained concrete surfaces with hone or stone.

C. Apply grout composed of 1 part Portland cement and 1-part clean, fine sand (smaller than 600 micro-m (No. 30) sieve). Work grout into the surface of concrete with cork floats or fiber brushes until pits and honeycomb are filled.

D. After grout has hardened, but it is still plastic, remove surplus grout with sponge rubber float and by rubbing with clean burlap.

E. In hot, dry weather fog spray surfaces with water to keep grout wet during setting period. Complete finished areas in the same day. Confine limits of finished areas to natural breaks in wall surface. Do not leave grout on concrete surface overnight.

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3.7 FIELD QUALITY CONTROL

A. Testing Agency: Engineer shall engage a qualified independent testing and inspecting agency acceptable to the Owner to sample materials, perform tests, and submit test reports during concrete placement according to requirements specified in this Article. Perform tests according to ACI 301.Testing Frequency: Perform one set of strength testing and one bond test for each product used for each day's work.

Prepare samples in accordance with ASTM C31.

B. Compressive Strength Testing: Determine strength at 3, 7, and 28 days.

Each test shall consist of two 6-inch diameter cylinders or three 4-inch diameter cylinders. Testing shall be in accordance with ASTM C39.

C. Bond Testing: Bond testing shall be performed at 7 days in accordance with ASTM C1583.

3.10. EVALUATION AND ACCEPTANCE OF WORK

A. Acceptance of Repairs (ACI 301):

1. Acceptance of completed concrete Work will be according to provisions of ACI 301.

2. Repair areas shall be sounded by Engineer and Contractor with hammer or rod after curing for 72 hours. Contractor shall repair all hollowness detected by removing and replacing patch or affected area at no extra cost to Owner.

3. If shrinkage cracks appear in repair area when the initial curing period is completed, repair shall be considered defective, and it shall be removed and replaced by Contractor at no extra cost.

4. Patches shall be considered defective if average strength does not meet minimum strength at 28 days or if average bond strength does not meet minimum requirements of 150 psi.

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