Specification 03300 - Cast in place concrete (002).pdf

U.S EMBASSY- SKOPJE, MACEDONIA 29 AUGUST, 2006

REVISION

CAST-IN-PLACE CONCRETE SECTION 03300 - 1

SECTION 03300 - CAST-IN-PLACE CONCRETE

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.

1.2 SUMMARY

A. This Section specifies cast-in-place concrete, including formwork, reinforcement, concrete materials, mix design, placement procedures, and finishes.

B. Cast-in-place concrete includes the following:

1. Slabs-on-grade.

2. Foundations and foundation walls.

3. Shear walls.

4. Superstructure.

5. Equipment pads and bases.

6. Perimeter walls and site structures.

7. Other cast-in-place concrete not specified above.

8. Concrete Fill for bollards

1.3 DEFINITIONS

A. Cementitious Materials: Portland cement alone or in combination with one of blended hydraulic cement, fly ash and other pozzolans, ground granulated blast-furnace slag, or silica fume.

1.4 SUBMITTALS

A. General: Project construction submittals and shop drawing data shall be provided in accordance with specific details noted int the Contractor’s Submittal Register per the requirements stated in Section 01301 – Constrtuction Submittals.

B. Product Data: For each type of manufactured material and product indicated.

C. Design Mixes: For each concrete mix. Include alternate mix designs when characteristics of materials, project conditions, weather, test results, or other circumstances warrant adjustments.

1. Indicate amounts of mix water to be withheld for later addition at Project site.

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D. Steel Reinforcement Shop Drawings: Details of fabrication, bending, and placement, prepared according to ACI 315, "Details and Detailing of Concrete Reinforcement." Include material, grade, bar schedules, stirrup spacing, bent bar diagrams, arrangement, and supports of concrete reinforcement. Include special reinforcement required for openings through concrete structures.

Show all wall and slab reinforcement in elevations including all openings larger than 300 mm in any dimension.

E. Formwork Shop Drawings: Prepared, signed and sealed by a professional engineer indicating fabrication and erection of forms of specific finished concrete surfaces. Show form construction including jointing, special form joints or reveals, location and pattern of form tie placement, and other items that affect exposed concrete visually. Show locations and detail construction joints for concrete work.

1. Shoring and Reshoring: Indicate proposed schedule and sequence of stripping formwork, shoring removal, and installing and removing reshoring.

2. Review is for general applications and features only. Designing formwork and shoring sequence for structural stability and efficiency is Contractor’s responsibility.

F. Welding Certificates: Copies of certificates for welding procedures and personnel.

G. Material Test Reports: From a qualified testing agency indicating and interpreting test results for compliance of the following with requirements indicated, based on comprehensive testing of current materials:

H. Material Certificates: Signed by manufacturers certifying that each of the following items complies with requirements, including where applicable, compatibility with other subsequent materials and finishes:

1. Cementitious materials and aggregates.

2. Form materials and form-release agents.

3. Steel reinforcement indicating physical and chemical analysis

4. Reinforcement accessories.

5. Fiber reinforcement.

6. Admixtures.

7. Waterstops.

8. Curing and sealing materials.

9. Floor and slab treatments.

10. Bonding agents.

11. Adhesives.

12. Vapor barriers.

13. Epoxy joint filler.

14. Joint-filler strips.

15. Repair materials.

16. Other proprietary items.

I. Minutes of preinstallation conference.

1.5 QUALITY ASSURANCE

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A. Installer Qualifications: An experienced installer who has completed concrete Work similar in material, design, and extent to that indicated for this Project and whose work has resulted in construction with a record of successful in-service performance.

B. Professional Engineer Qualifications: A professional engineer who is experienced in providing engineering services of the kind indicated. Engineering services are defined as those performed for formwork and shoring and reshoring installations that are similar to those indicated for this Project in material, design, and extent.

C. Manufacturer Qualifications: A firm experienced in manufacturing ready-mixed concrete products complying with ASTM C 94 requirements for production facilities and equipment.

D. Source Limitations: Obtain each type or class of cementitious material of the same brand from the same manufacturer's plant, each aggregate from one source, and each admixture from the same manufacturer.

E. Welding: Qualify procedures and personnel according to AWS D1.4, "Structural Welding Code--Reinforcing Steel."

F. Codes and Standards: Comply with provisions of the latest editions of the following codes, specifications, and standards included in the ACI Manual of Concrete Practice 2000 edition, except where more stringent requirements are shown or specified.

1. American Concrete Institute (ACI) 301, “Specifications for Structural Concrete for Buildings.”

2. ACI 117, “Specification for Tolerances for Concrete Construction and Materials”.

3. ACI 211.1, “Standard Practice for Selecting Proportions for Normal, Heavyweight, and Mass Concrete.”

4. ACI 304R, “Guide for Measuring, Mixing, Transporting, and Placing Concrete.”

5. ACI 305R, “Hot Weather Concrete.”

6. ACI 306R “Cold Weather Concrete”

7. ACI 309R, “Guide for Consolidation of Concrete.”

8. ACI 318M, “Building Code Requirements for Structural Concrete.”

9. ACI 347R, “Guide to Formwork for Concrete.”

10. Concrete Reinforcing Steel Institute (CRSI) “Manual of Standard Practice”.

G. Preinstallation Conference: Conduct conference at the Project site to comply with requirements of Division 1 Section “Project Meetings” and the following:

1. At least 35 days prior to submitting design mixes, conduct a meeting to review detailed requirements for preparing concrete design mixes and to determine procedures for satisfactory concrete operations. Review requirements for submittals, status of

CAST-IN-PLACE CONCRETE SECTION 03300 - 4

coordinating work, and availability of materials. Establish preliminary work progress schedule and procedures for materials inspection, testing, and certifications. Require representatives of each entity directly concerned with cast-in-place concrete to attend conference, including, but not limited to, the following:

a. Contractor’s superintendent.

b. Agency responsible for concrete design mixes.

c. Agency responsible for field quality control.

d. Ready-mix concrete producer.

e. Primary admixture manufacturers.

f. Concrete subcontractor.

g. Formwork subcontractor.

h. Steel reinforcing installer subcontractor.

i. Project Director and Quality Control, Manager

H. Place concrete after the placement of all forms, reinforcement, inserts, sleeves, and other embedments have been inspected and approved by the Contractor’s superintendent and the Quality Control Manager and reviewed by the Project Director

I. Place concrete only under the supervision of the Contractor’s superintendent and the Quality Control Manager.

J. The Contractor is responsible for the establishment of a quality control program to manage forming, reinforcement, production, delivery, placement, compaction, finishing, curing, protection and patching of all concrete. Comply with the requirements specified in Section 01401.

K. Provide the Quality Control manager and the Project Director with access to the site or to the plant to facilitate inspection of the reinforcement. Submit a schedule, showing the beginning and the duration of the shop fabrication, in sufficient time to allow for the proper inspection.

L. Provide the Quality Control Manager and the Project Director, with access to the concrete plant to facilitate inspection of concrete. Notify the Quality Control Manager when production of concrete is to commence and the plant location in sufficient time to allow for the proper inspection.

M. Inspection and testing will be performed by the Quality Control Manager in accordance with the requirements of this Section and Section 01401.

N. Provide free access to the Work and cooperate with the appointed Quality Control Manager.

O. Tests of the proposed cement, aggregates and other concrete ingredients will be performed to ensure conformance with the specified requirements.

P. The Quality Control Manager will make the concrete compressive test specimens and perform all the tests specified in this Section and Section 01401.

Q. The Quality Control Manager shall be the only entity authorized to allow the addition of any water to a concrete mix after batching.

CAST-IN-PLACE CONCRETE SECTION 03300 - 5

R. The Quality Control Manger shall have the authority to reject concrete prior to or during placement for reasons of non-compliance with the Contract Documents.

1.6 DELIVERY, STORAGE, AND HANDLING

A. Store cement, aggregate, admixture, water, embedded items and reinforcing in a manner to prevent deterioration or intrusion of any foreign matter. Do not use damaged or deteriorated materials.

B. Deliver, store, and handle steel reinforcement to prevent bending and damage.

1. Avoid damaging coatings on steel reinforcement.

2. Repair damaged epoxy coatings on steel reinforcement according to

ASTM D 3963/D 3963M.

PART 2 - PRODUCTS

2.1 FORM MATERIALS

A. Forms for Exposed Finish Concrete: Plywood, metal-framed plywood faced, or other acceptable panel-type materials to provide continuous, straight, smooth, exposed surfaces.

Furnish in largest practicable sizes to minimize number of joints or as shown on drawings.

B. Forms for Unexposed Finish Concrete: Plywood, lumber, metal, or another acceptable material.

Provide lumber dressed on at least two edges and one side for tight fit.

C. Chamfer Strips: Wood, metal, PVC or rubber strips, 20 mm by 20 mm.

D. Form Release Agent: Provide commercially formulated form release agent with a maximum of 350 mg/l volatile organic compounds (VOCs) that will not bond with, stain, or adversely affect concrete surfaces and will not impair subsequent treatments of concrete surfaces.

E. Form Ties: Factory-fabricated, adjustable-length, removable or snap-off metal form ties designed to prevent form deflection and to prevent spalling of concrete upon removal. Provide units that will leave no metal closer than 40 mm to the plane of the exposed concrete surface.

1. Provide ties that, when removed, will leave holes not larger than 25 mm in diameter in the concrete surface.

2.2 STEEL REINFORCEMENT

A. Reinforcing Bars, as indicated on the structural drawings, shall comply with either of the following requirements:

1. ASTM A 615/A 615M, Grade 420 (Grade 60), deformed bars complying with the special ductility requirements of ACI 318M, paragraph 21.2.5.

CAST-IN-PLACE CONCRETE SECTION 03300 - 6

2. ASTM A 706/A 706M deformed bars.

B. Epoxy-Coated Reinforcing Bars: ASTM A 775/A 775M.

C. Plain-Steel Wire: ASTM A 82, as drawn.

D. Deformed-Steel Wire: ASTM A 496.

E. Plain-Steel Welded Wire Fabric: ASTM A 185, fabricated from as-drawn steel wire into flat sheets.

F. Deformed-Steel Welded Wire Fabric: ASTM A 497, flat sheet.

2.3 REINFORCEMENT ACCESSORIES

A. Bar Supports: Bolsters, chairs, spacers, and other devices for spacing, supporting, and fastening reinforcing bars and welded wire fabric in place. Manufacture bar supports according to CRSI's "Manual of Standard Practice" from steel wire, plastic, or precast concrete or fiber-reinforced concrete of greater compressive strength than concrete, and as follows:

1. For concrete surfaces exposed to view where legs of wire bar supports contact forms, use CRSI Class 1 plastic-protected or CRSI Class 2 stainless-steel bar supports.

2. For slabs-on-grade, use supports with sand plates or horizontal runners where base material will not support chair legs.

3. For epoxy-coated reinforcement, use epoxy-coated or other dielectric-polymer-coated wire bar supports.

B. Joint Dowel Bars: Plain-Steel bars, ASTM A615M, Grade 420, cut bars true to length with ends square and free of burs.

C. Mechanical Splices and Connections: As indicated on Drawings.Use Bar Couplers as manufactured by Bar-LoK (MBT) Coupler Systems or approved equal. Welding of Reinforcing bars is not permitted.

2.4 CONCRETE MATERIALS

A. Portland Cement: ASTM C 150, Type I or Type I / II.

1. At Contractor’s option may use Type III.

2. Use one brand of cement throughout Project unless otherwise acceptable to Project Director and Quality Control Manager

B. Ground Granulated Blast-Furnace Slag (GGBF): ASTM C 989, Grade 100 or 120.

C. Silica Fume: ASTM C 1240.

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D. Normal-Weight Aggregate: ASTM C 33, uniformly graded, and as follows:

1. Coarse aggregate size for concrete in walls, columns, beams, and structural slabs shall not exceed 20 mm.

2. Coarse Aggregates: (a) General Use: 25 mm to 4.75 mm; (b) Walls, Columns, Beams, and Structural Slabs: 20 mm to 4.75 mm; (c) Tight Placement: 12.5 mm to 4.75 mm.

3. Fine Aggregates: Fineness modulus shall not be less than 2.3 nor more than 3.1.

4. Combined Aggregate Gradation: Well graded from coarsest to finest with not more than

18 percent and not less than 8 percent retained on an individual sieve, except that less than 8 percent may be retained on coarsest sieve, on the No. 50 (0.300 mm) sieve, and the No.

100 (0.150 mm) sieve.

5. Materials that contain particles that will discolor the surface shall not be used for any exposed concrete.

6. Provide aggregates from a single source for exposed concrete.

7. Do not use aggregates containing chloride ions in excess to the requirements of ACI for concrete construction in corrosive environments.

E. Water: Potable and/or Non-Potable complying with ASTM C 94 and ACI318, Section 3.4.

2.5 ADMIXTURES

A. General: Admixtures certified by manufacturer to contain not more than 0.1 percent water-soluble chloride ions by mass of cementitious material and to be compatible with other admixtures and cementitious materials. Do not use admixtures containing calcium chloride.

Accelerating admixtures shall not be used unless approved by the Quality Control Manager.

B. Air-Entraining Admixture: ASTM C260, Type C (not used)

C. Water-Reducing Admixture: ASTM C 494, Type A.

D. Retarding Admixture: ASTM C 494, Type B.

E. Accelerating (Non-Corrosive) Admixture: ASTM C 494, Type C.

F. Water-Reducing and Retarding Admixture: ASTM C 494, Type D.

G. Water-Reducing and Accelerating Admixture: ASTM C 494, Type E.

H. High Range, Water-Reducing Admixture (Superplasticizer): ASTM C 494, Type F.

I. High Range, Water-Reducing and Retarding Admixture: ASTM C 494, Type G.

J. Corrosion-Inhibiting Admixture: Commercially formulated, calcium nitrite, anodic inhibitor or mixed cathodic and anodic inhibitor; capable of forming a protective barrier and minimizing chloride reactions with steel reinforcement in concrete.

1. Available Products: Subject to compliance with requirements, products that may be incorporated into the Work include, but are not limited to, the following:

a. DCI or DCI-S; W. R. Grace & Co., Construction Products Div. (Basis for Design)

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b. Rheocrete CNI; Master Builders, Inc.

2.6 FIBER REINFORCEMENT (as indicated on drawings)

A. Synthetic Fiber: Fibrillated or monofilament polypropylene fibers engineered and designed for use in concrete, complying with ASTM C 1116, Type III, 12 to 25 mm long.

B. Available Products: Subject to compliance with requirements, products that may be incorporated into the Work include, but are not limited to, the following:

1. Fibrillated Fibers:

a. Fibrasol F; Axim Concrete Technologies (Basis for Design).

b. Fibermesh; Fibermesh, Div. of Synthetic Industries.

c. Forta; Forta Corporation.

d. Grace Fibers; W. R. Grace & Co., Construction Products Div.

2. Monofilament Fibers:

a. Fibrasol IIP; Axim Concrete Technologies (Basis for Design).

b. Fiberstrand 100; Euclid Chemical Co.

c. Fibermix Stealth; Fibermesh, Div. of Synthetic Industries.

d. Forta Mono; Forta Corporation.

e. Grace MicroFiber; W. R. Grace & Co., Construction Products Div.

2.7 WATERSTOPS

A. Flexible Rubber Waterstops: CE CRD-C 513, for embedding in concrete to prevent passage of fluids through joints. Factory fabricate corners, intersections, and directional changes.

1. Profile: Flat, dumbbell with center bulb.

2. Dimensions: 150mm by 10mm thick.

B. Flexible PVC Waterstops: CE CRD-C 572, for embedding in concrete to prevent passage of fluids through joints. Factory fabricate corners, intersections, and directional changes.

1. Profile: Flat, dumbbell with center bulb.

2. Dimensions: 150mm by 10mm thick.

C. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

1. Rubber Waterstops:

a. Greenstreak (Basis for Design).

b. Progress Unlimited Inc.

c. Westec Barrier Technologies; Div. of Western Textile Products, Inc.

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2. PVC Waterstops:

a. Greenstreak (Basis for Design).

b. Meadows: W. R. Meadows, Inc.

c. Murphy: Paul Murphy Plastics Co.

d. Progress Unlimited Inc.

e. Vinylex Corporation.

f. Sika Corporation.

D. Self-Expanding Strip Waterstops: Manufactured rectangular or trapezoidal strip, sodium bentonite or other hydrophylic material for adhesive bonding to concrete.

1. Available Products: Subject to compliance with requirements, products that may be incorporated into the Work include, but are not limited to, the following:

a. Volclay Waterstop-RX; Colloid Environmental Technologies Co.

b. Conseal CS-231; Concrete Sealants Inc.

c. Swellseal Joint; De Neef Construction Chemicals (U.S.) Inc.

d. Hydrotite; Greenstreak (Basis for Design).

2.8 VAPOR RETARDERS

A. Vapor Retarder: Polyethylene sheet, ASTM D 4397, not less than 0.20 mm (8 mils) thick.

B. Granular Fill: Clean mixture of crushed stone or crushed or uncrushed gravel; ASTM D 448, Size 57, with 100 percent passing a 38-mm sieve and 0 to 5 percent passing a 2.36-mm (No. 8) sieve.

2.9 FLOOR AND SLAB TREATMENTS

A. Slip-Resistive Aggregate Finish: Factory-graded, packaged, rustproof, non-glazing, abrasive aggregate of fused aluminum-oxide granules or crushed emery with emery aggregate containing not less than 50 percent aluminum oxide and not less than 25 percent ferric oxide; unaffected by freezing, moisture, and cleaning materials.

B. Penetrating Liquid Floor Treatment (Liquid Densifer/Sealer): For Warehouses and garages.

Chemically reactive, waterborne solution of inorganic silicate or siliconate materials and proprietary components; odorless; colorless; that penetrates, hardens, and densifies concrete surfaces, increases abrasion resistance, and provides a low sheen surface that is easy to clean and reduces the problem of tire mark removal.

C. Available Products: Subject to compliance with requirements, products that may be incorporated into the Work include, but are not limited to, the following:

1. Penetrating Liquid Floor Treatment:

a. Chemisil Plus; ChemMasters.

b. “Ashford Formula”, Curecrete Chemical Co.

c. “Euco Diamond Hard”, The Euclid Chemical Co. (Basis for Design).

CAST-IN-PLACE CONCRETE SECTION 03300 - 10

2.10 CURING MATERIALS

A. Evaporation Retarder: Waterborne, monomolecular film forming, manufactured for application to fresh concrete and exposed concrete slab surfaces for temporary protection from rapid moisture loss. Verify applicablility with any concrete toppings prior to utilization.

B. Absorptive Cover: AASHTO M 182, Class 2, burlap cloth made from jute or kenaf, weighing approximately 300 g/sq. m (9 oz./sq. yd.) dry.

C. Moisture-Retaining Cover: ASTM C 171, polyethylene film or white burlap-polyethylene sheet.

D. Water: Potable.

E. Clear, Waterborne, Membrane-Forming Curing Compound: ASTM C 309, Type 1 Class B. Do not apply over concrete that may receive concrete toppings, epoxy coatings, or urethane coatings unless specifically approved for this application by the manufacturer.

F. Clear, Waterborne, Membrane-Forming Curing and Sealing Compound: ASTM C 1315, Type 1, Class A. Do not apply over concrete that may receive concrete toppings, epoxy coatings, or urethane coatings unless specifically approved for this application by the manufacturer.

G. Available Products: Subject to compliance with requirements, products that may be incorporated into the Work include, but are not limited to, the following:

1. Evaporation Retarder:

a. Product 1a “Confilm” by Master Builders.

b. Product 1b “EucoBar” by Euclid Chemical Co. (Basis for Design).

c. Product 1c “E-Con” by L&M Construction Chemicals, Inc..

2. Clear, Waterborne, Membrane-Forming Curing Compound:

a. Product 3a “L&M Cure” by L&M Construction Chemicals, Inc. (Basis for

Design).

b. Product 3b “Day-Chem Sil-Cure (T-13)” by Dayton Superior.

c. Product 3c “Master Kure 200W” by Master Builders.

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

a. Product 5a (Safe Cure & Seal (J-19)” by Dayton Superior.

b. Product 5b “Master Kure N-Seal W” by Master Builders.

c. Product 5c “Super Diamond Clear VOX” by Euclid Chemical Co. (Basis for

Design).

2.11 RELATED MATERIALS

A. Bonding Agent: ASTM C 1059, Type II, non-redispersible, acrylic emulsion or styrene butadiene.

B. Epoxy Bonding Adhesive: ASTM C 881, two-component epoxy resin, capable of humid curing and bonding to damp surfaces, of type, class, and grade to suit requirements.

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C. Dovetail Anchor Slots: Hot-dip galvanized steel sheet, not less than 0.85 mm (22 gage) thick, with bent tab anchors. Temporarily fill or cover face opening of slots to prevent intrusion of concrete or debris.

D. Reglets: See 07620 Sheet Metal Flashing and Trim. Fabricate reglets of not less than 0.55 mm (26 gage) thick galvanized steel sheet. Temporarily fill or cover face opening of reglet to prevent intrusion of concrete or debris.

E. Epoxy Joint Filler: For control and construction joints of slab-on-grade in warehouses, a two component, 100% solids, low-range tensile strength semi-rigid epoxy with a minimum shore D hardness 50 (ASTM D676) and elongation of 6% (ASTM D 2240). The epoxy joint filler shall be mixed and installed in strict accordance with the direction of manufacturer. The joint filler shall not be filled sooner than 90 days after slab placement.

F. Joint Sealant for Isolation Joint at Slab-on-Grade:

1. Eucolastic I (Urethane sealant): Use closed cell polyethylene backer rod (Basis for Design).

2.12 REPAIR MATERIALS

A. Repair Underlayment: Cement-based, polymer-modified, self-leveling product that can be applied in thicknesses from 3 mm and that can be feathered at edges to match adjacent floor elevations.

1. Cement Binder: ASTM C 150, portland cement or hydraulic or blended hydraulic cement as defined in ASTM C 219.

2. Primer: Product of underlayment manufacturer recommended for substrate, conditions, and application.

3. Aggregate: Well-graded, washed gravel, 3 to 6 mm or coarse sand as recommended by underlayment manufacturer.

4. Compressive Strength: Not less than 30 MPa at 28 days when tested according to

ASTM C 109/C 109M.

B. Repair Topping: Traffic-bearing, cement-based, polymer-modified, self-leveling product that can be applied in thicknesses from 6 mm.

1. Cement Binder: ASTM C 150, portland cement or hydraulic or blended hydraulic cement as defined in ASTM C 219.

2. Primer: Product of topping manufacturer recommended for substrate, conditions, and application.

3. Aggregate: Well-graded, washed gravel, 3 to 6 mm or coarse sand as recommended by topping manufacturer.

4. Compressive Strength: Not less than 40 MPa at 28 days when tested according to

ASTM C 109/C 109M.

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2.13 CONCRETE MIXES

A. Prepare design mixes for each type and strength of concrete determined by laboratory trial batch method as specified ACI 211.1, ACI 301 and ACI 318M. Use an independent testing agency acceptable to the Project Director and Quality Contol Manager for preparing and reporting proposed mix designs. Do not use the same testing agency for field quality control testing.

B. Submit written reports to the Project Director and Quality Contol Manager of each proposed mix prepared and sealed by a professional engineer for each class of concrete at least 15 days prior to start of Work. Do not begin concrete production until the Archjtect/Engineer has approved proposed mix designs and has been reviewed by the Quality Control Manager and the Project Director.

C. Cementitious Materials: Limit percentage, by weight, of cementitious materials other than portland cement in concrete as follows:

1. Limit use of fly ash and ground granulated blast furnace (GGBF) slag to not exceed 20 percent of cementitious content by weight.

2. Limit use of silica fume to not exceed 10 percent of cementitious content by weight.

D. Design mixes to provide normal weight concrete with properties as indicated herein and on the Structural Drawings.

1. Perimeter Walls: Proportion normal-weight concrete mix as follows:

a. Compressive Strength (28 Days): 25 MPa minimum.

b. Maximum Slump: 125 mm

c. .Fiber reinforcement required as indicated on the drawings.

2. Slab on Grade, Suspended Slabs, and Building Frame Members: Proportion normal-weight concrete mix as follows:

a. Compressive Strength (28 Days): 30 MPa minimum.

b. Maximum Slump: 125 mm.

c. Maximum Slump for Concrete Containing High-Range, Water-Reducing

Admixture: 200 mm after admixture is added to concrete with 50 mm to 75 mm slump.

3. Mud Slabs:

a. Compressive Strength (28) days: 20 MPa minimum

b. Maximum Slump: 125 mm

E. Water-Cementitious Materials Ratio: Provide concrete for following conditions with maximum water-cementitious materials (W/C) ratios as follows:

1. Unless noted otherwise: Maximum W/C = 0.50.

2. Maximum Water-Cementitious Materials Ratio: 0.45 for concrete subject moderate sulfate exposure (per ACI 318M Table 4.3.1) or required to have low water permeability or subject to freezing and thawing while moist.

3. Maximum Water-Cementitious Materials Ratio: 0.40 for concrete subject to severe or very severe sulfate exposure (per ACI 318M Table 4.3.1) or for corrosion protection of

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steel reinforcement in concrete exposed to chlorides from deicing chemicals, salt, saltwater, brackish water, seawater, or spray from these sources.

F. Minimum Cementitious Content: For concrete subject sulfate exposure (per ACI 318M Table 4.3.1) including foundations protected with two layers of bituminous dampproofing:

1. Moderate Sulfate Exposure: 334 kg/m3 minimum cementitious content.

2. Severe Sulfate Exposure: 362 kg/m3 minimum cementitious content.

3. Very Severe Sulfate Exposure: 390 kg/m3 minimum cementitious content.

G. Limit water-soluble, chloride ion content in hardened concrete to 0.15 percent by weight of cement.

H. Synthetic Fiber: Uniformly disperse in concrete mix at manufacturer’s recommended rate, but not less than 0.90 kg/m3 (1.5 lb./cu. yd.).

I. Air Content : Use air-entraining admixtures in exterior exposed concrete unless otherwise indicated. Add air-entraining admixture at manufacturer’s prescribed rate to result in concrete at point of placement having total air content of 6 percent with a tolerance of plus or minus 1½ percent.

1. Do not air entrain concrete for trowel finished interior floors and suspended slabs.

2. Do not allow entrapped air content to exceed 3 percent.

3. Concrete exposed to sulfates shall be air-entrained.

J. Admixtures: Use admixtures according to manufacturers written instructions.

1. Use water-reducing admixture or high-range water-reducing admixture (superplasticizer) in concrete, as required, for placement and workability.

2. Use water-reducing and retarding admixtures when required by high temperatures, low humidity, or other adverse placement conditions.

3. Use high range water-reducing admixture in pumped concrete as required for pumpability and workability and concrete required to be watertight, and concrete with a water-cementitious materials ratio below 0.50.

4. Use corrosion-inhibiting admixture in concrete mixes where indicated. Corrosion inhibiting admixture is to be added at the Project site.

2.14 FABRICATING REINFORCEMENT

A. Fabricate steel reinforcement according to CRSI's "Manual of Standard Practice."

2.15 CONCRETE MIXING

A. Ready-Mixed Concrete: Measure, batch, mix, and deliver concrete according to ASTM C 94, and furnish batch ticket information.

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1. When air temperature is between 30 deg C and 32 deg C, reduce mixing and delivery time from 90 minutes to 75 minutes, and when air temperature is above 32 deg C, reduce mixing and delivery time to 60 minutes.

PART 3 - EXECUTION

3.1 FORMWORK

A. Design, erect, shore, brace, and maintain formwork, according to ACI 301 and as shown on formwork shop drawings which have been reviewed by the Project Director and Quality Control Manager, to support vertical, lateral, static, and dynamic loads, and construction loads that might be applied, until concrete structure can support such loads.

B. Construct formwork so concrete members and structures are of size, shape, alignment, elevation, and position indicated, within tolerance limits of ACI 117.

C. Limit concrete surface irregularities, designated by ACI 347R as abrupt or gradual, as follows:

1. Class A, 3 mm.

2. Class B, 6 mm.

3. Class C, 13 mm.

4. Class D, 25 mm.

D. Construct forms tight enough to prevent loss of concrete mortar.

E. Fabricate forms for easy removal without hammering or prying against concrete surfaces.

Contractor to protect concrete surfaces. Kerf wood inserts for forming keyways, reglets, recesses, and the like, for easy removal.

1. Do not use rust-stained steel form-facing material.

F. Set edge forms, bulkheads, and intermediate screed strips for slabs to achieve required elevations and slopes in finished concrete surfaces. Provide and secure units to support screed strips; use strike-off templates or compacting-type screeds.

G. Provide temporary openings for cleanouts and inspection ports where interior area of formwork is inaccessible. Close openings with panels tightly fitted to forms and securely braced to prevent loss of concrete mortar. Locate temporary openings in forms at inconspicuous locations.

H. Chamfer exterior corners and edges of permanently exposed concrete.

I. Form openings, chases, offsets, sinkages, keyways, reglets, blocking, screeds, and bulkheads required in the Work. Determine sizes and locations from trades providing such items.

J. Clean forms and adjacent surfaces to receive concrete. Remove chips, wood, sawdust, dirt, and other debris just before placing concrete.

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K. Retighten forms and bracing before placing concrete, as required, to prevent mortar leaks and maintain proper alignment.

L. Coat contact surfaces of forms with form-release agent, according to manufacturer's written instructions, before placing reinforcement.

3.2 EMBEDDED ITEMS

A. Place and secure anchorage devices and other embedded items required for adjoining work that are attached to or supported by cast-in-place concrete. Use setting drawings, templates, diagrams, instructions, and directions furnished with items to be embedded.

1. Install anchor bolts, accurately located, to elevations required.

2. Install reglets to receive top edge of foundation sheet waterproofing and to receive through-wall flashing in outer face of concrete frame at exterior walls, where flashing is shown at lintels, shelf angles, and other conditions.

3. Install dovetail anchor slots in concrete structures as indicated.

4. Install window and door embeds.

5. Install Blast resistant window embeds.

6.

3.3 REMOVING AND REUSING FORMS

A. General: Formwork, for sides of beams, walls, columns, and similar parts of the Work, that does not support weight of concrete may be removed after cumulatively curing at not less than 10 deg C for 24 hours after placing concrete provided concrete is hard enough to not be damaged by form-removal operations and provided curing and protection operations are maintained.

B. Leave formwork, for beam soffits, joists, slabs, and other structural elements, that supports weight of concrete in place until concrete has achieved the following:

1. At least 70 percent of 28-day design compressive strength, but not less than four days.

2. Determine compressive strength of in-place concrete by testing representative field- or laboratory-cured test specimens according to ACI 301.

3. Remove forms only if shores have been arranged to permit removal of forms without loosening or disturbing shores.

C. Clean and repair surfaces of forms to be reused in the Work. Split, frayed, delaminated, or otherwise damaged form-facing material will not be acceptable for exposed surfaces. Apply new form-release agent.

D. When forms are reused, clean surfaces, remove fins and Latinate, and tighten to close joints.

Align and secure joints to avoid offsets. Do not use patched forms for exposed concrete surfaces unless approved by Project Director and Quality Control Manager.

3.4 SHORES AND RESHORES

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A. Comply with ACI 318M, ACI 301, and recommendations in ACI 347R for design, installation, and removal of shoring and reshoring.

B. In multistory construction, extend shoring or reshoring over a sufficient number of stories to distribute loads in such a manner that no floor or member will be excessively loaded or will induce tensile stress in concrete members without sufficient steel reinforcement.

C. Plan sequence of removal of shores and reshore to avoid damage to concrete. Locate and provide adequate reshoring to support construction without excessive stress or deflection.

3.5 VAPOR RETARDERS

A. Vapor Retarder: Place, protect, and repair vapor-retarder sheets according to ASTM E 1643 and manufacturer's written instructions.

1. Place vapor retarder sheeting in position with longest dimension parallel the direction of pour.

2. Lap joints: 150 mm and seal with manufacturer’s recommended mastic or pressure-sensitive tape.

3.6 STEEL REINFORCEMENT

A. General: Comply with CRSI's "Manual of Standard Practice" for placing reinforcement.

1. Do not cut or puncture vapor retarder. Repair damage and reseal vapor retarder before placing concrete.

B. Install in accordance with steel reinforcement placement shop drawings that have been approved by the Architect/Engineer and reviewed by the Project Director and Quality Control Manager..

C. Clean reinforcement of loose rust and mill scale, earth, ice, and other foreign materials.

D. Accurately position, support, and secure reinforcement against displacement. Locate and support reinforcement with bar supports to maintain minimum concrete cover as approved by the Project Director and Quality Control Manager. .

i. Welding of reinforcing bars not permitted.

E. Set wire ties with ends directed into concrete, not toward exposed concrete surfaces.

F. Install welded wire fabric in longest practicable lengths on bar supports spaced to minimize sagging. Lap edges and ends of adjoining sheets at least one mesh spacing. Offset laps of adjoining sheet widths to prevent continuous laps in either direction. Secure overlaps with wire.

G. Epoxy-Coated Reinforcement: (not used)

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3.7 JOINTS

A. General: Construct joints true to line with faces perpendicular to surface plane of concrete.

B. Construction Joints: Install so strength and appearance of concrete are not impaired, at locations indicated or as approved by Project Director and Quality Contol Manager. Indicate locations and show details on shop drawing submittals.

1. Place joints perpendicular to main reinforcement. Continue reinforcement across construction joints, unless otherwise indicated. Do not continue reinforcement through sides of strip placements of floors and slabs.

2. Form from preformed galvanized steel, plastic keyway-section forms, or bulkhead forms with keys, unless otherwise indicated. Embed keys at least 40 mm into concrete.

3. Locate joints for beams, slabs, joists, and girders in the middle third of spans. Offset joints in girders a minimum distance of twice the beam width from a beam-girder intersection.

4. Locate horizontal joints in walls and columns at underside of floors, slabs, beams, and girders and at the top of footings or floor slabs.

5. Space vertical joints in walls as indicated. Locate joints beside piers integral with walls, near corners, and in concealed locations where possible.

6. Use a bonding agent at locations where fresh concrete is placed against hardened or partially hardened concrete surfaces.

C. Contraction (Control) Joints in Slabs-on Grade: Construct contraction joints in slabs-on-grade to form panels of patterns as shown. Use saw cuts 3 mm wide by one-fourth of the slab depth or inserts 6 mm wide by one-fourth of slab depth, unless otherwise indicated.

1. Form contraction joints by inserting premolded plastic, hardboard, or fiberboard strip into fresh concrete until top surface of strip is flush with slab surface. Tool slab edges round on each side of insert. After concrete has cured, remove inserts and clean groove of loose debris.

2. Contraction joints in unexposed floor slabs may be formed by saw cuts as soon as possible after slab finishing as may be safely done without dislodging aggregate.

3. If joint pattern is not shown, provide joints not exceeding 4.5 meters in either direction and located to be conform to bay spacing wherever possible (at column centerlines, half bays, third bays).

4. Discontinue reinforcing through joint only as shown on the drawings.

D. Isolation Joints in Slabs-on-Grade: After removing formwork, install joint-filler strips at slab junctions with vertical surfaces, such as column pedestals, foundation walls, grade beams, and other locations, as indicated.

1. Extend joint-filler strips full width and depth of joint, terminating flush with finished concrete surface, unless otherwise indicated.

2. Terminate full-width joint-filler strips not less than 12 mm or more than 25 mm below finished concrete surface where joint sealants, specified in Division 7 Section "Joint Sealants," are indicated.

3. Install joint-filler strips in lengths as long as practicable. Where more than one length is required, lace or clip sections together.

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E. Dowel Joints: Install dowel sleeves and dowels or dowel bar and support assemblies at joints where indicated.

1. Use dowel sleeves or lubricate or asphalt-coat one-half of dowel length to prevent concrete bonding to one side of joint.

3.8 WATERSTOPS

A. Flexible Waterstops: Install in construction joints as indicated to form a continuous diaphragm.

Install in longest lengths practicable. Support and protect exposed waterstops during progress of Work. Field-fabricate joints in waterstops according to manufacturer's written instructions.

B. Self-Expanding Strip Waterstops: Install in construction joints and at other locations indicated, according to manufacturer's written instructions, bonding or mechanically fastening and firmly pressing into place. Install in longest lengths practicable.

3.9 CONCRETE PLACEMENT

A. General: Comply with ACI 304, “ Guide for Measuring, Mixing, Transporting, and Placing Concrete,” and as specified.

B. Before placing concrete, verify that installation of formwork, reinforcement, and embedded items is complete and that required inspections have been performed.

C. Do not add water to concrete during delivery, at Project site, or during placement, unless approved by Project Director and Quality Control Manager.

D. Deposit concrete continuously or in layers of such thickness that no new concrete will be placed on concrete that has hardened enough to cause seams or planes of weakness. If a section cannot be placed continuously, provide construction joints as specified. Deposit concrete to avoid segregation and at such a rate of placement not to exceed the maximum shown on the formwork shop drawings.

E. Deposit concrete in forms in horizontal layers no deeper than 600 mm and in a manner to avoid inclined construction joints. Place each layer while preceding layer is still plastic, to avoid cold joints.

1. Consolidate placed concrete with mechanical vibrating equipment supplemented by hand spading, rodding, or tamping. Use equipment and procedures for consolidating concrete recommended by ACI 309R.

2. Do not use vibrators to transport concrete inside forms. Insert and withdraw vibrators vertically at uniformly spaced locations no farther than the visible effectiveness of the vibrator. Place vibrators to rapidly penetrate placed layer and at least 150 mm into preceding layer. Do not insert vibrators into lower layers of concrete that have begun to lose plasticity. At each insertion, limit duration of vibration to time necessary to consolidate concrete and complete embedment of reinforcement and other embedded items without causing mix constituents to segregate.

CAST-IN-PLACE CONCRETE SECTION 03300 - 19

F. Deposit and consolidate concrete for floors and slabs in a continuous operation, within limits of construction joints, until placement of a panel or section is complete.

1. Consolidate concrete during placement operations so concrete is thoroughly worked around reinforcement and other embedded items and into corners.

2. Maintain reinforcement in position on chairs during concrete placement.

3. Screed slab surfaces with a straightedge and strike off to correct elevations.

4. Slope surfaces uniformly to drains where required.

5. Begin initial floating using bull floats or darbies to form a uniform and open-textured surface plane, free of humps or hollows, before excess moisture or bleedwater appears on the surface. Do not further disturb slab surfaces before starting finishing operations.

G. Cold-Weather Placement: Comply with ACI 306.1 and as follows. Protect concrete work from physical damage or reduced strength that could be caused by frost, freezing actions, or low temperatures.

1. When air temperature has fallen to or is expected to fall below 4 deg C, uniformly heat water and aggregates before mixing to obtain a concrete mixture temperature of not less than 10 deg C and not more than 27 deg C at point of placement.

2. Do not use frozen materials or materials containing ice or snow. Do not place concrete on frozen subgrade or on subgrade containing frozen materials.

3. Do not use calcium chloride, salt, or other materials containing antifreeze agents or chemical accelerators, unless otherwise specified and approved in mix designs.

H. Hot-Weather Placement: Place concrete according to recommendations in ACI 305R and as follows, when hot-weather conditions exist:

1. Cool ingredients before mixing to maintain concrete temperature below 32 deg C at time of placement. Chilled mixing water or chopped ice may be used to control temperature, provided water equivalent of ice is calculated to total amount of mixing water. Using liquid nitrogen to cool concrete is Contractor's option.

2. Cover steel reinforcement with water-soaked burlap so steel temperature will not exceed ambient air temperature immediately before embedding in concrete.

3. Fog-spray forms, steel reinforcement, and subgrade just before placing concrete. Keep subgrade moisture uniform without standing water, soft spots, or dry areas.

4. Concrete placement shall not be started if the temperature is 40 deg. C and rising or until it is 43 deg. C and falling. All concrete placement shall be completed at ambient air temperature of less than 45 deg. C.

3.10 FINISHING FORMED SURFACES

A. Rough-Formed Finish: As-cast concrete texture imparted by form-facing material with tie holes and defective areas repaired and patched. Remove fins and other projections exceeding ACI 347R limits for class of surface specified.

B. Smooth-Formed Finish: As-cast concrete texture imparted by form-facing material, arranged in an orderly and symmetrical manner with a minimum of seams. Repair and patch tie holes and defective areas. Remove fins and other projections exceeding 3 mm in height.

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1. Apply to concrete surfaces exposed to public view or to be covered with a coating or covering material applied directly to concrete, such as waterproofing, dampproofing, veneer plaster, or painting.

C. Rubbed Finish: Apply the following to smooth-formed finished concrete:

1. Smooth-Rubbed Finish: Not later than one day after form removal, moisten concrete surfaces and rub with carborundum brick or another abrasive until producing a uniform color and texture. Do not apply cement grout other than that created by the rubbing process.

2. Grout-Cleaned Finish: Wet concrete surfaces and apply grout of a consistency of thick paint to coat surfaces and fill small holes. Mix one part portland cement to one and one-half parts fine sand with a 1:1 mixture of bonding admixture and water. Add white portland cement in amounts determined by trial patches so color of dry grout will match adjacent surfaces. Scrub grout into voids and remove excess grout. When grout whitens, rub surface with clean burlap and keep surface damp by fog spray for at least 36 hours.

D. Related Unformed Surfaces: At tops of walls, horizontal offsets, and similar unformed surfaces adjacent to formed surfaces, strike off smooth and finish with a texture matching adjacent formed surfaces. Continue final surface treatment of formed surfaces uniformly across adjacent unformed surfaces, unless otherwise indicated.

3.11 FINISHING FLOORS AND SLABS

A. General: Comply with recommendations in ACI 302.1R for screeding, restraightening, and finishing operations for concrete surfaces. Do not wet concrete surfaces. Specified Overall Values (SOV) for flatness and Minimum Local Values (MLV) for both FF (flatness) and FL (levelness) are measured according to ASTM E 1155, Standard Test Method for Determining Floor Flatness and Levelness Using the F-Number System. FL (levelness) shall be calculated for suspended slabs before slab shoring is removed.

B. Scratch Finish: While still plastic, texture concrete surface that has been screeded and bull-floated or darbied. to a tolerance of Specified Overall Value (SOV) FF18 / FL15 and Minimum Local Value (MLV) FF13 / FL10. Use stiff brushes, brooms, or rakes.

1. Apply scratch finish to surfaces indicated and to surfaces to receive concrete floor topping or mortar setting beds for ceramic or quarry tile, portland cement terrazzo, and other bonded cementitious floor finishes, concrete fill, and where indicated.

2. Finish surface to a tolerance of Specified Overall Value (SOV) FF18 / FL15 and Minimum Local Value (MLV) FF13 / FL10.

C. Float Finish: Consolidate surface with power-driven floats or by hand floating if area is small or inaccessible to power driven floats. Restraighten, cut down high spots, and fill low spots.

Repeat float passes and restraightening until surface is left with a uniform, smooth, granular texture. Grind smooth any surface defects that would telegraph through applied floor covering system.

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1. Apply float finish to surfaces indicated on the Architectural Drawings, to surfaces to receive trowel finish, and to floor and slab surfaces to be covered with fluid-applied or sheet waterproofing, built-up or membrane roofing, or sand-bed terrazzo.

2. Finish surface to a tolerance of Specified Overall Value (SOV) FF20 / FL18 and Minimum Local Value (MLV) FF15 / FL12.

D. Trowel Finish: After applying float finish, apply first trowel finish and consolidate concrete by hand or power-driven trowel. Continue troweling passes and restraighten until surface is free of trowel marks and uniform in texture and appearance. Grind smooth any surface defects that would telegraph through applied coatings or floor coverings.

1. Apply a trowel finish to surfaces indicated on Architectural Drawings and to floor and slab surfaces exposed to view or to be covered with resilient flooring, carpet, ceramic or quarry tile set over a cleavage membrane, paint, or another thin film-finish coating system.

2. Finish surface to a tolerance of Specified Overall Value (SOV) FF25 / FL20 and Minimum Local Value (MLV) FF17 / FL15.

E. Trowel and Fine-Broom Finish: Apply a partial trowel finish, stopping after second troweling, to surfaces indicated on Architectural Drawings and to surfaces where ceramic or quarry tile is to be installed by either thickset or thin-set method. Immediately after second troweling, and when concrete is still plastic, slightly scarify surface with a fine broom.

F. Broom Finish: Apply a broom finish to exterior concrete platforms, steps, and ramps, and elsewhere as indicated on Architectural Drawings.

1. Immediately after float finishing, slightly roughen trafficked surface by brooming with fiber-bristle broom perpendicular to main traffic route. Coordinate required final finish with Project Director and Quality Control Manger before application.

G. Slip-Resistive Aggregate Finish: Before final floating, apply slip-resistive aggregate finish where indicated on Architectural Drawings and to concrete stair treads, platforms, and ramps.

Apply according to manufacturer's written instructions and as follows:

1. Uniformly spread 12 kg/10 m2 (25 lbs./100 sq. ft.) of dampened slip-resistive aggregate over surface in one or two applications. Tamp aggregate flush with surface, but do not force below surface.

2. After broadcasting and tamping, apply float finish.

3. After curing, lightly work surface with a steel wire brush or an abrasive stone, and water to expose slip-resistive aggregate.

3.12 MISCELLANEOUS CONCRETE ITEMS

A. Filling In: Fill in holes and openings left in concrete structures, unless otherwise indicated, after work of other trades is in place. Mix, place, and cure concrete, as specified, to blend with in-place construction.