Specifications South Fork Foundation Stabilization.pdf

MOBILIZATION 011900

USDA FOREST SERVICE, R-4

SOUTH FORK FOUNDATION STABILIZATION

SECTION 011900 - MOBILIZATION

PART 1 - GENERAL

1.1 SUMMARY

A. This item is intended to compensate the Contractor for operations including, but not limited to, those necessary for the movement of personnel, equipment, supplies, and incidentals to the project site; for payment of premiums for bonds and insurance for the project; and for any other work and operations which must be performed or costs that must be incurred incident to the initiation of meaningful work at the site and for which payment is not otherwise provided for under the contract.

1.2 MEASUREMENT AND PAYMENT

A. The measurement shall be lump sum for mobilization. Payment shall be as follows:

1. Bond premiums will be reimbursed after receipt of the evidence of payment.

2. 50% of the lump sum, not to exceed 5% of the original contract amount, will be paid following completion of 5% of the original contract amount not including mobilization and bond premiums.

3. Payment of the remaining portion of the lump sum, up to 10% of the original contract amount, will be paid following completion of 10% of the original contract amount not including mobilization and bond premiums.

4. Any portion of the lump sum in excess of 10% of the original contract amount will be paid after final acceptance.

5. Progress payments for mobilization and preparatory work shall be subject to retainage.

PART 2 - PRODUCTS (NOT USED)

PART 3 - EXECUTION (NOT USED)

END OF SECTION 011900

April 2025

USDA Forest Service South Fork Dwelling Foundation Evaluation

JOINT SEALERS 079000

SECTION 079000 JOINT SEALERS

PART 1 - GENERAL

1.1 SUMMARY

A. This specification describes the sealing of joints and cracks with a one-component, gun-grade, elastomeric polyurethane sealant.

1.2 QUALITY ASSURANCE

A. Manufacturing qualifications: The manufacturer of the specified product shall be ISO 9001:2008 certified and have in existence a recognized ongoing quality assurance program independently audited on a regular basis.

B. Contractor qualifications: Contractor shall be qualified in the field of concrete repair and protection with a successful track record of 5 years or more. The contractor shall maintain qualified personnel who have received product training from a manufacturer's representative.

C. Install materials in accordance with all safety and weather conditions required by manufacturer or as modified by applicable rules and regulations of local, state and federal authorities having jurisdiction. Consult Material Safety Data Sheets for complete handling recommendations.

1.3 DELIVERY, STORAGE, AND HANDLING

A. All materials must be delivered in original, unopened containers with the manufacturer's name, labels, product identification, and batch numbers. Damaged material must be removed from the site immediately.

B. Store all materials off the ground and protect from rain, freezing or excessive heat until ready for use.

C. Condition the specified product as recommended by the manufacturer.

1.4 JOB CONDITIONS

A. Environmental Conditions: Do not apply material if it is raining or snowing or if such conditions appear to be imminent. Minimum application temperature 40ºF (5ºC) and rising.

B. Protection: Precautions should be taken to avoid damage to any surface near the work zone due to mixing and handling of the specified coating.

1.5 SUBMITTALS

A. Submit two copies of manufacturer's literature, to include: Product Data Sheets, and appropriate Material Safety Data Sheets (MSDS).

JOINT SEALERS 079000

1.6 WARRANTY

A. Provide a written warranty from the manufacturer against defects of materials for a period of one (1) year, beginning with the date of substantial completion of the project.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Sikaflex Concrete Fix, as manufactured by Sika Corporation, 201 Polito Avenue, Lyndhurst, NJ 07071 is considered to conform to the requirements of this specification.

2.2 MATERIALS

A. Polyurethane sealant:

1. The joint sealant shall be a moisture-cured, 1-component, polyurethane-based, non-sag elastomeric sealant. It shall be applicable in horizontal, vertical, and overhead joints.

B. Any primers, as required, recommended by the manufacturer of the specified product, approved by the engineer.

C. Backer rod or bond breaker tape, as approved by the engineer.

2.3 PERFORMANCE CRITERIA

A. Properties of the uncured polyurethane sealant:

1. Initial Cure (Tack-Free Time): 3-6 hours

Final Cure 5 – 7 days

2. Consistency: non-sag

3. Shore A Hardness (ASTM D-2240) at 21 days: 40+/- 5

4. Service Range: -40o to 170oF (-400 to 77 0 C)

5. The sealant shall be non-staining.

PART 3 - EXECUTION

3.1 SURFACE PREPARATION

A. Clean all surfaces. Cracks/Joints must be sound, clean, dry, frost-free, and free of oil and grease. Curing compound residues and any other foreign matter must be thoroughly removed.

3.2 MIXING AND APPLICATION

A. Cracks:

1. For best performance, Sikaflex® Concrete Fix should be gunned into joint when joint slot is at mid-point of its designed expansion and contraction.

Place nozzle of the gun into the bottom of the joint and fill the entire joint.

Keep the nozzle in the sealant, continue with a steady flow of sealant

JOINT SEALERS 079000

preceding the nozzle to avoid air entrapment. Avoid overlapping of sealant to eliminate entrapment of air. Tool as required. Maximum sealant depth is 1/2 in. (12.7 mm) and width is 1 in. (25.4 mm). Minimum depth is 1/4 (6.3

mm) and width is 1/4 in. (6.3 mm). Proper design is 2:1 width to depth ratio.

For use in horizontal joints in traffic areas, the absolute minimum depth of the sealant is 1/2 in. (12.7 mm). Always use bond breaker tape or closed cell backer rod for support on horizontal joints. Tool as necessary, with dry sealant spatula.

2. Adhere to all limitations and cautions for the polyurethane sealant as stated in the manufacturer's printed literature.

3.3 CLEANING

A. The uncured polyurethane sealant can be cleaned with an approved solvent. The cured polyurethane sealant can only be removed mechanically.

B. Leave finished work and work area in a neat, clean condition without evidence of spillovers onto adjacent areas.

END OF SECTION 079000

APRIL 2025

STEEL HELICAL PIERS 312600

SECTION 312600 - STEEL HELICAL PIERS

PART 1 - GENERAL

1.1 DESCRIPTION:

A. The work of this section consists of furnishing and installing steel helical piers.

1.2 QUALITY ASSURANCE

A. Installer Qualifications: Installation shall be done by a contractor with a minimum of 10 years experience installing helical piers and deep foundation systems. A list of 10 recent projects shall be submitted prior to starting installation.

B. A qualified inspector (when required) shall be present during helical pier installation in accordance with the local building code.

C. Welding: Meet requirements of AWS “Structural Welding Code,” D1.1, latest edition.

All welders shall be AWS certified.

1.3 SUBMITTALS

A. Submit shop drawings with plans, sections, and details indicating shaft and helix sizes, and include manufacturer's catalog cut and data sheets.

1.4 MEASUREMENT AND PAYMENT:

A. There will be no separate measurement or payment for work in this section. Payment will be included in the contract unit price for items shown in the schedule of items.

PART 2 - PRODUCTS

2.1 MATERIAL

A. Square Tubular Steel Helical Piers:

1. Pier Shafts (Lead Section and Extensions)

a. The 2-inch square tubular shaft is 2” x 2” x .25” wall thickness with connection bolt of 0.75” diameter SAE J429 Gr 5 steel (Fy=120 KSI) or equivalent. Structural tubing per ASTM A500 Gr C. Ultimate mechanical capacity 40,000 lbs. compression, 40,000 lbs. tension.

b. The 2.5-inch square tubular shaft is 2.5” x 2.5” x .25” wall thickness with connection bolt of 0.75” diameter SAE J429 Gr 5 steel (Fy=120 KSI) or equivalent. Structural tubing per ASTM A500 Gr C. Ultimate mechanical capacity 70,000 lbs. compression, 70,000 lbs. tension.

c. The 3-inch square tubular shaft is 3” x 3” x .25” wall thickness with connection bolt of 0.875” diameter SAE J429 Gr 5 steel (Fy=120 KSI) or equivalent. Structural tubing per ASTM A500 Gr C. Ultimate mechanical capacity 110,000 lbs. compression, 110,000 lbs. tension.

2. Helices: Carbon steel sheet, strip, or plate formed on matching metal dies to true helical shape, 0.5 inch (12.7 mm) thick, and shall conform to the following ASTM specifications:

a. 7,000 ft-lbs. (9.49 kN-m) 1.5-inch (38.1 mm) piers: ASTM A656 Grade 80.

STEEL HELICAL PIERS 312600

b. 11,000 ft.-lbs. (14.9 kN-m) 1.75 (44.5 mm) inch piers: ASTM A656 Grade 80.

3. Bolts: The sizes and types of bolts used to connect the helical pier extensions to lead sections, or another extension shall conform to the following ASTM specifications:

a. 1.5-inch (38.1 mm) helical piers: 0.75-inch (19.1 mm) diameter bolt per

ASTM A449.

b. 1.75-inch (44.5 mm) helical piers: 0.875-inch (22.2 mm) diameter bolt per

ASTM A193 Grade B7.

4. Plate Caps: 1/2” thick A36 steel top plate welded to top of coupler with 1/4” fillet weld all around coupler. Coupler as compatible with pier shaft fastened to shaft with weld, bolt or epoxy.

5. Couplings: Cold-forged welded to the shaft.

6. Finish: All material shall be galvanized per ASTM B633.

B. Modular Steel Helical Piers:

1. Pier Shafts (Lead Section and Extensions)

a. The 1.5-inch (38.1 mm) round cornered square (RCS) solid steel threaded shafts shall conform to the general requirements of ASTM A29 and the following descriptions: High strength low alloy (HSLA), low to medium carbon steel grade with improved strength due to fine grain size and structure having a torsional strength rating of 7,000 ft.-lbs. (9.49 kN-m).

b. The 1.75-inch (44.5 mm) round cornered square (RCS) solid steel threaded shafts shall conform to the general requirements of ASTM A29 and the following descriptions: High strength low alloy (HSLA), low to medium carbon steel grade with improved strength due to fine grain size and structure having a torsional strength rating of 11,000 ft.-lbs. (14.9 kN-m).

2. Helices: Attach to threaded shaft via steel keys. Helices made of carbon steel sheet, strip, or plate formed on matching metal dies to true helical shape, 0.5 inch (12.7

mm) thick, and shall conform to the following ASTM specifications:

a. 7,000 ft-lbs. (9.49 kN-m) 1.5-inch (38.1 mm) piers: ASTM A656 Grade 80.

b. 11,000 ft.-lbs. (14.9 kN-m) 1.75 (44.5 mm) inch piers: ASTM A656 Grade

80.

3. Bolts: The sizes and types of bolts used to connect the helical pier extensions to lead sections, or another extension shall conform to the following ASTM specifications:

a. 1.5-inch (38.1 mm) helical piers: 0.75-inch (19.1 mm) diameter bolt per

ASTM A449.

b. 1.75-inch (44.5 mm) helical piers: 0.875-inch (22.2 mm) diameter bolt per

ASTM A193 Grade B7.

4. Plate Caps: 1/2” thick A36 steel top plate welded to top of coupler with 1/4” fillet weld all around coupler. Coupler as compatible with pier shaft fastened to shaft with weld, bolt or epoxy.

5. Couplings: Cold-forged, attached to threaded shaft via steel keys.

6. Finish: All material shall be galvanized per ASTM B633.

C. Conventional Solid Bar Steel Helical Piers:

STEEL HELICAL PIERS 312600

1. Pier Shafts (Lead Section and Extensions)

a. The 1.5-inch (38.1 mm) round cornered square (RCS) solid steel shafts shall conform to the general requirements of ASTM A29 and the following descriptions: High strength low alloy (HSLA), low to medium carbon steel grade with improved strength due to fine grain size and structure having a torsional strength rating of 7,000 ft.-lbs. (9.49 kN-m).

b. The 1.75-inch (44.5 mm) round cornered square (RCS) solid steel shafts shall conform to the general requirements of ASTM A29 and the following descriptions: High strength low alloy (HSLA), low to medium carbon steel grade with improved strength due to fine grain size and structure having a torsional strength rating of 11,000 ft.-lbs. (14.9 kN-m).

2. Helices: Carbon steel sheet, strip, or plate formed on matching metal dies to true helical shape, 0.5 inch (12.7 mm) thick, and shall conform to the following ASTM specifications:

a. 7,000 ft-lbs. (9.49 kN-m) 1.5-inch (38.1 mm) piers: ASTM A656 Grade 80.

b. 11,000 ft.-lbs. (14.9 kN-m) 1.75 (44.5 mm) inch piers: ASTM A656 Grade

80.

3. Bolts: The sizes and types of bolts used to connect the helical pier extensions to lead sections, or another extension shall conform to the following ASTM specifications:

a. 1.5-inch (38.1 mm) helical piers: 0.75-inch (19.1 mm) diameter bolt per

ASTM A449.

b. 1.75-inch (44.5 mm) helical piers: 0.875-inch (22.2 mm) diameter bolt per

ASTM A193 Grade B7.

4. Plate Caps: 1/2” thick A36 steel top plate welded to top of coupler with 1/4” fillet weld all around coupler. Coupler as compatible with pier shaft fastened to shaft with weld, bolt or epoxy.

5. Couplings: Cold-forged welded to the shaft.

6. Finish: All material shall be galvanized per ASTM B633.

PART 3 - EXECUTION

3.1 EQUIPMENT:

A. Installation Equipment:

1. Shall be a rotary type of motor with equal forward and reverse torque capabilities.

This equipment shall be capable of continual adjustment of the torque drive unit's revolutions per minute (RPM's) during installation. Percussion drilling equipment will not be allowed.

2. Shall be capable of applying installation torque equal to the torque required to meet the pier loads.

3. Equipment shall be capable of applying axial compression (crowd) pressure and torque simultaneously.

B. Torque Monitoring Devices:

1. The torque being applied by the installing units shall be monitored throughout the installation by the installer. The torque monitoring device shall either be a part of

STEEL HELICAL PIERS 312600

the installing unit or an independent device in-line with the installing unit.

Calibration for either unit shall be available for review by the COR.

3.2 INSTALLATION PROCEDURES:

A. Advancing Sections:

1. Engage and advance the helical pier sections in a smooth, continuous manner with the rate of pier rotation in the range of 5 to 35 RPM.

2. Apply sufficient axial compression (crowd) pressure to uniformly advance the helical sections to approximately 3-inches (76.2 mm) per revolution. The rate of rotation and magnitude of crowd pressure must be adjusted for different soil conditions and depths to maintain the penetration rate.

3. If the helical section ceases to advance, refusal will have been reached, and the installation shall be terminated.

B. Termination Criteria:

1. The torque measured during the installation shall not exceed the torsional strength rating of the steel helical lead and extension sections.

2. The minimum depth criteria indicated on the Drawings must be satisfied prior to terminating the steel helical pier.

3. The top helix is to be located not less than five (5) feet (below the grade elevation unless otherwise approved by the COR.

4. If the torsional strength rating of the pier and/or installing unit has been reached prior to satisfying the minimum depth required, the installing contractor shall have the following options:

a. Terminate the installation at the depth obtained with the approval of the COR.

b. Remove the existing pier and install a pier with smaller and/or fewer helices.

This revised pier shall be terminated deeper than the terminating depth of the original pier as directed by the COR.

5. In the event the minimum installation torque is not achieved at minimum depth, the Contractor shall install the foundation deeper using additional plain extension sections.

6. The minimum specified installation torque shall have been met when the measured installation torque meets or exceeds the minimum specified installation torque in two successive readings of the measuring device, unless otherwise specified by the

COR.

7. The installer shall keep a written installation record for each helical pier. This record shall include the following information as a minimum:

a. Project name and location.

b. Name of authorized dealer/installer.

c. Name of installers foreman or representative witnessing the installation.

d. Date of installation.

e. Location of helical pier(s).

f. Description of lead section including number and diameter of helices and extensions used.

g. Overall depth of installation from a known reference point.

h. Installation torque at termination of pier.

STEEL HELICAL PIERS 312600

i. Load transfer device

END OF SECTION

CRUSHED AGGREGATE BASE OR SURFACE COURSE 321204

SOUTH FORK FOUNDATION STABILIZATION

SECTION 321204 - CRUSHED AGGREGATE BASE OR SURFACE COURSE

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes furnishing, hauling and placing one or more courses of aggregate base or surface course material on roadways, campground spurs, parking areas, concrete pads, sidewalks and pathways. In addition, may include furnishing, hauling, and placing crushed aggregate for bedding and backfill.

1.2 SUBMITTALS

A. Aggregate source, gradation, and material properties.

1. Submit target values within the gradation ranges shown in Table 321204-1 and /or 321204-2 for the required grading. After reviewing the Contractor’s proposed target values the CO will determine the final values for the gradation and notify the Contractor in writing.

B. Compaction density test results and proctor.

1.3 MEASUREMENT AND PAYMENT

A. There will be no separate measurement or payment for work in this Section. Payment will be included in the contract unit price as shown on the Schedule of Items.

PART 2 - PRODUCTS

2.1 AGGREGATES

A. General: Furnish aggregate Subbase, Base, or Surface Courses meeting the gradation D column shown in Table 321204-1. Aggregate grade selection shall be as shown on the Drawings and in the Schedule of Items.

B. Materials shall be obtained from an approved source. Furnish aggregates that consist of hard, durable particles or fragments of crushed stone, crushed slag, or crushed gravel meeting the appropriate gradation and conforming to the following:

1. Los Angeles abrasion, AASHTO T 96 …...…………………….……... 40% max

2. Sodium sulfate soundness loss (five cycles), AASHTO T 104 ……….. 12% max

3. Durability index, AASHTO T 210 ……………………………………. 35 min

4. Fractured faces, ASTM D 5821 (Subbase or Base)……………………. 50% min

5. Fractured faces, ASTM D 5821 (Surface Course).……………………. 75% min

6. Free from organic matter and lumps or balls of clay.

C. Obtain the aggregate gradation by crushing, screening, and blending processes as necessary.

2.2 AGGREGATE GRADATION

Table 321204-1, Crushed Aggregate Grading Requirements for Subbase and Base.

Percent Passing (AASHTO T27 and T11)

Sieve Grading A (Subbase)

Grading B (Subbase)

Grading C (Base)

Grading D (Base)

Grading E (Base)

2 1/2 -inch 100 2-inch 97-100 100 100 1-1/2-inch 97-100 1-inch 65-79 (6) 80-100 (6) 100 3/4-inch 60-94 (6) 86-100 (6) 100 1/2-inch 45-59 (7) 3/8-inch 40-69 (6) 51-82 (6) 62-90 (6) No. 4 28-42 (6) 40-60 (8) 31-54 (6) 36-64 (6) 36-74 (6) No. 40 9-17 (4) 12-26 (4) 12-26 (4) No. 200 4-8 (3) 4-12 (4) 4-7 (3) 4-7 (3) 4-7 (3)

() The value in the parentheses is the allowable deviation (+ / - ) from the target values.

Liquid Limit, AASHTO T89 = 25 max. Plastic Limit, AASHTO T-90 = nonplastic.

If the plasticity index (PI) is greater than 0, the TV range for the No. 200 sieve size is 8- 12 (4).

PART 3 - EXECUTION

3.1 GENERAL

A. Verify that subgrade is dry and in suitable condition, locate areas that are unstable or that require further compaction.

B. Proceed with aggregate placement only after unsatisfactory conditions have been corrected and subgrade is approved in writing by the Contracting Officer (CO).

3.2 PREPARATION OF SUBGRADE

A. The subgrade shall be prepared in accordance with requirements of other specifications sections.

B. The subgrade shall conform to the lines and grades shown on the Drawings. Suitable material shall be utilized in the preparation of the subgrade. When embankment or fill is necessary, subgrade shall be placed in compacted layers not exceeding 6 inches. Unless specified otherwise, subgrade shall be compacted to 95 percent of AASHTO T 99, method C or D.

C. Suitable material for subgrade shall be granular material or fine compatible soil free of excess moisture, muck, frozen lumps, roots, sod, and other deleterious material. Remove all rock particles and hard earth clods larger than 3 inches in the longest dimension.

3.3 MIXING AND SPREADING

A. Mix the aggregate and adjust the moisture content to obtain uniform moisture. Spread and shape the mixture on the prepared surface in a uniform layer not to exceed 6 inches in compacted thickness.

B. Route hauling equipment uniformly over the full width of the surface to minimize rutting or uneven compaction.

3.4 COMPACTING

A. Compact each layer of aggregate full width. Compact each layer to a density of at least 95 percent of the maximum density as determined by AASHTO T 99 method C or D.

B. Testing shall be at intervals specified in tables shown in Section 014100 “Quality Control.”

3.5 SURFACE AND CONSTRUCTION TOLERANCES

A. Shape the surface to the required template and as staked. Surface shall be graded and shaped smooth to within ½-inch in 10 feet.

B. Maintain the aggregate course to the correct lines, grade, and cross-section by blading, watering, and rolling until placement of the next course.

C. Upon completion of full placement and after haul trucks have completed their haul across section of the road, the road shall be finish bladed, watered, and rolled.

D. Aggregate shall be placed as shown on the drawings and as staked. Tolerance for thickness of aggregate shall be +/– ½-inch and for width shall be + 1-foot.

3.6 ACCEPTANCE

A. Aggregate shall be accepted following placement when shown to meet material quality, gradation, compaction requirements, required depth and width, and finish blading.

END OF SECTION 321204

May 2025

WASTE MATERIAL DISPOSAL 024100

SOUTH FORK FOUNDATION STABILIZATION

SECTION 024100 - WASTE MATERIAL DISPOSAL

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes the loading, handling, hauling, and placing of excess excavation material, unsuitable excavation material, clearing and grubbing debris, and construction and demolition debris.

1.2 MEASUREMENT AND PAYMENT

A. There will be no separate measurement or payment for work in this Section. Waste material disposal is considered incidental to other items of work shown in the Schedule of Items.

PART 2 - PRODUCTS – NOT APPLICABLE

PART 3 - EXECUTION

3.1 WASTE MATERIAL TO BE HAULED TO A LANDFILL

A. All demolition materials, garbage, and other refuse generated shall be removed from the project site and legally disposed off of Government property in an approved landfill.

B. All stumps, slash and other clearing and grubbing debris shall be hauled to a landfill.

C. The contractor is responsible for all costs and permits associated with landfill disposal.

D. The Government is not responsible for waste material upon its departure from the project site.

END OF SECTION 024100

PROJECT SITE PREPARATION AND GRADING 312100

SOUTH FORK FOUNDATION STABILIZATION

SECTION 312100 - PROJECT SITE PREPARATION AND GRADING

PART 1 - GENERAL

1.1 This Section includes the following:

A. Clearing, grubbing, sediment and erosion control measures, shaping, compacting, excavating, and/or filling to the established sub grade as shown on the drawings, details and as staked. Such items covered include, but are not limited to construction of subgrade for roads, parking areas, campground spurs, pathways, concrete slabs, subsurface drainage structures, and grading around constructed features.

B. This section also includes the disposal of waste materials generated.

1.2 RELATED SECTIONS:

A. The following Sections contain requirements that relate to this Section:

1. Section 024100 “Waste Material Disposal” for the loading, handling, hauling, and placing of excess excavation material, and unsuitable excavation material.

2. Section 312000 “Earthwork” for preparing subgrades for slabs-on-grade, walks, pavements, lawns, and plantings, and for excavating and backfilling for buildings, structures, utility trenches, and buried mechanical and electrical utilities.

1.3 REFERENCES

A. The publications listed below form a part of this specification to the extent referenced.

The publications are referred to in the text by the basic designation only.

1. Standard Moisture Density Test, AASHTO T-99, Method C or D.

2. Density of Soil In-Place by the Sand-Cone Method, AASHTO T191

3. Density of Soil In-Place by the Drive Cylinder Method, AASHTO T204

4. Density of Soil In-Place by the Rubber-Balloon Method, AASHTO T205

5. Standard Test Methods for Laboratory Compaction Characteristics of Soil Using

Standard Effort (12,400 ft-lbf/ft3 (600 kN-m/m3)), ASTM D698

6. Standard Test Method for Density and Unit Weight of Soil in Place by the Sand-

Cone Method, ASTM D1556

7. Standard Test Method for Density and Unit Weight of Soil in Place by the Rubber

Balloon Method, ASTM D2167

8. Standard Classification of Industrial Fluid Lubricants by Viscosity System, ASTM

D2422

1.4 METHOD OF MEASUREMENT AND PAYMENT:

A. There will be no separate measurement or payment for work in this Section. Payment will be included in the contract unit price as shown on the Schedule of Items.

PROJECT SITE PREPARATION AND GRADING 312100

PART 2 - EXECUTION

2.1 PREPARATION

A. Stripping Sod and Other Organic Materials: Sod, pine needles, and soil heavy in organic materials (topsoil) shall be stripped to mineral soil prior to any excavation or placement of fill material. Stripped material shall be stockpiled on site and placed on disturbed areas upon completion of grading operations. Excess stripped material shall be disposed of in accordance with Section 024100 “Waste Material Disposal”.

B. Clearing and Grubbing

1. All clearing and grubbing shall be performed in advance of beginning excavation and grading operations in accordance with Section 311000 “Clearing and Grubbing”.

2. Care shall also be taken to protect and preserve trees and plantings not marked for removal.

3. During all phases of construction the contractor shall confine all of his operations within the working limits as defined in Section 311000 “Clearing and Grubbing”.

2.2 GRADING

A. Graded areas shall be constructed of shallow cuts and fills using native excavated soil and/or select borrow. Some light excavation shall be performed to remove protruding boulders and surface irregularities and at other locations as staked by the Contracting Officer.

2.3 EARTHWORK

A. Shall be completed in accordance with Section 312000 "Earthwork" for the construction of subgrades for slabs-on-grade, family unit and group area pads, sidewalks, plantings, and for excavating and backfilling for buildings, structures, utility trenches, and buried mechanical and electrical utilities.

2.4 CLEANUP

A. The Contractor shall confine his operation to that area within the staked fill or cut line of existing roadways, parking areas, paths, etc. No equipment shall be moved over, operated from, or parked outside this staked fill or cut line, clearing limit, or existing roadway. No materials shall be moved over, stored, or obtained from outside the staked cut or fill lines except by written permission of the Contracting Officer. No rocks, stumps, limbs, debris, soil, or other material shall be left as a windrow or accumulation along the toe of fills, top of cuts, or adjacent areas.

END OF SECTION 312100

CAST-IN-PLACE CONCRETE 033000

SOUTH FORK FOUNDATION STABILIZATION

SECTION 033000 - CAST-IN-PLACE CONCRETE

PART 1 - GENERAL

1.1 SUMMARY

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

1.2 DEFINITIONS

A. Cementitious Materials: Portland cement alone or in combination with one or more of the following: blended hydraulic cement, fly ash and other pozzolans, ground granulated blast-furnace slag, and silica fume; subject to compliance with requirements.

1.3 SUBMITTALS

A. Product Data: For each type of product indicated.

B. Design Mixtures: For each concrete mixture. Indicate amounts of mixing water to be withheld for later addition at Project site.

C. Steel Reinforcement Shop Drawings when project design requires special consideration.

D. Field quality-control test reports.

1.4 MEASUREMENT AND PAYMENT

A. There will be no separate measurement or payment for work in this section. Payment will be included at the contract unit price for items shown on the Schedule of Items.

PART 2 - PRODUCTS

2.1 FORM-FACING MATERIALS

A. Smooth-Formed Finished Concrete: Form-facing panels that will provide continuous, true, and smooth concrete surfaces. Furnish in largest practicable sizes to minimize number of joints.

1. Plywood, metal, or other approved panel materials.

2. Exterior-grade plywood panels, suitable for concrete forms, complying with

DOC PS 1, and as follows:

a. Structural 1, B-B or better; mill oiled and edge sealed.

b. B-B (Concrete Form), Class 1 or better; mill oiled and edge sealed.

B. Rough-Formed Finished Concrete: Plywood, lumber, metal, or another approved material. Provide lumber dressed on at least two edges and one side for tight fit.

C. Forms for Cylindrical Columns, Pedestals, and Supports: Metal, glass-fiber-reinforced plastic, paper, or fiber tubes that will produce surfaces with gradual or abrupt irregularities not exceeding specified formwork surface class. Provide units with sufficient wall thickness to resist plastic concrete loads without detrimental deformation.

D. Form-Release Agent: Commercially formulated form-release agent 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, removable or snap-off metal or glass-fiber-reinforced plastic form ties designed to resist lateral pressure of fresh concrete on forms and to prevent spalling of concrete on removal.

2.2 STEEL REINFORCEMENT

A. Reinforcing Bars: ASTM A 615/A 615M, Grade 60 , deformed.

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

C. Deformed-Steel Wire: ASTM A 496.

2.3 REINFORCEMENT ACCESSORIES

A. Joint Dowel Bars: ASTM A 615/A 615M, Grade 60, plain-steel bars, cut bars true to length with ends square and free of burrs.

B. Bar Supports: Bolsters, chairs, spacers, and other devices for spacing, supporting, and fastening reinforcing bars and welded wire reinforcement in place. Manufacture bar supports from steel wire, plastic, or precast concrete according to CRSI's "Manual of Standard Practice," 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 steel wire or CRSI Class 2 stainless-steel bar supports.

2.4 CONCRETE MATERIALS

A. Cementitious Material: Use the following cementitious materials, of the same type, brand, and source, throughout Project:

1. Portland Cement: ASTM C 150, Type II.

B. Normal-Weight Aggregates: ASTM C 33, graded, from a single source.

1. Maximum Coarse-Aggregate Size: 1 inch nominal.

2. Fine Aggregate: Free of materials with deleterious reactivity to alkali in cement.

C. Water: ASTM C 94/C 94M and potable.

D. Fly ash, ground iron blast-furnace slag, or silica fume may partially replace cement in any mix as follows:

1. Fly Ash:

a. Class F – Not more than 20 percent of the minimum mass of portland cement may be replaced with class F fly ash.

b. Class C – Not more than 25 percent of the minimum mass of portland cement may be replaced with class C fly ash.

2. Ground Iron Blast-Furnace Slag: Not more than 25 percent of the minimum mass of portland cement may be replaced with ground iron blast-furnace slag.

3. Silica Fume (microsilica): Not more than 10 percent of the minimum mass of portland cement may be replaced with silica fume.

4. Additionally, fly ash, slag, and silica fume will constitute no more than 50 percent of the total replacement weight.

2.5 ADMIXTURES

A. Air-Entraining Admixture: ASTM C 260.

B. Chemical Admixtures: Provide admixtures certified by manufacturer to be compatible with other admixtures and that will not contribute water-soluble chloride ions exceeding those permitted in hardened concrete. Do not use calcium chloride or admixtures containing calcium chloride.

1. Retarding Admixture: ASTM C 494/C 494M, Type B.

C. Synthetic Fiber: Monofilament or fibrillated polypropylene fibers engineered and designed for use in concrete pavement, complying with ASTM C 1116, Type III, 1/2 to 1-1/2 inches long.

2.6 CURING MATERIALS

A. Absorptive Cover: AASHTO M 182, Class 2, burlap cloth made from jute or kenaf, weighing approximately 9 oz./sq. yd. when dry.

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

C. Water: Potable.

D. Clear, Waterborne, Membrane-Forming Curing Compound: ASTM C 309, Type 1, Class B, dissipating or nondissipating. Liquid Membrane-Forming Compounds. Material shall be certified by curing compound manufacturer to not interfere with bonding of floor covering.

2.7 RELATED MATERIALS

A. Expansion- and Isolation-Joint-Filler Strips: ASTM D 1751, asphalt-saturated cellulosic fiber or ASTM D 1752, cork or self-expanding cork.

B. Semirigid Joint Filler: Two-component, semirigid, 100 percent solids, epoxy resin with a Type A shore durometer hardness of 80 per ASTM D 2240.

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

D. Epoxy Bonding Adhesive: ASTM C 881, two-component epoxy resin, capable of humid curing and bonding to damp surfaces, of class suitable for application temperature and of grade to suit requirements, and as follows:

1. Types IV and V, load bearing, for bonding hardened or freshly mixed concrete to hardened concrete.

2.8 REPAIR MATERIALS

A. Repair Underlayment: Cement-based, polymer-modified, self-leveling product that can be applied in thicknesses from 1/8 inch (3.2 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, 1/8 to 1/4 inch or coarse sand as recommended by underlayment manufacturer.

4. Compressive Strength: Not less than [4100 psi ] at 28 days when tested according to ASTM C 109/C 109M.

B. Repair Overlayment: Cement-based, polymer-modified, self-leveling product that can be applied in thicknesses from 1/8 inch 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 topping manufacturer recommended for substrate, conditions, and application.

3. Aggregate: Well-graded, washed gravel, 1/8 to 1/4 inch or coarse sand as recommended by topping manufacturer.

4. Compressive Strength: Not less than [5000 psi] at 28 days when tested according to ASTM C 109/C 109M.

2.9 CONCRETE MIXTURES, GENERAL

A. Prepare design mixtures for each type and strength of concrete, proportioned on the basis of laboratory trial mixture or field test data, or both, according to ACI 301.

1. Use a qualified independent testing agency for preparing and reporting proposed mixture designs based on laboratory trial mixtures.

B. Limit water-soluble, chloride-ion content in hardened concrete to 0.06 percent by weight of cement.

C. Admixtures: Use admixtures according to manufacturer's written instructions.

D. Color Pigment: Add color pigment to concrete mixture according to manufacturer's written instructions and to result in hardened concrete color consistent with approved mockup.

2.10 CONCRETE MIXTURES FOR BUILDING ELEMENTS

A. Footings: Proportion normal-weight concrete mixture as follows:

1. Minimum Compressive Strength: 3500 psi at 28 days.

2. Maximum Water-Cementitious Materials Ratio: 0.50.

3. Slump Limit: 3-5 inch (75-125 mm), plus or minus 1 inch (25 mm).

4. Air Content: 4 percent, plus or minus 1 percent at point of delivery for [1-inch (25-mm)] nominal maximum aggregate size.

B. Foundation Walls: Proportion normal-weight concrete mixture as follows:

1. Minimum Compressive Strength: 3500 psi at 28 days.

2. Maximum Water-Cementitious Materials Ratio: 0.50.

3. Slump Limit: 4 inches, plus or minus 1 inch.

4. Air Content: 5 percent, plus or minus 1 percent at point of delivery for 1-inch nominal maximum aggregate size.

C. Slabs-on-Grade: Proportion normal-weight concrete mixture as follows:

1. Minimum Compressive Strength: 3500 psi at 28 days.

2. Minimum Cementitious Materials Content: 540 lb/cu. yd.

3. Slump Limit: 4 inches, plus or minus 1 inch.

4. Air Content: 5 percent, plus or minus 1 percent at point of delivery for 1-inch nominal maximum aggregate size.

5. Air Content: Do not allow air content of troweled finished floors to exceed 3 percent.

6. Synthetic Fiber: Uniformly disperse in concrete mixture at manufacturer's recommended rate, but not less than [1.0 lb/cu. yd.].

2.11 FABRICATING REINFORCEMENT

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

2.12 CONCRETE MIXING

A. Ready-Mixed Concrete: Measure, batch, mix, and deliver concrete according to ASTM C 94/C 94M and ASTM C 1116 and furnish batch ticket information.

1. When air temperature is between 85 and 90 deg F, reduce mixing and delivery time from 1-1/2 hours to 75 minutes; when air temperature is above 90 deg F, reduce mixing and delivery time to 60 minutes.

B. Project-Site Mixing: Measure, batch, and mix concrete materials and concrete according to ASTM C 94/C 94M. Mix concrete materials in appropriate drum-type batch machine mixer.

1. For mixer capacity of 1 cu. yd. or smaller, continue mixing at least 1-1/2 minutes, but not more than 5 minutes after ingredients are in mixer, before any part of batch is released.

2. For mixer capacity larger than 1 cu. yd., increase mixing time by 15 seconds for each additional 1 cu. yd.

3. Provide batch ticket for each batch discharged and used in the Work, indicating Project identification name and number, date, mixture type, mixture time, quantity, and amount of water added. Record approximate location of final deposit in structure.

PART 3 - EXECUTION

3.1 FORMWORK

A. Design, erect, shore, brace, and maintain formwork, according to ACI 301, to support vertical, lateral, static, and dynamic loads, and construction loads that might be applied, until 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, 1/8 inch for smooth-formed finished surfaces.

2. Class B, 1/4 inch for rough-formed finished surfaces.

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

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

Provide crush or wrecking plates where stripping may damage cast concrete surfaces.

Provide top forms for inclined surfaces steeper than 1.5 horizontal to 1 vertical.

1. Install keyways, reglets, recesses, and the like, for easy removal.

2. 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 or round 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.

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 is 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 rods, accurately located, to elevations required and complying with tolerances in Section 7.5 of AISC's "Code of Standard Practice for Steel Buildings and Bridges."

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 50 deg F for 48 hours after placing concrete, if concrete is hard enough to not be damaged by form-removal operations and curing and protection operations are maintained.

1. Leave formwork for beam soffits, joists, slabs, and other structural elements that supports weight of concrete in place until concrete has achieved at least 70 percent of its 28-day design compressive strength.

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

B. 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.

C. When forms are reused, clean surfaces, remove fins and laitance, and tighten to close joints. Align and secure joints to avoid offsets. Do not use patched forms for exposed concrete surfaces unless approved by Contracting Officer.

3.4 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. Clean reinforcement of loose rust and mill scale, earth, ice, and other foreign materials that would reduce bond to concrete.

C. Accurately position, support, and secure reinforcement against displacement. Locate and support reinforcement with bar supports to maintain minimum concrete cover. Do not tack weld crossing reinforcing bars.

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

3.5 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 the Contracting Officer.

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

C. Contraction Joints in Slabs-on-Grade: Form weakened-plane contraction joints, sectioning concrete into areas as indicated. Construct contraction joints for a depth equal to at least one-fourth of concrete thickness as follows:

1. Grooved Joints: Form contraction joints after initial floating by grooving and finishing each edge of joint to a radius of 1/8 inch. Repeat grooving of contraction joints after applying surface finishes. Eliminate groover tool marks on concrete surfaces.

2. Sawed Joints: Form contraction joints with power saws equipped with shatterproof abrasive or diamond-rimmed blades. Cut 1/8-inch-wide joints into concrete when cutting action will not tear, abrade, or otherwise damage surface and before concrete develops random contraction cracks. No Sawed Joints are allowed on concrete exposed to freezing.

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

3.6 CONCRETE PLACEMENT

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

B. Do not add water to concrete during delivery, at Project site, or during placement unless approved by the Contracting Officer.

C. Before test sampling and placing concrete, water may be added at Project site, subject to limitations of ACI 301.

D. Deposit concrete continuously in one layer or in horizontal 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 indicated. Deposit concrete to avoid segregation.

1. Deposit concrete in horizontal layers of depth to not exceed formwork design pressures and in a manner to avoid inclined construction joints.

2. Consolidate placed concrete with mechanical vibrating equipment according to

ACI 301.

3. Do not use vibrators to transport concrete inside forms. Insert and withdraw vibrators vertically at uniformly spaced locations to rapidly penetrate placed layer and at least 6 inches 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 mixture constituents to segregate.

E. 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, before excess bleedwater appears on the surface. Do not further disturb slab surfaces before starting finishing operations.

F. 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 average high and low temperature is expected to fall below 40 deg F for three successive days, maintain delivered concrete mixture temperature within the temperature range required by ACI 301.

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 mixture designs.

G. Hot-Weather Placement: Comply with ACI 301 and as follows:

1. Maintain concrete temperature below 90 deg F 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. Fog-spray forms, steel reinforcement, and subgrade just before placing concrete.

Keep subgrade uniformly moist without standing water, soft spots, or dry areas.

3.7 FINISHING FORMED SURFACES

A. 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 defects.

Remove fins and other projections that exceed specified limits on formed-surface irregularities.

B. Rubbed Finish: Apply the following to smooth-formed finished as-cast concrete where indicated:

1. 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.

C. 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.

3.8 FINISHING FLOORS AND SLABS

A. General: Comply with ACI 302.1R recommendations for screeding, restraightening, and finishing operations for concrete surfaces. Do not wet concrete surfaces.

B. 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.

1. Apply float finish to surfaces to receive trowel finish and to be covered with fluid-applied or sheet waterproofing.

C. Trowel Finish: After applying float finish, apply first troweling 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.