Technical Exhibit D-Div 03 CONCRETE 23 May 2023.pdf

POM Job Order Contracting (SATOC) 2503

SECTION TABLE OF CONTENTS

DIVISION 03 - CONCRETE

SECTION 03 30 53

MISCELLANEOUS CAST-IN-PLACE CONCRETE

05/14

PART 1 GENERAL

1.1 SUMMARY

1.2 REFERENCES

1.3 SUBMITTALS

1.4 QUALITY CONTROL

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

2.1.1 Strength

2.1.2 Construction Tolerances

2.1.3 Concrete Mixture Proportions

2.2 MATERIALS

2.2.1 Cementitious Materials

2.2.1.1 Portland Cement

2.2.1.2 Blended Hydraulic Cement

2.2.1.3 Pozzolan

2.2.2 Aggregates

2.2.3 Admixtures

2.2.3.1 Air-Entraining Admixture

2.2.3.2 Accelerating Admixture

2.2.3.3 Water-Reducing or Retarding Admixture

2.2.4 Water

2.2.5 Reinforcing Steel

2.2.6 Expansion Joint Filler Strips, Premolded

2.2.7 Joint Sealants - Field Molded Sealants

2.2.8 Formwork

2.2.9 Form Coatings

2.2.10 Vapor Barrier

2.2.11 Curing Materials

2.3 READY-MIX CONCRETE

2.4 ACCESSORIES

2.4.1 Curing Compound

PART 3 EXECUTION

3.1 PREPARATION

3.1.1 Embedded Items

3.1.2 Formwork Installation

3.1.3 Vapor Barrier Installation

3.1.4 Production of Concrete

3.1.4.1 Ready-Mixed Concrete

3.1.4.2 Concrete Made by Volumetric Batching and Continuous Mixing

3.2 CONVEYING AND PLACING CONCRETE

3.2.1 Cold-Weather Requirements

SECTION 03 30 53 Page 1

3.2.2 Hot-Weather Requirements

3.3 EXTERIOR SLAB AND RELATED ITEMS

3.3.1 Pavements

3.3.2 Sidewalks

3.3.3 Curbs and Gutters

3.4 FINISHING

3.4.1 Temperature Requirement

3.4.2 Finishing Formed Surfaces

3.4.3 Finishing Unformed Surfaces

3.4.3.1 Expansion and Contraction Joints

3.5 CURING AND PROTECTION

3.6 FORM WORK

3.6.1 Removal of Forms

3.7 STEEL REINFORCING

3.7.1 Fabrication

3.7.2 Splicing

3.7.3 Supports

3.8 EMBEDDED ITEMS

3.9 TESTING AND INSPECTING

3.9.1 Field Testing Technicians

3.9.2 Preparations for Placing

3.9.3 Sampling and Testing

3.9.4 Action Required

3.9.4.1 Placing

3.9.4.2 Air Content

3.9.4.3 Slump

-- End of Section Table of Contents --

SECTION 03 30 53 Page 2

SECTION 03 30 53

MISCELLANEOUS CAST-IN-PLACE CONCRETE

05/14

PART 1 GENERAL

1.1 SUMMARY

Perform all work in accordance with ACI 318 and these specifications.

1.2 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN CONCRETE INSTITUTE (ACI)

ACI 117 (2010; Errata 2011) Specifications for Tolerances for Concrete Construction and Materials and Commentary

ACI 301 (2016) Specifications for Structural Concrete

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

ACI 305R (2020) Guide to Hot Weather Concreting

ACI 306R (2016) Guide to Cold Weather Concreting

ACI 318 (2014; Errata 1-2 2014; Errata 3-5 2015;

Errata 6 2016; Errata 7-9 2017) Building Code Requirements for Structural Concrete (ACI 318-14) and Commentary (ACI 318R-14)

ACI 347R (2014; Errata 1 2017) Guide to Formwork for Concrete

ACI SP-66 (2004) ACI Detailing Manual

ASTM INTERNATIONAL (ASTM)

ASTM A615/A615M (2022) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

ASTM A1064/A1064M (2017) Standard Specification for Carbon-Steel Wire and Welded Wire Reinforcement, Plain and Deformed, for Concrete

ASTM C31/C31M (2021a) Standard Practice for Making and Curing Concrete Test Specimens in the Field

SECTION 03 30 53 Page 3

ASTM C33/C33M (2018) Standard Specification for Concrete Aggregates

ASTM C39/C39M (2021) Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

ASTM C94/C94M (2022a) Standard Specification for Ready-Mixed Concrete

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

ASTM C150/C150M (2022) Standard Specification for Portland Cement

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

ASTM C173/C173M (2016) Standard Test Method for Air Content of Freshly Mixed Concrete by the Volumetric Method

ASTM C231/C231M (2022) Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method

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

ASTM C309 (2019) Standard Specification for Liquid Membrane-Forming Compounds for Curing Concrete

ASTM C494/C494M (2019; E 2022) Standard Specification for Chemical Admixtures for Concrete

ASTM C595/C595M (2021) Standard Specification for Blended Hydraulic Cements

ASTM C618 (2022) Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

ASTM C685/C685M (2017) Standard Specification for Concrete Made by Volumetric Batching and Continuous Mixing

ASTM C920 (2018) Standard Specification for Elastomeric Joint Sealants

ASTM C989/C989M (2022) Standard Specification for Slag Cement for Use in Concrete and Mortars

ASTM C1064/C1064M (2017) Standard Test Method for Temperature of Freshly Mixed Hydraulic-Cement Concrete

ASTM C1157/C1157M (2020a) Standard Performance Specification

SECTION 03 30 53 Page 4 for Hydraulic Cement

ASTM C1260 (2021) Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar-Bar Method)

ASTM C1293 (2020a) Standard Test Method for Determination of Length Change of Concrete Due to Alkali-Silica Reaction

ASTM C1567 (2021) Standard Test Method for Potential Alkali-Silica Reactivity of Combinations of Cementitious Materials and Aggregate (Accelerated Mortar-Bar Method)

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

ASTM D75/D75M (2019) Standard Practice for Sampling Aggregates

ASTM D1752 (2018) Standard Specification for Preformed Sponge Rubber, Cork and Recycled PVC Expansion Joint Fillers for Concrete Paving and Structural Construction

ASTM E96/E96M (2022) Standard Test Methods for Gravimetric Determination of Water Vapor Transmission Rate of Materials

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

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

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

40 CFR 247 Comprehensive Procurement Guideline for Products Containing Recovered Materials

1.3 SUBMITTALS

Government approval is required for submittals with a "G" or "S" classification. Submittals not having a "G" for information only. When used, a code following the "G" classification identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Installation Drawings; G

SD-03 Product Data

SECTION 03 30 53 Page 5

Air-Entraining Admixture Accelerating Admixture Water-Reducing or Retarding Admixture Curing Materials Expansion Joint Filler Strips, Premolded Joint Sealants - Field Molded Sealants

Conveying and Placing Concrete Formwork Mix Design Data; G Ready-Mix Concrete Curing Compound Mechanical Reinforcing Bar Connectors

SD-06 Test Reports

Aggregates Concrete Mixture Proportions; G

Compressive Strength Testing; G Slump; G Air Content Water

SD-07 Certificates

Cementitious Materials Pozzolan

Aggregates Delivery Tickets

SD-08 Manufacturer's Instructions

Curing Compound

1.4 QUALITY CONTROL

Indicate specific locations of Concrete Placement, Forms, Steel Reinforcement, Accessories, Expansion Joints, Construction Joints, Contraction Joints, andControl Joints, as applicable, on installation drawings and include, but not be limited to, square feet of concrete placements, thicknesses and widths, plan dimensions, and arrangement of cast-in-place concrete section.

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

The Government retains the option to sample and test joint sealer, joint filler material, aggregates and concrete to determine compliance with the specifications. Provide facilities and labor as may be necessary to assist the Government in procurement of representative test samples.

Obtain samples of aggregates at the point of batching in accordance with ASTM D75/D75M. Sample concrete in accordance with ASTM C172/C172M.

Determine slump and air content in accordance with ASTM C143/C143M and

SECTION 03 30 53 Page 6

ASTM C231/C231M, respectively, when cylinders are molded. Prepare, cure, and transport compression test specimens in accordance with ASTM C31/C31M.

Test compression test specimens in accordance with ASTM C39/C39M. Take samples for strength tests not less than once each shift in which concrete is produced from each strength of concrete required. Provide a minimum of six specimens from each sample; two to be tested at 28 days (90 days if pozzolan is used) for acceptance, two will be tested at 7 days for information and two held in reserve.

2.1.1 Strength

Acceptance test results are the average strengths of two specimens tested at 28 days (90 days if pozzolan is used). The strength of the concrete is considered satisfactory so long as the average of three consecutive acceptance test results equal or exceed the specified compressive strength, f'c, but not more than 20 percent, and no individual acceptance test result falls below f'c by more than 500 psi.

2.1.2 Construction Tolerances

Apply a Class "C" finish to all surfaces except those specified to receive a Class "D" finish. Apply a Class "D" finish to all post-construction surfaces which will be permanently concealed. Surface requirements for the classes of finish required are as specified in ACI 117 .

2.1.3 Concrete Mixture Proportions

Concrete mixture proportions are the responsibility of the Contractor.

Mixture proportions must include the dry weights of cementitious material(s); the nominal maximum size of the coarse aggregate; the specific gravities, absorptions, and saturated surface-dry weights of fine and coarse aggregates; the quantities, types, and names of admixtures; and quantity of water per yard of concrete. Provide materials included in the mixture proportions of the same type and from the same source as will be used on the project. Class F fly ash must be used at a rate between 15 and 35 percent of the total cementitious material by weight to mitigate the potential of alkali-silica reactivity. The specified compressive strength f'c is 4,000 psi at 28 days (90 days if pozzolan is used). The maximum nominal size coarse aggregate is 1 inch, in accordance with ACI 304R . The air content must be between 4.5 and 7.5 percent with a slump between 2 and 5 inches. The maximum water-cementitious material ratio is 0.45. Submit the applicable test reports and mixture proportions that will produce concrete of the quality required, ten days prior to placement of concrete.

2.2 MATERIALS

Submit manufacturer's literature from suppliers which demonstrates compliance with applicable specifications for the specified materials.

2.2.1 Cementitious Materials

Submit Manufacturer's certificates of compliance, accompanied by mill test reports, attesting that the concrete materials meet the requirements of the specifications in accordance with the Special Clause "CERTIFICATES OF COMPLIANCE". Also, certificates for all material conforming to EPA's Comprehensive Procurement Guidelines (CPG), in accordance with 40 CFR 247 .

Provide cementitious materials that conform to the appropriate specifications listed:

SECTION 03 30 53 Page 7

2.2.1.1 Portland Cement

ASTM C150/C150M, Type II or V, low alkali including false set requirements with tri-calcium aluminates (C3A) content less than 10 percent and a maximum cement-alkali content of 0.80 percent Na2Oe (sodium oxide) equivalent.

2.2.1.2 Blended Hydraulic Cement

Provide blended cement conforming to ASTM C595/C595M and ASTM C1157/C1157M , Type IP, IL or IS, including the optional requirement for mortar expansion and sulfate soundness and consist of a mixture of ASTM C150/C150M Type I, or Type II cement and a complementary cementing material. The slag added to the Type IS blend must be ASTM C989/C989M ground granulated blast-furnace slag. The pozzolan added to the Type IP blend must be ASTM C618 Class F, interground with the cement clinker. Provide the manufacturer's written statement that the amount of pozzolan in the finished cement will not vary more than plus or minus 5 mass percent of the finished cement from lot-to-lot or within a lot. Do not change the percentage and type of mineral admixture used in the blend from that submitted for the aggregate evaluation and mixture proportioning.

2.2.1.3 Pozzolan

Provide pozzolan that conforms to ASTM C618, Class F, including requirements of Tables 1A and 2A with loss on ignition (LOI) limited to 6 percent.

2.2.2 Aggregates

Aggregate must meet the quality and grading requirements of ASTM C33/C33M.

Coarse aggregate must conform to Size No. 67. For fine and coarse aggregates meet the quality and grading requirements of ASTM C33/C33M and test and evaluate for alkali-aggregate reactivity in accordance with ASTM C1260. Perform evaluation of fine and coarse aggregates separately and in combination, matching the proposed mix design proportioning. All results of the separate and combination testing must have a measured expansion less than 0.08 percent at 16 days after casting in accordance with ASTM C1260; or must have a measured expansion of less than 0.04 percent at one year after casting in accordance with ASTM C1293. If the test data indicates an expansion of 0.08 percent or greater in accordance with ASTM C1260 or an expansion pf 0.04 percent or greater in accordance with ASTM C1293, reject the aggregate(s) or perform additional testing using ASTM C1567. Perform the additional testing using ASTM C1567 using the low alkali portland cement in combination with ground granulated blast furnace (GGBF) slag, or Class F fly ash. Use GGBF slag in the range of 40 to 50 percent of the total cementitious material by mass. Use Class F fly ash in the range of 25 to 40 percent of the total cementitious material by mass. Submit certificates of compliance and test reports for aggregates showing the material(s) meets the quality and grading requirements of the specifications under which it is furnished.

2.2.3 Admixtures

Provide admixtures, when required or approved, in compliance with the appropriate specification listed. Retest chemical admixtures that have been in storage at the project site, for longer than 6 months or that have been subjected to freezing, at the expense of the Contractor at the

SECTION 03 30 53 Page 8 request of the Contracting Officer and will be rejected if test results are not satisfactory.

2.2.3.1 Air-Entraining Admixture

Provide air-entraining admixture that meets the requirements of

ASTM C260/C260M.

2.2.3.2 Accelerating Admixture

Accelerators, when proposed and approved, must meet the requirements of ASTM C494/C494M, Type C or E.

2.2.3.3 Water-Reducing or Retarding Admixture

Provide water-reducing or retarding admixture meeting the requirements of ASTM C494/C494M, Type A, B, or D.

2.2.4 Water

Mixing and curing water in compliance with the requirements of ASTM C1602/C1602M ; potable, and free of injurious amounts of oil, acid, salt, or alkali. Submit test report showing water complies with

ASTM C1602/C1602M .

2.2.5 Reinforcing Steel

Provide reinforcing bars conforming to the requirements of ASTM A615/A615M , Grade 60, deformed. Provide welded steel wire reinforcement conforming to the requirements of ASTM A1064/A1064M . Detail reinforcement not indicated in accordance with ACI 301 and ACI SP-66 . Provide mechanical reinforcing bar connectors in accordance with ACI 301 and provide 125 percent minimum yield strength of the reinforcement bar.

2.2.6 Expansion Joint Filler Strips, Premolded

Expansion joint filler strips, premolded of sponge rubber conforming to ASTM D1752, Type I.

2.2.7 Joint Sealants - Field Molded Sealants

Conform to ASTM C920, Type M, Grade NS, Class 25, use NT for vertical joints and Type M, Grade P, Class 25, use T for horizontal joints.

Provide polyethylene tape, coated paper, metal foil, or similar type bond breaker materials. The backup material needs to be compressible, nonshrink, nonreactive with the sealant, and a nonabsorptive material such as extruded butyl or polychloroprene foam rubber. Immediately prior to installation of field-molded sealants, clean the joint of all debris and further cleaned using water, chemical solvents, or other means as recommended by the sealant manufacturer or directed.

2.2.8 Formwork

Design and engineer the formwork as well as its construction in accordance with ACI 301 Section 2 and 5 and ACI 347R . Fabricate of wood, steel, or other approved material. Submit formwork design prior to the first concrete placement.

SECTION 03 30 53 Page 9

2.2.9 Form Coatings

Provide form coating in accordance with ACI 301 .

2.2.10 Vapor Barrier

ASTM E1745 Class A polyethylene sheeting, minimum 15 mil thickness or other equivalent material with a maximum permeance rating of 0.04 perms per ASTM E96/E96M.

2.2.11 Curing Materials

Provide curing materials in accordance with ACI 301 , Section 5.

2.3 READY-MIX CONCRETE

Provide ready-mix concrete with mix design data conforming to ACI 301 Part

2. Submit delivery tickets in accordance with ASTM C94/C94M for each ready-mix concrete delivery, include the following additional information: .

a. Type and brand cement

b. Cement content in 94-pound bags per cubic yard of concrete

c. Maximum size of aggregate

d. Amount and brand name of admixture

e. Total water content expressed by water cementitious material ratio

2.4 ACCESSORIES

2.4.1 Curing Compound

Provide curing compound conforming to ASTM C309. Submit manufactures instructions for placing curing compound.

PART 3 EXECUTION

3.1 PREPARATION

Prepare construction joints to expose coarse aggregate. The surface must be clean, damp, and free of laitance. Construct ramps and walkways, as necessary, to allow safe and expeditious access for concrete and workmen.

Remove snow, ice, standing or flowing water, loose particles, debris, and foreign matter. Satisfactorily compact earth foundations. Make spare vibrators available. Placement cannot begin until the entire preparation has been accepted by the Government.

3.1.1 Embedded Items

Secure reinforcement in place after joints, anchors, and other embedded items have been positioned. Arrange internal ties so that when the forms are removed the metal part of the tie is not less than 2 inches from concrete surfaces permanently exposed to view or exposed to water on the finished structures. Prepare embedded items so they are be free of oil and other foreign matters such as loose coatings or rust, paint, and scale. The embedding of wood in concrete is permitted only when

SECTION 03 30 53 Page 10 specifically authorized or directed. Provide all equipment needed to place, consolidate, protect, and cure the concrete at the placement site and in good operating condition.

3.1.2 Formwork Installation

Forms must be properly aligned, adequately supported, and mortar-tight.

Provide smooth form surfaces, free from irregularities, dents, sags, or holes when used for permanently exposed faces. Chamfer all exposed joints and edges , unless otherwise indicated.

3.1.3 Vapor Barrier Installation

Install in accordance with ASTM E1643. Apply vapor barrier over capillary water barrier provided per Section 31 00 00 EARTHWORK. Lap edges not less than 12 inches. Seal all joints with pressure-sensitive adhesive not less than 2 inches wide. Protect the vapor barrier at all times to prevent injury or displacement prior to and during concrete placement.

3.1.4 Production of Concrete

3.1.4.1 Ready-Mixed Concrete

Provide ready-mixed concrete conforming to ASTM C94/C94M except as otherwise specified.

3.1.4.2 Concrete Made by Volumetric Batching and Continuous Mixing

Conform to ASTM C685/C685M.

3.2 CONVEYING AND PLACING CONCRETE

Convey and place concrete in accordance with ACI 301 , Section 5.

3.2.1 Cold-Weather Requirements

Place concrete in cold weather in accordance with ACI 306R

3.2.2 Hot-Weather Requirements

Place concrete in hot weather in accordance with ACI 305R

3.3 EXTERIOR SLAB AND RELATED ITEMS

Prepare subgrade in accordance with Section 31 00 00 EARTHWORK and Section 32 11 23 Aggregate Base Course as applicable.

3.3.1 Pavements

Construct pavements and equipment pads where shown on the drawings. After forms are set and underlying material prepared as specified, place the concrete uniformly throughout the area and thoroughly vibrated. As soon as placed and vibrated, strike off the concrete and screed to the crown and cross section and to such elevation above grade that when consolidated and finished, the surface of the pavement is at the required elevation.

Tamp the entire surface with the strike off, or consolidated with a vibrating screed, and continue this operation until the required compaction and reduction of internal and surface voids are accomplished.

Take care to prevent bringing excess paste to the surface.

SECTION 03 30 53 Page 11

3.3.2 Sidewalks

Minimum concrete thickness of 4 inches. Provide contraction joints at 5 feet spaces unless otherwise indicated. Cut contraction joints 1 inch deep with a jointing tool after the surface has been finished. Provide transverse expansion joints 1/2 inch thick at changes in direction and where sidewalk abuts curbs, steps, rigid pavement, or other similar structures. Provide a transverse slope of 1/4 inch per foot, unless otherwise indicated. Limit variations in cross section to 1/4 inch in 5 feet.

3.3.3 Curbs and Gutters

Form, place and finish concrete by hand using a properly shaped "mule" or construct using a slipform machine specially designed for this work. Cut contraction joints 3 inches deep with a jointing tool after the surface has been finished. Provide 1/2 inch wide expansion joints at 100 feet maximum spacing unless otherwise indicated.

3.4 FINISHING

3.4.1 Temperature Requirement

Do not finish or repair concrete when either the concrete or the ambient temperature is below 50 degrees F.

3.4.2 Finishing Formed Surfaces

Remove all fins and loose materials , and surface defects including filling of tie holes. Repair all honeycomb areas and other defects.

Remove all unsound concrete from areas to be repaired. Ream or chip surface defects greater than 1/2 inch in diameter and holes left by removal of tie rods in all surfaces not to receive additional concrete and fill with dry-pack mortar. Brush-coat the prepared area with an approved epoxy resin or latex bonding compound or with a neat cement grout after dampening and filling with mortar or concrete. Use a blend of portland cement and white cement in mortar or concrete for repairs to all surfaces permanently exposed to view so that the final color when cured is the same as adjacent concrete.

3.4.3 Finishing Unformed Surfaces

Finish unformed surfaces in accordance with ACI 301 , Section 5..3.4 and the following table

FINISH LOCATION

Float All surfaces exposed to view, except per below

Trowel

Broom or Belt Foot or vehicle traffic surfaces

3.4.3.1 Expansion and Contraction Joints

Make expansion and contraction joints in accordance with the details shown

SECTION 03 30 53 Page 12 or as otherwise specified. Provide 1/2 inch thick transverse expansion joints where new work abuts an existing concrete. Provide expansion joints at a maximum spacing of 30 feet on center in sidewalks , unless otherwise indicated. Provide contraction joints at a maximum spacing of 6 linear feet in sidewalks , unless otherwise indicated. Cut contraction joints at a minimum of 1inch deep with a jointing tool after the surface has been finished.

3.5 CURING AND PROTECTION

Cure and protect in accordance with ACI 301 , Section 5.

3.6 FORM WORK

Provide form work in accordance with ACI 301 , Section 2 and Section 5.

3.6.1 Removal of Forms

Remove forms in accordance with ACI 301 , Section 2.

3.7 STEEL REINFORCING

Reinforcement must be free from loose, flaky rust and scale, and free from oil, grease, or other coating which might destroy or reduce the reinforcement's bond with the concrete.

3.7.1 Fabrication

Shop fabricate steel reinforcement in accordance with ACI 318 and ACI SP-66 .

Provide shop details and bending in accordance with ACI 318 and ACI SP-66 .

3.7.2 Splicing

Perform splices in accordance with ACI 318 and ACI SP-66 .

3.7.3 Supports

Secure reinforcement in place by the use of metal or concrete supports, spacers, or ties.

3.8 EMBEDDED ITEMS

Before placing concrete, take care to determine that all embedded items are firmly and securely fastened in place. Provide embedded items free of oil and other foreign matter, such as loose coatings of rust, paint and scale. Embedding of wood in concrete is permitted only when specifically authorized or directed.

3.9 TESTING AND INSPECTING

Report the results of all tests and inspections conducted at the project site informally at the end of each shift. Submit written reports weekly.

Deliver within three days after the end of each weekly reporting period.

See Section 01 45 00 QUALITY CONTROL.

3.9.1 Field Testing Technicians

The individuals who sample and test concrete must have demonstrated a knowledge and ability to perform the necessary test procedures equivalent

SECTION 03 30 53 Page 13 to the ACI minimum guidelines for certification of Concrete Field Testing Technicians, Grade I.

3.9.2 Preparations for Placing

Inspect foundation or construction joints, forms, and embedded items in sufficient time prior to each concrete placement to certify that it is ready to receive concrete.

3.9.3 Sampling and Testing

a. Obtain samples and test concrete for quality control during placement. Sample fresh concrete for testing in accordance with ASTM C172/C172M. Make six test cylinders.

b. Test concrete for compressive strength at 7 and 28 days for each design mix and for every 100 cubic yards of concrete. Test two cylinders at 7 days; two cylinders at 28 days; and hold two cylinders in reserve. Conform test specimens to ASTM C31/C31M. Perform compressive strength testing conforming to ASTM C39/C39M.

c. Test slump at the site of discharge for each design mix in accordance with ASTM C143/C143M. Check slump at least once during each shift that concrete is produced for each strength of concrete required.

d. Test air content for air-entrained concrete in accordance with ASTM C231/C231M. Test concrete using lightweight or extremely porous aggregates in accordance with ASTM C173/C173M. Check air content at least every time a slump test is performed.

e. Determine temperature of concrete at time of placement in accordance with ASTM C1064/C1064M . Check concrete temperature at least every time a slump and air content test is performed.

3.9.4 Action Required

3.9.4.1 Placing

Do not begin placement until the availability of an adequate number of acceptable vibrators, which are in working order and have competent operators, has been verified. Discontinue placing if any lift is inadequately consolidated.

3.9.4.2 Air Content

Whenever an air content test result is outside the specification limits, adjust the dosage of the air-entrainment admixture prior to delivery of concrete to forms.

3.9.4.3 Slump

Whenever a slump test result is outside the specification limits, adjust the batch weights of water and fine aggregate prior to delivery of concrete to the forms. Make the adjustments so that the water-cementitious material ratio does not exceed that specified in the submitted concrete mixture proportion and the required concrete strength is still met.

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SECTION 03 30 53 Page 14

SECTION 03 30 53 Page 15

SECTION TABLE OF CONTENTS

DIVISION 03 - CONCRETE

SECTION 03 37 13

SHOTCRETE

02/18

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 QUALIFICATIONS

1.4 TESTING DURING CONSTRUCTION

1.4.1 Quality Control

1.4.2 Testing Shotcrete

1.4.3 Test Panels

1.4.4 Testing In-Place Shotcrete

1.4.5 Reporting of Quality Assurance Test Results

1.4.6 Action Required for Shotcrete Defects

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Portland Cement

2.1.2 Supplementary Cementitious Materials

2.1.3 Aggregate

2.1.4 Water

2.1.5 Admixtures

2.1.6 Curing Materials

2.1.6.1 Sheet Materials

2.1.6.2 Curing Compounds

2.1.6.3 Architectural Finishes

2.2 SHOTCRETE PROPERTIES

2.2.1 Compressive Strength

2.2.2 Air Content

2.2.3 Resistance to Alkali-Silica Reaction

2.3 MIXTURE PROPORTIONS

2.4 BATCHING, MIXING, AND DELIVERY

PART 3 EXECUTION

3.1 PREPARATION OF SURFACE TO RECEIVE SHOTCRETE

3.1.1 Earth

3.1.2 Concrete and Masonry

3.1.3 Shotcrete

3.1.4 Forms

3.2 JOINTS

3.2.1 Construction Joints

3.3 APPLICATION

3.3.1 General

3.3.2 Placement Techniques

3.3.2.1 Placement Control

3.3.2.2 Corners

SECTION 03 37 13 Page 1

3.3.2.3 Placement Around Reinforcement

3.3.3 Cover of Reinforcement

3.3.4 Placement Precautions

3.4 REPAIR OF DEFECTS

3.4.1 Defects

3.4.2 Repairs

3.4.3 Minor Patching

3.5 FINISH

3.5.1 Gun Finish

3.5.2 Cutting Screed

3.5.3 Flash Coat

3.5.4 Float and Trowel Finish

3.6 CURING

3.7 PROTECTION

3.8 TOLERANCES

-- End of Section Table of Contents --

SECTION 03 37 13 Page 2

SECTION 03 37 13

SHOTCRETE

02/18

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN CONCRETE INSTITUTE (ACI)

ACI CP-60 (2015) Craftman Workbook for ACI Certification of Shotcrete Nozzleman

ACI 117 (2010; Errata 2011) Specifications for Tolerances for Concrete Construction and Materials and Commentary

ASTM INTERNATIONAL (ASTM)

ASTM C33/C33M (2018) Standard Specification for Concrete Aggregates

ASTM C94/C94M (2022a) Standard Specification for Ready-Mixed Concrete

ASTM C127 (2015) Standard Test Method for Density, Relative Density (Specific Gravity), and Absorption of Coarse Aggregate

ASTM C128 (2015) Standard Test Method for Density, Relative Density (Specific Gravity), and Absorption of Fine Aggregate

ASTM C150/C150M (2022) Standard Specification for Portland Cement

ASTM C171 (2020) Standard Specification for Sheet Materials for Curing Concrete

ASTM C231/C231M (2022) Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method

ASTM C309 (2019) Standard Specification for Liquid Membrane-Forming Compounds for Curing Concrete

ASTM C457/C457M (2016) Standard Test Method for Microscopical Determination of Parameters of the Air-Void System in Hardened Concrete

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ASTM C494/C494M (2019; E 2022) Standard Specification for Chemical Admixtures for Concrete

ASTM C618 (2022) Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

ASTM C685/C685M (2017) Standard Specification for Concrete Made by Volumetric Batching and Continuous Mixing

ASTM C881/C881M (2020a) Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete

ASTM C989/C989M (2022) Standard Specification for Slag Cement for Use in Concrete and Mortars

ASTM C1064/C1064M (2017) Standard Test Method for Temperature of Freshly Mixed Hydraulic-Cement Concrete

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

ASTM C1140/C1140M (2011; R 2019) Standard Practice for Preparing and Testing Specimens from Shotcrete Test Panels

ASTM C1141/C1141M (2015) Standard Specification for Admixtures for Shotcrete

ASTM C1293 (2020a) Standard Test Method for Determination of Length Change of Concrete Due to Alkali-Silica Reaction

ASTM C1315 (2019) Standard Specification for Liquid Membrane-Forming Compounds Having Special Properties for Curing and Sealing Concrete

ASTM C1385/C1385M (2010; R 2017) Standard Practice for Sampling Materials for Shotcrete

ASTM C1436 (2013) Standard Specification for Materials for Shotcrete

ASTM C1480/C1480M (2007; R 2012) Standard Specification for Packaged, Pre-Blended, Dry, Combined Materials for Use in Wet or Dry Shotcrete Application

ASTM C1567 (2021) Standard Test Method for Potential Alkali-Silica Reactivity of Combinations of Cementitious Materials and Aggregate (Accelerated Mortar-Bar Method)

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

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Cement Concrete

ASTM C1604/C1604M (2005; R 2012) Standard Test Method for Obtaining and Testing Drilled Cores of Shotcrete

ASTM C1778 (2016) Standard Guide for Reducing the Risk of Deleterious Alkali-Aggregate Reaction in Concrete

1.2 SUBMITTALS

Government approval is required for submittals with a "G" classification. Submittals not having a "G" classification are for information only. When used, a code following the "G" classification identifies the office that will review the submittal for the Government.

Submit the following in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:

SD-06 Test Reports

Testing During Construction; G

Aggregate

Water

Mixture Proportions; G

Repair of Defect;G

Resistance to Alkali-Silica Reaction

SD-07 Certificates

Qualifications; G

Portland Cement

Supplementary Cementitious Materials

Admixtures; G

Curing Materials

Testing Agency; G

1.3 QUALIFICATIONS

Shotcrete will be produced by either the Dry or Wet Method. Submit qualifications and experience of the proposed workers including the supervisor, nozzlemen, and crew. Submit a resume for each nozzleman certifying that each has not less than 1 year's experience for the particular type of shotcrete to be applied. The resume shall include company name, address, and telephone number, name of

SECTION 03 37 13 Page 5 supervisor, and detailed description of work performed. All nozzlemen shall be certified in accordance with ACI CP-60 . Qualifications of additional nozzlemen throughout the job shall be similarly submitted for approval.

1.4 TESTING DURING CONSTRUCTION

1.4.1 Quality Control

Provide submittals for the "Quality Control Plan", "Quality Control Personnel Certifications", Testing Agency and, Laboratory Qualifications for Concrete Qualification Testing per section 03 30 53 MISCELLANEOUS

CAST-IN-PLACE CONCRETE.

1.4.2 Testing Shotcrete

a. Compressive strength samples: Use in-place shotcrete test specimens.

b. Test samples: Sample shotcrete in accordance with ASTM C1385/C1385M .

The Contractor is responsible for the curing and protection of test panels on site prior to the time that they are transported to the testing agency's laboratory.

d. Air content of mixture: For wet-mixture shotcrete test air content at discharge from the truck chute in accordance with ASTM C231/C231M prior to placement.

For dry-mix shotcrete, test air content in hardened concrete using

ASTM C457/C457M

e. Temperature of shotcrete mixture: Determine the temperature of the mixture using material sampled prior to discharge from the truck chute into the pump for wet-mixture shotcrete or the shotcrete machine for dry-mix shotcrete. Complete testing in accordance with

ASTM C1064/C1064M .

1.4.3 Test Panels

a. Construct a test panel for each mixture, each nozzleman, and each work day or for every 50 cubic yardplaced, whichever results in the most panels. The face dimensions of a test panel must be a minimum of 16 x 16 in. with a minimum depth of 5 in.

b. Condition test panels in accordance with ASTM C1140/C1140M until transported to the testing agency's laboratory.

c. Obtain test specimens from test panels using procedures outlined in ASTM C1140/C1140M or ASTM C1604/C1604M . Cores will be a nominal 3 in.

diameter.

d. Test shotcrete specimens for compliance in accordance with ASTM C1604/C1604M for compressive strength.

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1.4.4 Testing In-Place Shotcrete

a. Obtain core specimens from locations designated by the Contracting Officer in accordance with ASTM C1140/C1140M .

b. Condition test specimens by soaking as specified in ASTM C1604/C1604M .

c. Test specimens in accordance with the paragraph titled "Testing Shotcrete".

1.4.5 Reporting of Quality Assurance Test Results

Provide copies of any test results generated for quality assurance to the Contractor, Contracting Officer, and concrete supplier.

1.4.6 Action Required for Shotcrete Defects

Submit Repair of Defect procedures for defects for the Contracting Officer's acceptance. Refer to the paragraph titled "REPAIR OF DEFECTS" for details.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Portland Cement

Provide cement in compliance with ASTM C150/C150M Type II or V low alakli.

Submit mill test reports showing manufacturing location, and compliance with applicable ASTM standards.

2.1.2 Supplementary Cementitious Materials

Provide supplementary cementitious materials (SCMs) complying with ASTM C618 for fly ash and natural pozzolans or ASTM C989/C989M for slag cement.

Submit supplementary cementitious materials types, mill test reports showing manufacturing location, and compliance with applicable ASTM standards.

2.1.3 Aggregate

Aggregates must comply with ASTM C33/C33M. The combined aggregate gradation must comply with grading No. 2 of ASTM C1436.

Submit aggregate source, producers' names, gradations, specific gravities, compliance with ASTM C33/C33M, and evidence that this data is not more than 1 year old.

Submit aggregate absorption in accordance with ASTM C127 for coarse aggregate and ASTM C128 for fine aggregate.

2.1.4 Water

Water must be potable and comply with ASTM C1602/C1602M requirements. Wash water is not permitted.

2.1.5 Admixtures

Provide admixtures in compliance with ASTM C1141/C1141M or, for hydration

SECTION 03 37 13 Page 7 control admixtures, with ASTM C494/C494M.

Submit admixture types, brand names, producers, manufacturer's technical data sheets describing technical properties and performance in shotcrete and showing compatibility with each other and the project cementitious materials.

2.1.6 Curing Materials

2.1.6.1 Sheet Materials

Provide sheet materials for curing in compliance with ASTM C171.

2.1.6.2 Curing Compounds

Provide curing compounds in compliance with ASTM C309 or ASTM C1315.

Provide volatile organic compounds (VOC) content in compliance with local air quality standards if those requirements are more stringent.

2.1.6.3 Architectural Finishes

Do not use curing materials that cause stains for shotcrete having an architectural finish.

2.2 SHOTCRETE PROPERTIES

2.2.1 Compressive Strength

The required compressive strength is 4,000 psi at 28 days.

2.2.2 Air Content

The percent air content of concrete is 10 plus or minus (±) 1.0 percent.

2.2.3 Resistance to Alkali-Silica Reaction

Use one of the three options below for qualifying concrete mixtures to reduce the potential of alkali-silica reaction.

a. For each aggregate used in concrete, do not exceed 0.04 percent at 1 year for the expansion result determined in accordance with ASTM C1293.

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

ASTM C1567.

c. Alkali content in concrete must not exceed 4 pounds per cubic yard for moderately reactive aggregate or 3 pounds per cubic yard for highly reactive aggregate. Determine reactivity determined by testing in accordance with ASTM C1293 and categorized in accordance with

ASTM C1778.

2.3 MIXTURE PROPORTIONS

Proportion shotcrete mixture by mass complying with ASTM C94/C94M, to satisfy the specified properties. For prepackaged materials meeting

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ASTM C1480/C1480M , submit suppliers' technical data showing compliance with requirements. For mixture acceptance purposes, the average compressive strength of at least three cores shall be at least equal to

1.2 times the required compressive strengthSubmit water-cementitious materials ratio (w/cm) for wet-mixture shotcrete only.

2.4 BATCHING, MIXING, AND DELIVERY

Batch, mix, and deliver wet-mixture shotcrete in accordance with ASTM C94/C94M, ASTM C685/C685M, or ASTM C1116/C1116M as applicable. For dry-mixture, batch, mix and deliver in accordance with ASTM C685/C685M or

ASTM C1116/C1116M .

Use predampening or other methods suitable for prewetting the dry materials with packaged preblended material for dry-mixture shotcrete.

PART 3 EXECUTION

3.1 PREPARATION OF SURFACE TO RECEIVE SHOTCRETE

3.1.1 Earth

Prepare surfaces to line and grade. Dampen surfaces immediately prior to shooting. Standing water is not acceptable.

3.1.2 Concrete and Masonry

All unsound and loose materials shall be removed by sandblasting, grinding, or high-pressure water jets before applying shotcrete. Any area to be repaired shall be chipped off or scarified to remove offsets which would cause an abrupt change in thickness without suitable reinforcement. Edges shall be tapered to leave no square shoulders at the perimeter of a cavity. The surface shall be dampened but without visible free water.

3.1.3 Shotcrete

Prepare surfaces to line and grade. Dampen surfaces immediately prior to shooting. Standing water is not acceptable. When a layer of shotcrete is to be covered by a succeeding layer at a later time, it shall first be allowed to develop its initial set. Then all laitance, loose material, and rebound shall be removed by brooming or scraping. Hardened laitance set shall be removed by sandblasting and the surface thoroughly cleaned.

3.1.4 Forms

Use material of adequate thickness for formwork to resist movement during shooting. Reinforce, secure, and brace forms to minimize the effects of vibration during shooting. Construct forms to allow escape of placement air, overspray, and rebound. Use form-release coating material on removable forms unless the formed surface is to subsequently receive an additional coating.

3.2 JOINTS

3.2.1 Construction Joints

Taper construction joints at approximately 45 degrees from receiving surface. Form joints by cutting plastic shotcrete. Make joints at slab

SECTION 03 37 13 Page 9 intersections at 90 degrees. Roughen shotcrete in the joint face while it is still plastic.

3.3 APPLICATION

3.3.1 General

Place shotcrete using suitable delivery equipment and procedures. The area to which shotcrete is to be applied shall be clean and free of rebound or overspray.

3.3.2 Placement Techniques

3.3.2.1 Placement Control

Thickness, method of support, air pressure, and water content of shotcrete shall be controlled to preclude sagging or sloughing off. Shotcreting shall be discontinued or suitable means shall be provided to screen the nozzle stream if wind or air currents cause separation of the nozzle stream during placement.

3.3.2.2 Corners

Horizontal and vertical corners and any area where rebound cannot escape or be blown free shall be filled first.

3.3.2.3 Placement Around Reinforcement

The nozzle shall be held at such distance and angle to place material behind reinforcement before any material is allowed to accumulate on the face of the reinforcement. In the dry-mix process, additional water may be added to the mixture when encasing reinforcement to facilitate a smooth flow of material behind the bars. Shotcrete shall not be placed through more than one layer of reinforcing steel rods or mesh in one application unless demonstrated by preconstruction tests that steel is properly encased.

3.3.3 Cover of Reinforcement

The following minimum cover must be provided

a. PlacFor shotcrete used as linings, coatings, slab, or wall: 1-1/2 inches.

b. For required structural reinforcement in beams, girders, and columns:

1-1/2 inches.

3.3.4 Placement Precautions

The following precautions shall be taken during placement.

a. Placement shall be stopped if drying or stiffening of the mixture takes place at any time prior to delivery to the nozzle.

b. Rebound or previously expended material shall not be used in the shotcrete mixture.

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3.4 REPAIR OF DEFECTS

3.4.1 Defects

Defective areas larger than 48 square inches or 2 inches deep shall be removed and replaced with fresh shotcrete. These defects include honeycombing, lamination, dry patches, voids, or sand pockets. Defective areas shall be removed in accordance with the procedures described in paragraph EXISTING CONCRETE and replaced with fresh shotcrete.

3.4.2 Repairs

All repairs shall be made within 1 week of the time the deficiency is discovered. All unacceptable materials shall be removed and repaired by the procedures described in the following two paragraphs. Voids and holes left by the removal of tie rods in all permanently exposed surfaces not to be backfilled and in surfaces to be exposed to water shall be reamed and completely filled with dry-patching mortar as specified below.

3.4.3 Minor Patching

Minor patching may be accomplished with a dry-pack mixture, or with materials as approved by the Contracting Officer. Patches that exceed 0.1 cubic foot in volume shall receive a brush coat of approved epoxy resin meeting ASTM C881/C881M, Type II, as a prime coat. Care shall be taken not to spill epoxy or overcoat the repair surface so that the epoxy runs or is squeezed out onto the surface which will remain exposed to view. Epoxy resin shall be used in strict conformance with manufacturer's recommendations with special attention paid to pot life, safety, and thin film tack time.

3.5 FINISH

3.5.1 Gun Finish

Unless otherwise specified, provide undisturbed final layer of shotcrete as applied from nozzle without hand finishing.

3.5.2 Cutting Screed

After the surface has taken its initial set (crumbling slightly when cut), slice off excess material outside the forms and ground wires with a downward cutting motion using a sharp-edged cutting screed. Then remove ground wires and float the irregularities.

3.5.3 Flash Coat

Apply a thin coat of shotcrete containing finer sand applied from a distance greater than normal to the surface as soon as possible after the screeding.

3.5.4 Float and Trowel Finish

Provide final surface finish using steel trowel. Avoid troweling of thin sections of shotcrete unless both troweling and commencement of moisture curing take place within a relatively short period after placement of

SECTION 03 37 13 Page 11 shotcrete.

3.6 CURING

When the daily mean temperature is above 40°F, cure continuously for a minimum of 7 consecutive days or for the time necessary to attain 70 percent of the specified compressive or flexural strength, whichever period is less.

If shotcrete is placed with daily mean temperatures 40°F or lower, provide cold weather protection until the shotcrete achieves 70 percent of the specified strength.

Complete moist curing by one of the following methods:

a. Ponding or continuous sprinkling for a minimum of 7 days;

b. Covering with an absorptive mat or sand that is kept continuously wet;

c. Covering with impervious sheet material;

d. Use of curing compounds; apply twice the rate for formed surfaces as recommended by manufacturer if the surface is a gun finish.

Do not use natural curing in lieu of that specified in this paragraph unless the relative humidity of the air in contact with the shotcrete remains at or above 85 percent and such curing is authorized by Contracting Officer.

Submit curing materials and curing procedures for shotcrete including product data sheets indicating conformance with specification requirements.

3.7 PROTECTION

Immediately after placement, protect shotcrete from premature drying or excessively hot or cold temperatures and mechanical injury.

Maintain shotcrete protection to prevent freezing of the shotcrete and to ensure the necessary strength development for structural safety. Remove protection in such a manner that the maximum decrease in temperature measured at the surface of the shotcrete in a 24-hour period does not exceed the following:

a. 50°F for sections less than 12 in. in the least dimension;

b. 40°F for sections from 12 to 36 in. in the least dimension.

Protect surfaces not intended for shotcrete placement against deposit of rebound and overspray or impact from nozzle stream.

3.8 TOLERANCES

Provide dimensional tolerances of shotcrete in compliance with ACI 117

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