H.08.04_Specification Amended Section 03 31 30 Marine Concrete 06232021.pdf

CRANEY ISLAND BULKHEAD REFURBISHMENT BULKHEAD

SECTION TABLE OF CONTENTS

DIVISION 03 - CONCRETE

SECTION 03 31 30

MARINE CONCRETE

02/19

PART 1 GENERAL

1.1 REFERENCES

1.2 DEFINITIONS

1.3 SUBMITTALS

1.4 MODIFICATION OF REFERENCES

1.5 DELIVERY, PLACING, STORAGE, AND HANDLING OF CONCRETE

1.6 CONCRETE QUALITY CONTROL

1.6.1 Quality Control Personnel

1.6.1.1 Quality Manager Qualifications

1.6.1.2 Field Testing Technician and Testing Agency

1.6.2 Laboratory Qualifications for Concrete Qualification Testing

1.6.3 Laboratory Accreditation

1.7 CONCRETE DURABILITY

1.7.1 Concrete Mixture Proportions

1.7.2 Concrete Design Requirements

1.7.3 Concrete Mixture Qualifications

1.7.3.1 Previously Approved Concrete Mixtures

1.7.3.2 New Concrete Mixtures

1.7.4 Concrete Qualification Program

1.7.4.1 Fresh Concrete Properties

1.7.4.2 Hardened Concrete Properties

1.7.4.3 Supplemental Corrosion Protection

1.7.5 Mass Concrete Temperature Control Plans

1.8 CONCRETE

1.8.1 Drawings

1.8.1.1 Formwork

1.8.1.2 Reinforcing Steel

1.8.1.3 Joints

1.8.2 Pre-Construction Submittals

1.8.2.1 Curing Concrete Elements

1.8.2.2 Concrete Curing Plan

1.8.2.3 Form Removal Schedule

1.8.2.4 Concrete Placement and Compaction

1.8.2.5 Concrete Report

1.8.2.6 Coatings

1.8.2.7 Preconstruction Testing of Materials

1.8.2.8 Material Safety Data Sheets (Msds)

1.8.2.9 Mixture Designs

1.8.3 Sampling

1.8.3.1 Ingredient Material Sampling

1.8.4 Reporting

1.8.4.1 Daily Inspection Reports

1.8.4.2 Sampling Logs

1.8.4.3 Quality Control Data

1.8.4.4 Quality Team Meetings

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1.8.4.5 Non-conforming materials

1.8.5 Test Reports

1.8.5.1 Concrete Mixture Requirements

1.8.5.2 Supplementary Cementing Materials

1.8.5.2.1 Ground Granulated Blast-Furnace Slag

1.8.5.2.2 Ultra Fine Fly Ash or Pozzolan

1.8.5.3 Silica Fume

1.8.5.4 Aggregates

1.8.5.5 Admixtures

1.8.5.6 Portland Cement

1.8.5.7 Testing During Construction

1.8.5.8 Test Section

1.8.5.9 Acceptability of Work

PART 2 PRODUCTS

2.1 CEMENTITIOUS MATERIALS

2.1.1 Portland Cement

2.1.2 Blended Cements

2.1.3 Pozzolan

2.1.3.1 Fly Ash

2.1.3.2 Raw or Calcined Natural Pozzolan

2.1.3.3 Ultra Fine Fly Ash and Ultra Fine Pozzolan

2.1.4 Ground Granulated Blast-Furnace (GGBF) Slag

2.1.5 Silica Fume

2.1.6 Supplementary Cementitious Materials (SCM) Content

2.2 AGGREGATES

2.3 WATER

2.4 ADMIXTURES

2.4.1 Air Entraining

2.4.2 Accelerating

2.4.3 Retarding

2.4.4 Water Reducing

2.4.5 Corrosion Inhibitors

2.5 NON-SHRINK GROUT

2.6 MATERIALS FOR FORMS

2.6.1 Form Ties and Form-Facing Material

2.7 REINFORCEMENT

2.7.1 Reinforcing Bars

2.7.1.1 Reinforcement and Protective Coating

2.7.2 Mechanical Reinforcing Bar Connectors

2.7.3 Welded Wire Fabric

2.7.4 Wire

2.8 ACCESSORY MATERIALS

2.8.1 Polyvinylchloride Waterstops

2.8.2 Materials for Curing Concrete

2.8.2.1 Impervious Sheeting

2.8.2.2 Pervious Sheeting

2.8.2.3 Liquid Membrane-Forming Compound

2.8.3 Liquid Chemical Sealer-Hardener Compound

2.8.4 Expansion/Contraction Joint Filler

2.8.5 Joint Sealants

2.8.5.1 Horizontal Surfaces

2.8.5.2 Vertical Surfaces

PART 3 EXECUTION

3.1 FORMS

3.1.1 Coating

SECTION 03 31 30 Page 2

3.1.2 Removal of Forms and Supports

3.1.2.1 Special Requirements for Reduced Time Period

3.1.3 Reshoring

3.2 PLACING REINFORCEMENT AND MISCELLANEOUS MATERIALS

3.2.1 Coated Reinforcing

3.2.2 Reinforcement Supports

3.2.3 Splicing

3.2.4 Future Bonding

3.2.5 Cover

3.2.6 Setting Miscellaneous Material and Prestress Anchorages

3.2.7 Construction Joints

3.2.8 Expansion Joints and Contraction Joints

3.2.9 Waterstop Splices

3.2.10 Pits and Trenches

3.3 BATCHING, MEASURING, MIXING, AND TRANSPORTING CONCRETE

3.3.1 Measuring

3.3.2 Mixing

3.3.3 Transporting

3.4 PLACING CONCRETE

3.4.1 Vibration

3.4.2 Cold Weather

3.4.3 Hot Weather

3.4.4 Prevention of Plastic Shrinkage Cracking

3.4.5 Mass Concrete

3.4.6 Depositing Concrete Under Water

3.5 SURFACE FINISHES EXCEPT FLOOR, SLAB, AND PAVEMENT

3.5.1 Defects

3.5.2 Formed Surfaces

3.5.2.1 Tolerances

3.5.2.2 As-Cast Rough Form

3.5.2.3 As-Cast Form

3.6 FINISHES FOR HORIZONTAL CONCRETE SURFACES

3.6.1 Finish

3.6.1.1 Scratched

3.6.1.2 Floated

3.6.1.3 Broomed

3.6.1.4 Pavement

3.6.1.5 Concrete Toppings Placement

3.7 CURING AND PROTECTION

3.7.1 Wet Curing

3.7.1.1 Ponding or Immersion

3.7.1.2 Fog Spraying or Sprinkling

3.7.1.3 Pervious Sheeting

3.7.1.4 Impervious Sheeting

3.7.2 Liquid Membrane-Forming Curing Compound

3.7.2.1 Application

3.7.2.2 Protection of Treated Surfaces

3.7.3 Liquid Chemical Sealer-Hardener

3.7.4 Curing Periods

3.8 FIELD QUALITY CONTROL

3.8.1 Fresh Concrete Properties

3.8.1.1 Slump Tests

3.8.1.2 Temperature Tests

3.8.1.3 Air Content Tests

3.8.1.4 Unit Weight Test

3.8.2 Hardened Concrete Properties

3.8.2.1 Compressive Strength Tests

3.8.2.2 Chloride Ion Penetration Test

3.8.2.3 Chloride Ion Concentration

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3.8.2.4 Anti-Washout Admixture

3.8.2.5 Non-Destructive Tests

3.8.3 Core Samples and Compressive Strength Testing

3.8.4 Acceptance of Concrete Strength

3.8.4.1 Standard Molded and Cured Strength Specimens

3.8.4.2 Non-Destructive Tests

3.8.4.3 Extracted Core Tests

3.8.5 Inspection

3.9 REPAIR, REHABILITATION AND REMOVAL

3.9.1 Crack Repair

3.9.2 Repair of Weak Surfaces

3.9.3 Failure of Quality Assurance Test Results

-- End of Section Table of Contents --

SECTION 03 31 30 Page 4

SECTION 03 31 30

MARINE CONCRETE

02/19

PART 1 GENERAL

1.1 REFERENCES

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

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS

(AASHTO)

AASHTO M 182 (2005; R 2017) Standard Specification for Burlap Cloth Made from Jute or Kenaf and Cotton Mats

AASHTO R 80 (2017) Standard Practice for Determining the Reactivity of Concrete Aggregates and Selecting Appropriate Measures for Preventing Deleterious Expansion in New Concrete Construction

AASHTO T 358 (2017) Standard Method of Test for Surface Resistivity Indication of Concrete's Ability to Resist Chloride Ion Penetration

AMERICAN CONCRETE INSTITUTE (ACI)

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

ACI 121R (2008) Guide for Concrete Construction Quality Systems in Conformance with ISO

ACI 201.2R (2016) Guide to Durable Concrete

ACI 211.1 (1991; R 2009) Standard Practice for Selecting Proportions for Normal, Heavyweight and Mass Concrete

ACI 214R (2011) Evaluation of Strength Test Results of Concrete

ACI 301 (2016) Specifications for Structural Concrete

ACI 304.2R (2017) Guide to Placing Concrete by Pumping Methods

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

SECTION 03 31 30 Page 5

ACI 305R (2010) Guide to Hot Weather Concreting

ACI 306R (2016) Guide to Cold Weather Concreting

ACI 308.1 (2011) Specification for Curing Concrete

ACI 309R (2005) Guide for Consolidation of Concrete

ACI 311.4R (2005) Guide for Concrete Inspection

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

ACI SP-15 (2011) Field Reference Manual: Standard Specifications for Structural Concrete ACI 301-05 with Selected ACI References

ACI SP-66 (2004) ACI Detailing Manual

AMERICAN WELDING SOCIETY (AWS)

AWS D1.4/D1.4M (2011) Structural Welding Code - Reinforcing Steel

APA - THE ENGINEERED WOOD ASSOCIATION (APA)

APA PS 1 (2009) Structural Plywood (with Typical APA Trademarks)

ASTM INTERNATIONAL (ASTM)

ASTM A276/A276M (2017) Standard Specification for Stainless Steel Bars and Shapes

ASTM A615/A615M (2020) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

ASTM A706/A706M (2016) Standard Specification for Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement

ASTM A767/A767M (2016) Standard Specification for Zinc-Coated (Galvanized) Steel Bars for Concrete Reinforcement

ASTM A934/A934M (2016) Standard Specification for Epoxy-Coated Prefabricated Steel Reinforcing Bars

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ASTM A955/A955M (2020c) Standard Specification for Deformed and Plain Stainless-Steel Bars for Concrete Reinforcement

ASTM A1035/A1035M (2020) Standard Specification for Deformed and Plain, Low-carbon, Chromium, Steel Bars for Concrete Reinforcement

ASTM A1055/A1055M (2016) Standard Specification for Zinc and Epoxy Dual Coated Steel Reinforcing Bars

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

ASTM C31/C31M (2019a) Standard Practice for Making and Curing Concrete Test Specimens in the Field

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

ASTM C39/C39M (2020) Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

ASTM C42/C42M (2020) Standard Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete

ASTM C78/C78M (2018) Standard Test Method for Flexural Strength of Concrete (Using Simple Beam with Third-Point Loading)

ASTM C94/C94M (2020) Standard Specification for Ready-Mixed Concrete

ASTM C138/C138M (2017a) Standard Test Method for Density (Unit Weight), Yield, and Air Content (Gravimetric) of Concrete

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

ASTM C150/C150M (2020) Standard Specification for Portland Cement

ASTM C157/C157M (2017) Standard Test Method for Length Change of Hardened Hydraulic-Cement Mortar and Concrete

ASTM C171 (2016) Standard Specification for Sheet Materials for Curing Concrete

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

SECTION 03 31 30 Page 7

Volumetric Method

ASTM C192/C192M (2019) Standard Practice for Making and Curing Concrete Test Specimens in the Laboratory

ASTM C231/C231M (2017a) 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 C294 (2012; R 2017) Standard Descriptive Nomenclature for Constituents of Concrete Aggregates

ASTM C295/C295M (2019) Standard Guide for Petrographic Examination of Aggregates for Concrete

ASTM C309 (2011) Standard Specification for Liquid Membrane-Forming Compounds for Curing Concrete

ASTM C311/C311M (2018) Standard Test Methods for Sampling and Testing Fly Ash or Natural Pozzolans for Use in Portland-Cement Concrete

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

ASTM C469/C469M (2014) Static Modulus of Elasticity and Poisson's Ratio of Concrete in Compression

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

ASTM C496/C496M (2017) Standard Test Method for Splitting Tensile Strength of Cylindrical Concrete Specimens

ASTM C595/C595M (2020) Standard Specification for Blended Hydraulic Cements

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

ASTM C666/C666M (2015) Resistance of Concrete to Rapid Freezing and Thawing

ASTM C805/C805M (2018) Standard Test Method for Rebound Number of Hardened Concrete

ASTM C920 (2018) Standard Specification for Elastomeric Joint Sealants

ASTM C989/C989M (2018a) Standard Specification for Slag

SECTION 03 31 30 Page 8

Cement for Use in Concrete and Mortars

ASTM C1017/C1017M (2013; E 2015) Standard Specification for Chemical Admixtures for Use in Producing Flowing Concrete

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

ASTM C1074 (2011) Standard Practice for Estimating Concrete Strength by the Maturity Method

ASTM C1077 (2017) Standard Practice for Agencies Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Testing Agency Evaluation

ASTM C1107/C1107M (2020) Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Nonshrink)

ASTM C1152/C1152M (2020) Standard Test Method for Acid-Soluble Chloride in Mortar and Concrete

ASTM C1157/C1157M (2020) Standard Performance Specification for Hydraulic Cement

ASTM C1202 (2019) Standard Test Method for Electrical Indication of Concrete's Ability to Resist Chloride Ion Penetration

ASTM C1231/C1231M (2015) Standard Practice for Use of Unbonded Caps in Determination of Compressive Strength of Hardened Concrete Cylinders

ASTM C1240 (2020) Standard Specification for Silica Fume Used in Cementitious Mixtures

ASTM C1260 (2014) Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar-Bar Method)

ASTM C1567 (2013) Standard Test Method for Potential Alkali-Silica Reactivity of Combinations of Cementitious Materials and Aggregate (Accelerated Mortar-Bar Method)

ASTM C1602/C1602M (2018) Standard Specification for Mixing Water Used in Production of Hydraulic Cement Concrete

ASTM C1610/C1610M (2017) Standard Test Method for Static Segregation of Self-Consolidating Concrete Using Column Technique

ASTM C1611/C1611M (2014) Standard Test Method for Slump Flow of Self-Consolidating Concrete

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ASTM C1621/C1621M (2017) Standard Test Method for Passing Ability of Self-Consolidating Concrete by J-Ring

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

ASTM D512 (2012) Chloride Ion in Water

ASTM D516 (2016) Standard Test Method for Sulfate Ion in Water

ASTM D1179 (2016) Standard Test Methods for Fluoride Ion in Water

ASTM D1751 (2004; E 2013; R 2013) Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types)

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

ASTM D3867 (2016)Standard Test Methods for Nitrite-Nitrate in Water

ASTM D6690 (2015) Standard Specification for Joint and Crack Sealants, Hot Applied, for Concrete and Asphalt Pavements

ASTM E329 (2020) Standard Specification for Agencies Engaged in Construction Inspection, Testing, or Special Inspection

CONCRETE REINFORCING STEEL INSTITUTE (CRSI)

CRSI 10MSP (2018) Manual of Standard Practice

U.S. ARMY CORPS OF ENGINEERS (USACE)

COE CRD-C 39 (1981) Test Method for Coefficient of Linear Thermal Expansion of Concrete

COE CRD-C 61 (1989A) Test Method for Determining the Resistance of Freshly Mixed Concrete to Washing Out in Water

COE CRD-C 572 (1974) Corps of Engineers Specifications for Polyvinylchloride Waterstops

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FS SS-S-200 (Rev E; Am 1; Notice 1) Sealant, Joint, Two-Component, Jet-Blast-Resistant, Cold-Applied, for Portland Cement Concrete

SECTION 03 31 30 Page 10

Pavement

1.2 DEFINITIONS

a. "Atmospheric zone" is any portion of the waterfront structure above the splash zone.

b. "Buried zone" is any portion of the structure permanently buried in soil.

c. "Cementitious material" as used herein shall include portland cement and any pozzolanic material such as fly ash, natural pozzolans, ground granulated blast-furnace slag and silica fume.

d. "Concrete System" is the term describing a structural element comprised of concrete, reinforcing steel and concrete cover.

e. "Design strength" (f'c) is the specified compressive strength of concrete at time(s) specified by Contracting Officer to meet structural design criteria. Typical duration is 28 days; however, the Contracting Officer and Engineer of Record are encouraged to consider specifying strength at 56 or 90 days. For concrete mixtures containing 35 percent fly ash or more, the duration shall be a minimum of 56 days.

f. "Field test strength" (fcr) is the required compressive strength of concrete to meet structural and durability criteria. Determine (fcr) during mixture proportioning process.

g. "High-volume fly ash concrete" has a minimum of 35 percent Class F fly ash as a partial replacement to portland cement.

h. "Marine concrete" is all concrete that will be in contact with seawater or brackish water, tidal variations, splash, or spray from water in navigable waterways. Piles driven on land that extend below the water table that contains saltwater or brackish water shall be designed as marine concrete. Components of a marine structure that are permanently buried in soil shall be considered marine concrete. In addition, structures may need to be designed using these criteria even though they are not adjacent to the waterfront. For example, structures located several hundred yards from the waterfront often deteriorate prematurely due to salt spray and salt fog brought to the structure by prevailing winds. An assessment of existing structures near the construction site can be an excellent indicator for the Engineer of Record and Owner to decide if the proposed structure should follow the guidelines for marine concrete.

i. "Mass Concrete" is any concrete system that approaches a maximum temperature of 158 degrees F within the first 72 hours of placement.

In addition, it includes all concrete elements with a section thickness of 3 feet or more regardless of temperature.

j. "Mixture proportioning" is the process of designing concrete mixture proportions to enable it to meet the strength, durability and constructability requirements and of the project while minimizing the initial and life-cycle cost.

k. "Mixture proportions" are the masses or volumes of individual ingredients used to make a unit measure (cubic yard or meter) of concrete.

SECTION 03 31 30 Page 11

l. "Pozzolan" is a siliceous or siliceous and aluminous material, which in itself possesses little or no cementitious value but will, in finely divided form and in the presence of moisture, chemically react with calcium hydroxide at ordinary temperatures to form compounds possessing cementitious properties.

m. "Process control sampling" is sampling and testing conducted by the Contractor to monitor the quality of materials or processes. Process control sampling is intended to indicate the quality of materials at critical steps in production that allow intervention prior to using a material on the project.

n. "Quality Acceptance Limit" (QAL) is the limiting value of a test result that indicates acceptable material quality. Quality acceptance limits are based on design criteria that may be either upper-bound limits where smaller values indicate acceptable material, such as Doh; or lower-bound limits where larger values indicate acceptable material, such as compressive strength.

o. "Quality acceptance sampling" is sampling and testing conducted by the Contractor, or an independent testing agency, to evaluate the quality of materials used on the project. Quality acceptance sampling is conducted at regular intervals identified as "lots" to represent the quality of that portion of the material used in the project.

p. "Required compressive strength" (f'c) is the mean compressive strength of concrete required to meet structural criteria. The required strength is the mean concrete strength for tests of properly batched concrete at the age specified herein.

q. "Service life" is the Owner's stated expectation for the number of years that the structure will function without needing major concrete rehabilitation. A service life of 75 years for pile supported piers, wharves and bridges is a reasonable objective. Service life is defined as the number of years before major restoration is necessary given minimal maintenance to the structure during its life. Major restoration is defined as extensive areas that require extensive repairs using a jack hammer or other destructive means to prepare the concrete for rehabilitation. Service life is further defined as the summation of the corrosion initiation period (Ti) and the corrosion propagation period (Tp) for a given concrete system.

r. "Service Life Modeling" in the context of this document refers to a methodology to predict the length of time in service at which a defined level of deterioration will occur. Service life modeling is not required in this specification.

s. "Splash zone" is the portion of the structure just above the tidal zone. This portion of the structure is predominantly dry, but is likely to intermittently wet by wave action and wind driven spray. For the purposes of this specification, the splash zone is defined as follows:

(1) for locations protected by seawalls or otherwise sheltered from open-ocean waves, the 6 feet area just above the tidal zone;

(2) for unprotected locations, the 20 feet area just above the tidal zone.

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t. "Submerged zone" is defined as the submerged portion of the structure.

For the purposes of this specification, any element or portion thereof that is located below Mean Lower Low Water (MLLW).

u. "Supplemental Corrosion Protection" includes (but is not limited to) fusion-bonded epoxy-coated steel reinforcing, galvanized steel reinforcing, stainless reinforcing, corrosion inhibitors, barrier coatings to the concrete surface, and cathodic protection.

v. "Supplementary cementing materials" (SCM) include coal fly ash, granulated blast-furnace slag, natural or calcined pozzolans, and ultra-fine coal ash when used in such proportions to replace the portland cement that result in considerable improvement to sustainability, durability and in some cases a reduction in initial cost.

w. "Test Section" is a slab or wall separate from the main structure and constructed prior to main construction as an all inclusive demonstration of methods and materials. The adequacy of the Test Section must be approved by the owner's representative prior to construction of the project.

x. "Tidal zone" is defined as the portion of the structure regularly wetted by wave action. For the purposes of this specification, any element or portion thereof that is located between Mean Lower Low Water (MLLW) and Mean Higher High Water (MHHW) is in the tidal zone.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

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

SD-01 Preconstruction Submittals

Curing Concrete Elements

Form Removal Schedule

Concrete Placement And Compaction

Concrete Curing Plan

Concrete Qualification Program; G

Laboratory Qualifications; G

Quality Control Personnel; G

Concrete Quality Control Program; G

SD-02 Shop Drawings

Construction and Expansion Joints; G

Formwork

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Reinforcing Steel; G

Reproductions of contract drawings are unacceptable.

SD-03 Product Data

Joint Filler

Joint Sealants

Materials for Curing Concrete

Non-Shrink Grout

Preformed Joint Filler

Reinforcing Bars; G

Reinforcement Supports

Sealer-Hardener

Waterstops

Epoxy Coatings; G

Material Safety Data Sheets (Msds)

SD-05 Design Data

Mixture Designs; G

Mass Concrete Temperature Control Plans; G

SD-06 Test Reports

Mass Concrete Mock-up

Air Entraining

Aggregates

Admixtures

Cement

Concrete Mixture Proportions

Concrete Test Reports

Fresh Concrete Properties

Hardened Concrete Properties

Mechanical Reinforcing Bar Connectors

Reinforcing Bars

SECTION 03 31 30 Page 14 e4ecejyc Cross-Out

Reinforcement and Protective Coating

Silica Fume

Supplementary Cementing Materials

Water

SD-07 Certificates

Admixtures

Cementitious Materials

Cementitious Material Mill Certificates

Field Testing Technician and Testing Agency

SD-08 Manufacturer's Instructions

Coatings

SD-11 Closeout Submittals

Aggregate Moisture Content

Aggregate Sampling

Concrete Test Reports

Quality Control Charts

Daily Inspection Reports

Quality Team Meetings

Sampling Logs

1.4 MODIFICATION OF REFERENCES

Accomplish work in accordance with ACI publications except as modified herein. Consider the advisory or recommended provisions to be mandatory, as though the word "shall" had been substituted for the words "should" or "could" or "may," wherever they appear. Interpret reference to the "Building Official," the "Structural Engineer," and the "Architect/Engineer" to mean the Contracting Officer.

1.5 DELIVERY, PLACING, STORAGE, AND HANDLING OF CONCRETE

Follow ACI 301, ACI 304R, and ASTM A934/A934M requirements and recommendations. Do not deliver concrete until vapor barrier, forms, reinforcement, embedded items, and chamfer strips are in place and ready for concrete placement. Store reinforcement of different sizes and shapes in separate piles or racks raised above the ground. Protect materials from contaminants such as grease, oil, and dirt. Ensure materials can be accurately identified after bundles are broken and tags removed.

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1.6 CONCRETE QUALITY CONTROL

The objective of the concrete quality control program is for the Contractor to outline the procedures that will be used to construct a structure that will meet the project criteria. The Contractor shall develop and submit for approval a concrete quality control program in accordance with the guidelines of ACI 121R and as specified herein. The plan shall include approved laboratories. The Contractor shall provide direct oversight for the concrete qualification program inclusive of associated sampling and testing. If concrete cylinders tested during production indicate inadequate strength, excessive chloride ion penetration, or inadequate mixing, then the owner may require the Contractor to extract concrete core samples from the hardened concrete for analysis at Contractor's expense to assure that the quality of the concrete as placed and cured will satisfy the project criteria.

Develop and submit for approval a concrete quality control program in accordance with the guidelines of ACI 121R. Maintain a copy of ACI SP-15 and CRSI 10MSP at the project site.

1.6.1 Quality Control Personnel

The contractor shall submit for approval an organizational chart defining the quality control hierarchy, the responsibilities of the various positions, including the names and qualifications of the individuals in those positions.

Submit American Concrete Institute certification for the following:

a. CQC personnel responsible for inspection of concrete operations.

b. Lead Foreman or Journeyman of the Concrete Placing, Finishing, and Curing Crews.

c. Field Testing Technicians: ACI Concrete Field Testing Technician, Grade I.

d. Laboratory Testing Technicians: ACI Concrete Strength Testing Technician and Laboratory Testing Technician, Grade I or II.

e. Petrographer: Bachelor of Science degree in geology or petrography, trained in petrographic examination of concrete aggregate according to ASTM C294 and ASTM C295/C295M and trained in identification of the specific deleterious processes and tests identified in this specification. Resume shall detail the education, training and experience related to the project-specific test methods and deleterious materials and shall be submitted at least 20 days before petrographic and deleterious materials examination is to commence.

f. Concrete Batch Plant Operator: National Ready Mix Concrete Association (NRMCA) Plant Manager Certification at the Plant Manager level.

1.6.1.1 Quality Manager Qualifications

The quality manager shall hold a current license as a professional engineer in a U.S. state or territory with experience on at least five similar projects. Evidence of extraordinary proven experience may be considered by the Contracting Officer as sufficient to act as the Quality Manager.

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1.6.1.2 Field Testing Technician and Testing Agency

Submit data on qualifications of proposed testing agency and technicians for approval by the Contracting Officer prior to performing testing on concrete.

a. Work on concrete under this contract shall be performed by an ACI Concrete Field Testing Technician Grade 1 qualified in accordance with ACI SP-2 or equivalent. Equivalent certification programs shall include requirements for written and performance examinations as stipulated in ACI SP-2.

b. Testing agencies that perform testing services on reinforcing steel shall meet the requirements of ASTM E329.

c. Testing agencies that perform testing services on concrete materials shall meet the requirements of ASTM C1077.

1.6.2 Laboratory Qualifications for Concrete Qualification Testing

The concrete testing laboratory shall have the necessary equipment and experience to accomplish required testing. The laboratory shall meet the requirements of ASTM C1077, and be Cement and Concrete Reference Laboratory (CCRL) inspected.

1.6.3 Laboratory Accreditation

Laboratory and testing facilities shall be provided by and at the expense of the Contractor. The laboratories performing the tests shall be accredited in accordance with ASTM C1077, including ASTM C78/C78M and ASTM C1260. The accreditation shall be current and shall include the required test methods, as specified.

a. Aggregate Testing and Mix Proportioning: Aggregate testing and mixture proportioning studies shall be performed by an accredited laboratory and under the direction of a licensed/registered civil engineer in a U.S. state or territory, who shall sign all reports and designs.

b. Acceptance Testing: Furnish all materials, labor, and facilities required for molding, curing, testing, and protecting test specimens at the site and in the laboratory. Furnish and maintain boxes or other facilities suitable for storing and curing the specimens at the site while in the mold within the temperature range stipulated by

ASTM C31/C31M.

c. Contractor Quality Control: All sampling and testing shall be performed by an approved, onsite, independent, accredited laboratory.

1.7 CONCRETE DURABILITY

1.7.1 Concrete Mixture Proportions

At least 60 days prior to concrete placement, submit concrete mixture proportions, ingredient material certificates and test data, and trial batch test data for each class of concrete proposed for use on the project. Submittal shall clearly indicate where each mixture will be used when more than one mixture design is submitted. Obtain approval from Contracting Officer prior to placement.

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1.7.2 Concrete Design Requirements

Proportion concrete mixtures to meet the requirements listed in Table 1 in accordance with the procedures outlined in ACI 201.2R and ACI 211.1.

The mixture proportions for concrete shall be developed by the Contractor to produce the required compressive strength (f'c), drying shrinkage, durability, and constructability. The amount of cementitious material in the mixture can be minimized as long as the concrete still meets the mixture design requirements for durability and strength.

The mixture proportions and Water-Cementitious Materials Ratio for marine concrete shall be developed by the Contractor to produce the design strength (f'c) and to provide durability, workability, and mixture consistency to facilitate placement, compaction into the forms and around reinforcement without segregation or bleeding. The requirements for durability specified in Table 1 and Table 2 below shall be incorporated in the mixture proportions.

The use of silica fume is discouraged. Silica fume shall only be used for OCONUS (outside continental United States) projects where Class F fly ash and ground granulated blast furnace (GGBF) slag are not available, and when approved by the Contracting Officer. If needed, the mixture may contain a maximum of 7 percent silica fume by mass of total cementing material.

Concrete mixtures containing any percentage of silica fume shall be evaluated at every 100 cubic yards of concrete for the first 500 cubic yards, then every 500 cubic yards thereafter to ensure that the silica fume is properly dispersed in hardened concrete samples. A qualified laboratory shall microscopically examine a sectioned sample and document the results.

Provide at the Contractor's expense the services of a manufacturer's technical representative, experienced in mixing, proportioning, placement procedures, and curing of concrete containing silica fume.

The concrete mixture shall contain one of the CCM/SCM listed in Table 3, or a linear combination thereof. The minimum amount of portland cement is 50 percent of the total mass of cementitious material.

Air content: Concrete shall be air entrained and shall conform to the air limits specified in ACI 301 for exposure and the aggregate size used and tested in accordance with ASTM C231/C231M. The average spacing factor for three consecutive tests shall not exceed 0.008 in with no individual test exceeding 0.010 in as determined by ASTM C457/C457M. Variations outside the limits specified shall not be reason to reject the concrete in locations not subject to freeze-thaw conditions.

Slump: The concrete mixture shall be proportioned to have, at the point of deposit, a maximum slump of 4 inches as determined by ASTM C143/C143M when admixtures that affect slump are not used. Where an ASTM C494/C494M, Type F or G admixture is used, the slump after the addition of the admixture shall not exceed 8 inches. Slump tolerances shall comply with the requirements of ACI 117.

Table 1 - Concrete Design Requirements

Prescriptive requirements Minimum Maximum

ASTM C666/C666M Method A Durability Factor at 300 cycles 90 --

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Table 1 - Concrete Design Requirements

Prescriptive requirements Minimum Maximum

Concrete ASTM C157/C157M Drying Shrinkage percent, at 28 days except for high volume fly ash (HVFA) at 56 days.

-- 0.05 percent

Initial acid-soluble chloride content in cast-in-place concrete per ASTM C1152/C1152M, percent/cement

-- 0.10

Initial acid-soluble chloride content in prestressed concrete determined following ASTM C1152/C1152M, percent/cement

-- 0.08

Average spacing factor for three specimen following ASTM C457/C457M inch

-- 0.008 with no value greater than 0.010

Chloride ion penetrability ASTM C1202 at 56 days, Coulombs -- 1000

Alternatively to ASTM C1202, the concrete surface resistivity AASHTO T 358 at 56 days can be measured, kohm-cm

20 --

Table 2 - Concrete Quality Requirements

Zone Exposure Condition Maximum

W/CM

Submerged zone, Tidal Splash Zone

(a) Directly exposed to salt water 0.40

(b) Subject to severe abrasion 0.40

Atmospheric Zone (a) Directly exposed to marine atmosphere

0.40

(b) Protected from direct exposure to marine atmosphere

0.45

Buried Zone (a) Permanently buried in soil 0.40

Table 3 - Supplementary Cementing Material Requirements

SCM Minimum Content

Class N Pozzolan or Class F Fly Ash SiO2 plus Al2O3 plus Fe2O3 > 65 percent or where exposed to sulphates as defined in ACI 318 Table 4.2.1

30 percent

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Table 3 - Supplementary Cementing Material Requirements

Class N Pozzolan or Class F Fly Ash SiO2 plus Al2O3 plus Fe2O3 greater than 70 percent

25 percent

Class N Pozzolan or Class F Fly Ash SiO2 plus Al2O3 plus Fe2O3 greater than 80 percent

20 percent

Class N Pozzolan or Class F Fly Ash SiO2 plus Al2O3 plus Fe2O3 greater than 90 percent

15 percent

Ultra fine fly ash/Pozzolan 7 percent

Ground granulated blast-furnace slag 40 percent

1.7.3 Concrete Mixture Qualifications

1.7.3.1 Previously Approved Concrete Mixtures

For identical concrete mixtures previously approved for use within the past 18 months, the previous mixture qualification submittal may be re-submitted without further trial batch testing if accompanied by:

a. A copy of the prior approvals indicating the project name, project number, and location.

b. Ingredient material test data conducted within 12 months of the submittal date.

c. Copies of the previously approved trial batch test data.

d. A log containing at least 15 sequential test results with the calculated mean and standard deviation of the production concrete for air content, and compressive strength.

If the Contractor changes material type, class, sources, or suppliers;

chemical composition; and/or mix proportions, the Contractor shall provide a written opinion of the significance of the change(s). The change(s) may require additional testing at the discretion of the Contracting Officer in consultation with the agency's Subject Matter Expert in Concrete Materials.

1.7.3.2 New Concrete Mixtures

a. Submit complete ingredient material test data, including applicable reference specifications. Submit additional data regarding concrete aggregates if the source of aggregate changes.

b. Submit copies of test reports by independent test lab conforming to ASTM C1077 showing that the mixture has been successfully tested to produce concrete with the properties specified and that mixture will be suitable for the job conditions as described. Test reports shall be submitted along with the concrete mixture proportions. Obtain approval before concrete placement.

c. Test a minimum of one trial batch of production concrete. If batching facilities are located such that the haul-time will exceed 30 minutes, a simulated haul time shall be included in the trial batch.

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(1) Test and report fresh concrete property tests of each trial batch as follows:

(a) Slump in accordance with ASTM C143/C143M.

(b) Air content in accordance with ASTM C231/C231M or

ASTM C173/C173M.

(c) Unit weight in accordance with ASTM C138/C138M.

(d) Temperature in accordance with ASTM C1064/C1064M.

(2) Cast specimens, test, and report hardened concrete property tests of each trial batch as follows:

(a) Compressive strength at 3, 7, 28, 56 and 90 days in accordance with ASTM C39/C39M. Use of unbonded caps in accordance with ASTM C1231/C1231M is permitted.

(b) Drying shrinkage.

(c) Tensile strength (if required).

(d) Freeze-thaw durability factor (if required) shall be determined as the mean of six test specimens comprised of at least two specimens cast from each batch.

(e) Initial chloride ion content.

(f) Spacing factor in accordance with ASTM C457/C457M.

(g) Chloride ion penetrability in accordance with ASTM C1202.

(3) Moist cure concrete intended for cast-in-place applications in accordance with the standard moist curing conditions described in ASTM C192/C192M unless otherwise specified. Moist cure concrete intended for precast applications in the manner proposed for use on the project.

d. For concrete mixtures that are proposed to contain corrosion inhibitors, the Contractor shall submit the chloride ion penetration values from at least one batch of the mixture with and without the admixture making appropriate adjustments to maintain constant water to cementitious materials ratio. The purpose is to establish a correlation with respect to an adjusted value for production chloride ion penetration.

1.7.4 Concrete Qualification Program

1.7.4.1 Fresh Concrete Properties

a. Air Content: The mixture shall be proportioned and tested for qualification.

b. Slump: The mixture shall be proportioned and tested for qualification.

c. Self-Consolidating Concrete: When self-consolidating concrete is proposed for use, the mixture shall be proportioned and tested for qualification using:

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(1) ASTM C1611/C1611M slump flow shall not be greater than 24 inches, with visual stability index not greater than 1.

(2) ASTM C1621/C1621M Passing ability using the J-ring. Spread within 1 inch less than the slump flow.

(3) Passing ability using the L-Box between 4 and 8 seconds

(4) ASTM C1610/C1610M, static segregation shall be less than 4.0 percent.

For process control sampling, the slump flow limit as determined by ASTM C1611/C1611M shall be no greater than 24 inches and the visual stability index limit shall be no greater than 1.0.

d. Underwater concrete: When the concrete is intended for placement under water using the tremie technique, the concrete shall be proportioned to be cohesive and flow with minimal segregation. Viscosity modifying admixtures are permitted for underwater concrete. Proportioning guidance in ACI 304R shall be considered. Concrete mixtures shall be qualified for tremie placement methods based on a trial placement approved by the Contracting Officer.

1.7.4.2 Hardened Concrete Properties

a. Compressive Strength: The structural engineer shall specify the minimum compressive strength results at 28 days. Determine compressive strength (f'cr) for qualification of concrete mixtures and for quality acceptance testing. A compressive strength test result is defined as the mean of three properly conducted tests on 4 by 8 inch cylinders in accordance with ASTM C39/C39M. Alternatively and for concrete mixtures containing a maximum size aggregate greater than 1 inch, a strength test result shall be defined as the mean of two properly conducted 28-day tests on 6 by 12 inch cylindrical specimens in accordance with ASTM C39/C39M. In addition:

(1) Specified Compressive Strength: For structural concrete elements exposed in a marine environment, the minimum specified 28 day design strength is denoted as (f'c). Strength of concrete containing 35 percent or more fly ash shall be specified at a minimum of 56 days.

(2) Required Average Strength: The concrete shall be proportioned such that the minimum required average compressive strength (f'cr) exceeds the specified design strength (f'c) as per ACI 301.

(3) The average compressive strength may not exceed the specified strength at the same age by more than 20 percent unless approved by the Engineer of Record.

(4) Strength of any individual concrete placement shall be considered satisfactory if both the following requirements are met:

(a) The arithmetic mean of any three consecutive lot strength tests is between 1.0 and 1.2 f'c, and;

(b) No individual strength test result is less than 0.90 f'c.

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(5) In the event that a placement is represented by single sampling lot, strength shall be considered satisfactory if either:

(a) The mean of the initial test is between 1.0 and 1.2 f'c, or;

(b) The mean of the initial test and retest is between 1.0 and 1.2 f'c, and neither strength test result is less than 0.90 f'c.

(6) For underwater concrete, cast compressive strength samples by placing concrete in four 5-gallon buckets below water using similar placement as the project. Permanently mark buckets as "3 days," "7 days," "28 days," and "Extra." Include date and station. Provide specimen sets at every 100 cubic yards of concrete with a minimum of one set per day of underwater concrete placement.

(a) Retrieve buckets at specified intervals and extract three cores from each bucket. Conduct compressive strength test in accordance with ASTM C42/C42M.

(b) Strength of underwater concrete shall be satisfactory if the compressive strength result from extracted cores at the age of the specified strength is between 0.85 and 1.2 f'c with no individual strength test result less than 0.75 f'c.

b. Drying Shrinkage: Determine drying shrinkage for qualification of concrete mixtures prior to the fabrication of the Test Section and from samples made during the fabrication of the Test Section (see the paragraph TEST SECTION). No test results shall exceed the limits in Table 1. A drying shrinkage test result shall be the mean value from three or more individual specimens constituting a test set. If an individual specimen's measurements deviate from the mean value by more than 0.009 percent length change, the specimen's measurements shall be discarded and a new average established. Casting more than three specimens for each set is permitted. Test procedures and test specimens shall conform to the following:

Drying shrinkage specimens, typically 3 by 3 by 11.25 inch prisms for 1 inchmaximum size aggregate or smaller, shall be fabricated, cured, dried, and measured at 28 days in the manner delineated in ASTM C157/C157M. Mixtures containing 50 percent or more supplementary cementing materials shall meet the shrinkage criteria at 56 days.

c. Tensile strength: Determine splitting-tensile strength of concrete only for qualification of concrete mixtures. Determine and report the splitting-tensile strength result of each class of concrete in accordance with ASTM C496/C496M as the mean of three properly conducted tests at the age specified for f'c and again at 90-days age for information only.

d. Freeze-thaw durability: Determine the freeze-thaw durability factor of concrete for qualification of concrete mixtures, if required by environmental conditions. Determine and report the freeze-thaw durability factor of each class of concrete in accordance with ASTM C666/C666M Method-A. Start testing after 28 days of moist curing. The minimum acceptable durability factor shall be as per Table 1.

e. Acid Soluble Chloride Ion Content: Determine the chloride ion content

SECTION 03 31 30 Page 23 only for qualification of concrete mixtures. Determine acid soluble chloride ion content in accordance with ASTM C1152/C1152M. The limits for allowable acid-soluble chloride ion concentrations in hardened concrete are listed in Table 1.

f. Chloride Ion Penetrability: Determine the resistance of concrete to the penetration of chloride ions in accordance with ASTM C1202 during the prequalification phase. The average of three samples shall meet the limit specified Table 1.

1.7.4.3 Supplemental Corrosion Protection

Requirements for the use of supplemental corrosion protection, if any, shall be indicated on the plans.

1.7.5 Mass Concrete Temperature Control Plans

a. Thirty days minimum prior to concrete placement, submit for approval a mass concrete temperature control plan that includes:

(1) Location and identification of temperature monitoring sensors.

(2) Product data for automated temperature sensors and recording equipment.

(3) Cooling pipe layout diagram with sizes and materials, if used.

(4) Proposed insulation materials and associated R-values.

(5) Anticipated form removal schedule and curing procedures.

(6) Maximum allowable concrete placement temperature for the range of anticipated ambient temperatures based on thermal modeling.

(7) Monitoring procedures and contingency plans.

Concrete placement temperature shall be based on results of thermal modeling for the element incorporating: the heat of hydration and specific heat capacity for the concrete mixture, solar gain, and heat transfer to the environment through formwork, insulation, and cooling techniques.

Mass concrete temperature control shall be monitored using automated temperature recording devices that allow wireless transmission of data to an on-site host computer for real-time monitoring of temperatures.

Temperature control sensor layout for each placement shall be provided with individual sensor ID identified.

Minimum sensor requirements include at least two sensors for each placement located as follows:

(1) The geometric center of the element cross-section.

(2) Within 3 inches of the side forms at mid-height.

(3) Within 3 inches of the top surface located directly above the center sensors.

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MASS CONCRETE IS NOT APPLICABLE.

(4) Within 3 inches from the top corner at the intersection of side forms.

(5) Ambient temperature sensors placed in a shaded location.

Procedures for installing, protecting sensors during placement, and testing sensors a minimum of 24 hours prior to concrete placement shall be provided. Initiate sensor recording at least 2 hours prior to placement. Verify function of all sensors prior to and upon completion of concrete placing operations. Provide additional sensors for placements greater than 400 cubic yards at each location.

Submit procedures for controlling concrete temperatures within the following limits:

(1) Maximum temperature shall be less than 158 degrees F.

(2) Maximum temperature differential between the mean of all functioning center sensor temperatures to any individual surface or corner sensor shall be less than 36 degrees F.

(3) Temperature control procedures shall remain in effect until the differential between the ambient low temperature and mean of all functioning center sensor temperatures is less than 36 degrees F.

(4) An additional submittal shall be provided for the Contracting Officer's approval in the event the Contractor fails to control temperatures within the limits listed above. The submittal shall include documentation of any cracks that develop, identify revisions to control procedures to prevent future cracking, and procedures to seal or otherwise mitigate defects.

b. Mass Concrete Mock-up: For concrete mixtures intended for mass concrete, cast thirty-one 4 by 8 inch cylinder specimens in accordance with ASTM C192/C192M, three 3 by 3 by 11.25 inch concrete prisms in accordance with ASTM C157/C157M, and at least one semi-adiabatic cube from a trial batch.

The semi adiabatic cube shall have a minimum dimension of 3 feet per side, and shall be insulated all sides with a minimum R-value of 30.

Install pairs of thermocouples at the center of mass, the middle of each side, the top surface, and the top corner. Automatically record the temperature of each sensor hourly for one week. Additional cubes may be cast to calibrate active cooling system performance.

(1) Conduct compressive strength development testing at 3, 7, 28 , and 90 days age using three specimens per age in accordance with ASTM C39/C39M, and develop a compressive strength prediction equation for the concrete mixture in accordance with ASTM C1074.

(2) Conduct tensile strength tests at 3, 7, 28, and 90 days on two specimens per age in accordance with ASTM C496/C496M, and develop a tensile strength prediction equation for the concrete mixture in accordance with ASTM C1074.

(3) Conduct elastic modulus tests at 3, 7, 28, and 90 days on two specimens per age in accordance with ASTM C469/C469M, and develop an elastic modulus prediction equation for the concrete mixture in accordance with ASTM C1074.

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Conduct coefficient of thermal expansion testing in accordance with COE CRD-C 39 after 28 days of moist curing. Test specimens in a saturated condition.

Report all test results and predictive equations in the mock-up submittal.

The predictive equations may be used by the Contractor to establish the duration of temperature control and form removal based on the allowable temperature differential between the concrete core and ambient low temperature.

1.8 CONCRETE

1.8.1 Drawings