ATT_02a_Division_03_Concrete.pdf

1 Division 03 - Concrete

DIVISION 03 - CONCRETE

SECTION 03300- CAST-IN-PLACE-CONCRETE

PART 1 - GENERAL

A. Summary:

1. This Section applies to cast-in–place concrete, including formwork, reinforcing, mix design, placement procedures, and finishes:

a. Foundations and footings

b. Slabs-on grade

c. Tank walls

d. Elevator pits and slabs

e. Equipment pads and bases

B. Submittals:

a. Submittals: Submit in accordance with Division 1 requirements.

b. Product data for proprietary materials and items, including reinforcement and forming accessories, admixtures, patching compounds, vapor retarder, waterstops, joint systems, curing compounds, dry-shake finish materials, and others if requested by Project Manager.

c. Shop drawings for reinforcement detailing fabricating, bending, and placing of concrete reinforcement. Comply with ACI 315 “Manual of Standard Practice for

Detailing Reinforced Concrete Structures”.

d. Shop drawings for formwork indicating fabrication and erection of forms for specific concrete surfaces. Show form construction including jointing, special form joints or reveals, location and pattern of form tie placement, and other items that affect exposed concrete visually.

e. Samples: 12 inch x 12 inch sample of vapor barrier and joint tape to be used for installation.

f. Submit digital copy of ready-mixed concrete mix design indicating how manufacturer will achieve required PSI ratings as specified.

g. Submit digital copy of results of concrete cylinder tests by an INDEPENDENT testing laboratory and one additional copy to Concrete Supplier. Number of cylinders as specified in Part 3 of this Specification.

h. Test results will be on testing agency’s letterhead and will contain the following:

1. Name of Project

2. Name of Contractor/Client

3. Date of each test

4. Age of the Concrete

5. Maximum Load (pounds)

6. Result Strength

7. Fracture Type

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Section 03300- Cast-In-Place Concrete Cont.

i. Obtain cylinders samples for testing for each day’s pour exceeding 4 cu. yd.

plus additional sets for each 50 cu. yd. more than the first 25 cu. yd. for each concrete class placed in any one day in any one day per ACI 301-96. Exterior pedestrian pathways and integral curbs and gutters are exempt from this requirement.

j. Ready-mixed concrete delivered will be accommodated by delivery tickets showing the following:

1. Date and time of leaving the plant.

2. Type of cement and weight.

3. Quantity of water and time added.

4. Admixtures and weight.

5. Site arrival time.

6. Site leaving time.

k. Testing laboratory will submit test reports for concrete materials and mix design tests. Contractor will submit a digital copy to ESD. The test report will document the use of the recycled material defined in the Specification.

l. Provide certification from admixture manufacturers that chloride content complies with specification requirements.

m. Hot weather and cold weather concreting plan will include curing method and specific curing plan, ready mixed supplier plan, contingency plans, and materials list as a minimum. All hot weather plans will meet requirements of

ACI 305. All cold weather plans will meet requirements of ACI 306.

n. A pouring plan will be submitted by the Contractor to the ESD PM, through

MICC, for approval showing the location of all construction joints.

C. Quality Assurance:

1. Codes and Standards: Comply with provisions of the latest revision of the following codes, specifications, and standards, except where more stringent requirements are shown or specified:

a. American Concrete Institute (ACI) 211 “Proportions for Normal

Heavyweight and Mass Concrete”.

b. American Concrete Institute (ACI) 301 “Specifications for Structural

Concrete for Buildings”.

c. ACI 318, “Building Code Requirements for Reinforced Concrete”.

d. ACI 347, “Recommended Practice for Concrete Formwork”.

e. ACI 350, “Environmental Engineering Concrete Structures”.

f. Concrete Reinforcing Steel Institute (CRSI) “Manual of Standard

Practice”.

g. ASTM 94 C 94 Standard Specifications for Ready-Mix Concrete”.

h. IBC, Latest Edition.

2. Concrete Testing Service: ESD may, at its own discretion, engage a testing agency to perform material evaluation tests.

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3. Materials and installed work may require testing and retesting at any time during progress of the Work. Any retesting of rejected materials for installed

Work, will be done at Contractor’s expense.

Section 03300- Cast-In-Place Concrete Cont.

4. Contractor will review requirements for status of work, and availability of materials inspection, testing, and certifications. Require representatives of each entity directly concerned with cast-in-place concrete to attend conference, including, but not limited to, the following:

a. Contractor’s Superintendent.

b. Agency responsible for the concrete design mixes.

c. Agency responsible for field quality control.

d. Ready-mix concrete producer.

e. Primary admixture manufacturer.

D. Quality Control Testing During Construction:

1. General: The Contractor will employ a testing agency to perform tests and to submit test reports. The testing agency will be approved by ESD Inspections.

Any retesting due to non-acceptable Work or materials will be at the

Contractor’s expense.

2. Sampling and testing for quality control during concrete placement may include the following, as directed by the ESD PM.

a. Sampling Fresh Concrete: ASTM C 172, except as modified for slump to comply with ASTM C 94.

b. Slump: ASTM C 143; one test at point of discharge for each day’s pour of each type of concrete; additional tests when concrete consistency seems to have changed or as directed by ESD Inspections.

c. Air Content: ASTM C 173, volumetric method for lightweight and normal weight concrete; ASTM C 231, pressure method for normal weight concrete; one for each days pour of each type of air-entrained concrete.

d. Concrete Temperature: ASTM c 1064; one test hourly when air temperature is 40 deg F and below, when 90 deg F and above, and one test for each set of compressive-strength specimens.

e. Compression Test Specimen: ASTM C 31; two sets of four standard cylinders for each compressive-strength test, unless otherwise directed.

Mold and store cylinders for laboratory-cured test specimens except when field-cured test specimens are required.

f. Compressive-Strength Tests: ASTM C 39; one set for each day’s pour exceeding 3 cu. yd. plus additional sets for each 50 cu. yd. more than the first 25 cu. yd. of each concrete class placed in any one day; one specimen tested at 7 days, one tested at 14 days, and one tested at 28 days, and one specimen retained in reserve for later testing, if required.

Exterior pedestrian pathways and integral curbs and gutters are exempt from this requirement.

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g. When frequency of testing will provide fewer than three strength tests for a given class of concrete, conduct testing from at least five randomly selected batching or from each batch, if fewer than five are used.

h. When strength of field-cured cylinders is less than 85 percent of companion laboratory-cured cylinders, evaluate current operations and provide corrective procedures for protecting and curing the in-place concrete.

i. Strength level of concrete will be considered satisfactory if averages of sets of three consecutive strength tests are equal or exceed specified compressive-strength and no individual strength test results fall below specified compressive strength by more than 500 psi.

j. Test results will be reported in writing to ESD Inspections, through

MICC, ready-mix producer within 24 hours after tests. Reports of compressive strength tests will contain the Project identification name and number, date of concrete placement, name of concrete testing service, concrete type and class, location of concrete batch in structure, design compressive breaking strength, and type of break for 7-day, 14-day and

28-day tests.

k. Nondestructive Testing: Impact hammer, sonoscope, or other nondestructive device may be permitted but will not be used as the sole basis for acceptance or rejection.

l. Additional Test: The testing agency will make additional tests of in-place concrete when test results indicate specified concrete strengths and other characteristics have not been attained in the structure, as directed by ESD

m. Inspections. Testing agency may conduct tests to determine adequacy of concrete by cored cylinders complying with ASTM C 42, or by other methods as directed. These additional test will be at the Contractor’s expense.

PART 2 – PRODUCTS

A. Form Materials:

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

Furnish in largest practicable sizes to minimize number of joints and to conform to joint system shown on drawings. Forms will be designed for reuse.

One time forms will not be allowed.

2. Use plywood complying with U.S. Product Standard PS-1 “B-B” (Concrete

Form) Plywood, Class I, exterior Grade or better, mil-oiled and edge-sealed, with each piece bearing legible inspection trademark. Forms will be designed for reuse. One time forms will not be allowed.

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3. Forms for Unexposed Finish Concrete: Plywood, lumber, metal, or another acceptable material. Provide lumber dresses on at least two edges and one side for tight fit. Forms will be designed for reuse. One time forms will not be allowed.

4. Forms for Cylindrical Columns and Supports: Metal, glass-fiber-reinforced plastic, or paper or fiber tubes that will produce smooth surfaces without joint indications. Provide units with sufficient wall thickness to resist wet concrete loads without deformation.

5. Form Release Agent: Provide commercial vegetable based formulation form release agent with a low volatile organic compounds (VOCs) that will not bond with, stain, or adversely affect concrete surfaces and will not impair subsequent treatments of concrete surfaces.

6. Form Ties: Factory-fabricated, adjustable-length, removable or snap-off form ties designed to prevent form deflection and to prevent spalling of concrete upon removal. Provide units that will leave no metal closer than 1 ½ inches to the plane of the exposed concrete surface.

7. Provide ties that, when removed, will leave holes in the concrete surface no larger than 1 inch and no smaller than 1/2 inch in diameter. Form ties for exposed concrete will be of the cone-washer type. The cones will be made of approved wood or plastic.

8. Ties for liquid containment structures will have integral waterstop that is tightly welded to the tie.

9. Common wire will not be allowed for form ties.

B. Reinforcing Materials:

1. Reinforcing- fiber-type for slabs installed over engineered base fill.

2. Reinforcing as indicated on the drawings.

3. Reinforcing Bars- ASTM A 615, Grade 60 deformed

4. Steel Wire- ASTM 82, plain, cold drawn steel

5. Welded Wire Fabric: ASTM A 185, welded steel wire fabric

6. Supports for Reinforcement- Bolsters, chairs, spacers, and other devices for spacing supporting, and fastening reinforcing bars and, use wire bar-type supports complying with CRSI specifications.

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

8. For exposed-to-view concrete surfaces where legs of supports are in contact with forms, provide supports with legs that are protected by plastic (CRSI, C lass 1) or stainless steel (CRSI, Class 2).

C. Concrete Materials:

1. Portland Cement:

a. ASTM C 150, Type II

b. Compressive Strength Tests- ASTM C 39, 4000 psi

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c. Fiber Reinforced for slab on grade.

2. Fly Ash- ASTM C 618, Type F

a. Use one brand of cement and fly ash throughout Project unless otherwise specified by ESD Project Manager.

3. Normal-Weight Aggregates- ASTM C 33.

4. For exposed concrete surfaces, do not use fine or course aggregates that contain substances that cause spalling.

D. Vapor Retarder:

1. Vapor Retarder: Provide vapor retarder that is resistant to deterioration where tested in accordance with ASTM E 154, and ASTM D 4397, as follows:

a. Polyethylene sheet, 10 mil thick, with maximum permeance rating of 0.13 perm (7.5 ng/Pa x s x sq. m.).

2. Overlap all seams 8” (min). Tape all joints with self-adhesive, non-permeable material.

E. Concrete Base:

1. Concrete is to be installed over base of Dense Grade Aggregate (DGA), 8 inches (minimum) thickness.

F. Water: Potable:

1. Admixtures, General: Provide concrete admixtures that contain no more than

0.1 percent chloride ions.

a. Air-Entraining, Admixture: ASTM C 260, certified by manufacturer to be compatible with other required admixtures:

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

a. Monex Air or Monex NVR, Monex Resources, Inc.

b. Air-Tite, Comrmix Construction Chemicals

c. Air-Mix or Perma-Air, Euclid Chemical Co.

b. Water-Reducing Admixtures: ASTM C 494, Type A or D.

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

a. Monex Resources, Inc.

b. Chemtard, ChemMasters Corp.

c. PSI N, Cormix Construction Chemicals.

c. High-Range Water Reducing Admixture: ASTM C 494, Type F or Type

G.

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

a. Monex SP or Mighty RD, Monex Resources, Inc.

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b. Super P, Anti-Hydro Company, Inc.

c. Eucon 37, Euclid Chemical Company.

G. Calcium Chloride:

1. The use of calcium chloride WILL NOT be permitted.

H. Related Materials:

1. Reglets: Where sheet flashing or bituminous membranes are terminated in reglets, provide reglets of not less than 0.0217 inch-thick galvanized sheet steel. Fill reglet or cover face opening to prevent intrusion of concrete or debris.

2. Dovetail Anchor Bolts: Hot-dip galvanized sheet steel, not less than 0.0336 inch-thick with bent tab anchors. Fill slot with temporary filler or cover face opening to prevent intrusion of concrete or debris.

3. Waterstops: Provide ribbed, dumbbell-type waterstops at construction joints exposed to water pressure, including groundwater pressure, and other joints as indicated. Provide ribbed dumbbell type with centerbulb waterstops at expansion joints. All waterstops will be a minimum of 1/2” thick x 9” wide.

All waterstops will be provided with either metal grommets or integral tie wires located at the top and bottom of the waterstop spaced at 12” o.c.

4. Polyvinyl Chloride Waterstops: Corps of Engineers CRD-C-572

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

1. The Burke Co.

2. Greenstreak Plastic Products Co.

3. Meadows, Inc.

4. Progress Unlimited.

5. Schlegal Corp.

6. Vinylex Corp.

3. Sand Cushion: Clean, manufactured or natural sand.

4. Absorption Cover: Burlap cloth made from jute or kenaf, weighing approximately 9 oz. /sq. yd., complying with AASHTO M 182, Class 2.

5. Water-resistant barrier consisting of heavy kraft papers laminated together with glass-fiber reinforcement and overcoated with black polyethylene on each side.

6. Absorptive Cover: Burlap cloth made from jute or kenaf, weighing approximately 9 oz. /sq. yd., complying with AASHTO M 182, Class 2.

7. Moisture-Retaining Cover: One of the following, complying with ASTM C

171:

1. Waterproof paper.

2. Polyethylene film.

3. Polyethylene-coated burlap.

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8. Epoxy Adhesive: ASTM C 881, two-component material suitable for use on dry or damp surfaces. Provide material type, grade, and class to suit Project requirements.

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

1. Burke Epoxy M.V., The Burke Co.

Section 03300- Cast-In-Place Concrete Cont.

2. Spec-Bond 100, Concrete Marketing and Mfg. Co.

3. Resi-Bond (J-58), Dayton Superior.

4. Euco Epoxy System #452 or #620, Euclid Chemical Co.

5. Epoxtite Binder 2390, A.C. Horn, Inc.

6. Epabond, L&M Construction Chemicals, Inc.

9. Bonding Agent: Polyvinyl acetate or acrylic base.

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

1. Acrylic Bondcrete, The Burke Co.

2. Strongbond, Conspec Marketing and Mfg. Co.

3. Day-Chem Ad Bond, Dayton Superior Corp.

4. SBR Latex, Euclid Chemical Co.

5. Daraweld C, W.R. Grace & Co.

6. Hornweld, A.C. Horn, Inc.

10. Curing Agent Surface Sealer: Colorless, odorless, non-toxic, non-combustible, non-flammable, free of volatile organic compounds (VOCs).

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

1. Ashford Formula as manufacture by Curecrete Distribution Inc. or an approved equal.

11. Anchor Bolts: Anchor bolts will be embedded type (Cast into concrete pour) unless otherwise called out on the drawings as Adhesive Type or Expansion

Type.

12. Embedded anchor bolts are to be ASTM A 36 material with heavy hex nut tack welded to the embedded threads. The minimum embedment (top of concrete to the top of the tack welded nut) will be as follows:

Diameter Embedment

3/4" 1’-1”

1” 1’-6”

1-1/4" 1’-10"

13. Adhesive anchor bolts are to be 304, stainless-steel which use self-contained aggregate, resin, and hardener cartridges which develop the following values:

Anchor Diameter Embedment Allow Load (lbs.)

Inches Inches Tension Shear

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1/4 3-3/4 550 590

1/2 3-1/2 2130 2200

5/8 4 2930 3330

3/4 4-3/4 3870 4800

1 6 7200 7470

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

a. Hilti HVA Adhesive Anchor System

14. Expansion anchor bolts are to be 304 stainless-steel which develop the following minimum values:

Anchor Diameter Embedment Allow Load (lbs.)

Inches Inches Tension Shear

1/4 3-3/4 650 500

1/2 3-1/2 2400 2400

5/8 4 3200 3800

3/4 4-3/4 4800 5000

1 6 7000 9000

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

a. Hilti Kwick Bolt II

I. Proportioning and Designing Mixes:

1. Prepare design mixes for each type and strength of concrete specified by either laboratory trial batch or field experience methods as specified in ACI

301, ACI 211, and ACI 350. For the trial batch method, use an independent testing agency acceptable to ESD PM for preparing and reporting proposed mix designs.

2. Do not use the same testing agency for field quality control testing.

3. Fly ash content to be a minimum of 15% and maximum of 25 percent of the total cementitious content, by weight. Fly ash will be used in all structural concrete.

4. Submit written reports to ESD PM of each proposed mix for each class of concrete at least 15 days prior to start of Work. Do not begin concrete production until proposed mix designs have been reviewed and approved by

ESD PM.

J. Design Mixes to Provide Concrete with the Following Properties as Indicated on Schedules:

Class 7 Day 28 Day Maximum Minimum

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Water

Cementitious

Ratio

Cementitious

Material

(lbs/CY)

Structural 2670 4000 0.44 611

Non-Structural 2000 3000 0.50 508

Structural, High Strength

2670 4000 0.40 658

K. Structural, High Density Concrete will be used in all structures where concrete is intended to be watertight in service.

L. Slump Limits:

1. Proportion and design mixes to result in concrete slump at point of placement as follows:

a. Ramps, slabs, and sloping surfaces: Not more than 3 inches.

b. Reinforced foundation systems: Not less than 1 inch and not more than 3 inches.

c. Concrete containing high-range water-reducing admixture

(superplasticizer): Not more than 8 inches after adding admixture to site-verified 2-3 inch slump concrete.

M. Adjustment to Concrete Mixes:

1. Mix design adjustments may be requested by Contractor when characteristics of materials, job conditions, weather, test results, or other circumstances warrant, as accepted by ESD Inspections. Laboratory test data for revised mix design and strength results must be submitted to and accepted by ESD

Inspections before using in the Work.

N. Admixtures:

1. Use high-range water-reducing admixture in pumper concrete, concrete for heavy-use industrial slabs, concrete required to be water-tight, and concrete with water-cement ratios below 0.50.

2. Use air-entraining admixture in exterior exposed concrete unless otherwise indicated. Add air-entraining admixture at manufacturer’s prescribed rate to result in concrete at point of placement having total air content of 4% with a tolerance of plus or minus 1.0 percent.

O. Ready-Mixed Concrete:

1. General: Comply with requirements of ASTM C 94, and as specified.

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

PART 3 - EXECUTION:

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E. General:

1. Coordinate the installation of joint materials, vapor retarder/barrier, and other related materials with placement of forms and reinforcement steel.

2. Forms:

a. General: Design, erect, support, brace, and maintain formwork to support vertical, lateral, static, and dynamic loads that be applied until concrete structure can support such loads. Construct formwork so concrete members and structures remain in correct size, shape, alignment, elevation, and position. Maintain formwork construction tolerances and surface irregularities complying with the following ACI 347 limits:

b. Provide Class A tolerances for concrete surfaces exposed to view.

c. Provide Class B tolerance for other concrete surfaces.

3. Construct forms to sizes, shapes, lines, and dimensions shown and to obtain accurate alignment, location, grades, level, and plumb Work in the finished structures. Provide for openings, offset, sinkages, keyways, recesses, moldings, rustifications, reglets, chamfers, blocking, screeds, bulkheads, anchorages, and inserts, and other features required in the Work. Use selected materials to obtain designed finishes. Solidly butt joints and provide backup at joints to prevent cement paste from leaking.

4. Provide temporary openings for clean-outs and inspections where interior area of formwork in inaccessible before and during concrete placement. Securely brace temporary openings and set tightly to forms to prevent losing of concrete mortar. Locate temporary openings in forms at inconspicuous locations.

5. Fabricate forms for easy removal without hammering or prying against concrete surfaces. Provide crush plates or wrecking plates where stripping may damage cast concrete surfaces. Provide top forms for inclined surfaces where slope is too steep to place concrete with bottom forms only. Kerf wood inserts for forming keyways, reglets, recesses, and the like, for easy removal.

6. Thoroughly clean forms and adjust surface to receive concrete. Remove chips, wood, sawdust, dirt, or other debris just before placement of concrete.

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

7. Chamfer all exposed corners and edges, using wood, metal, or PVC, or rubber chamfer strips fabricated to produce uniform smooth lines and tight edge joints. Chamfer edges to be 3/4 inch, unless otherwise approved by ESD

Inspector.

8. Provisions for Other Trades: Provide openings in concrete formwork to accommodate Work by other trades. Determine size and location of openings, recesses, and chases from trades providing such items. Accurately place and securely support items built into forms.

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9. Cleaning and Tightening: Thoroughly clean forms and adjacent surfaces to receive concrete. Remove chips, wood, sawdust, dirt, or other debris just before placing concrete. Retighten forms and bracing before placing concrete, as required, to prevent mortar leaks and maintain proper alignment.

F. Placing Reinforcement:

1. General: Comply with Concrete Reinforcing Steel Institute’s recommended practice for “Placing Reinforcing Bars” for details and methods of reinforcement placement and supports and as specified.

2. Avoid cutting or punching vapor retarded/barrier during reinforcement placement and concrete operations. Repair damages before placing concrete.

3. Clean reinforcement of loose rust and mil scale, earth, ice, and other materials that reduce or destroy bond with concrete.

4. Accurately position, support, and secure reinforcement against displacement

.Locate and support reinforcing by metal chairs, runners, bolsters, spacers, and j-hangers, as approved by ESD Inspections.

5. Place reinforcement to maintain minimum coverages as indicated for concrete protection. Arrange, space, and securely tie bars and bar supports to hold reinforcement in position during concrete placement operations. Set wire ties so ends are directed into concrete, not towards exposed concrete surfaces.

Minimum concrete cover, as indicated below, unless noted otherwise:

a. Cast against and permanently exposed to earth: 3 in.

b. Formed surfaces exposed to earth or weather: 2 in.

c. Formed surfaces not exposed to earth or weather:

1. Walls, slabs, joists: .75 in.

2. Beams, girders and columns:1.5 in.

3. Non-formed surfaces exposed to weather: 2 in.

6. Lap splices will be in accordance with the following table, unless noted otherwise. Where classes are not called out on drawings, use Class “C” splices for f ’c=4000 psi fy=60,000 psi

Bar Size Splice (inches)

#4 29

#5 36

#6 43

#7 54

#8 71

#9 90

G. Joints:

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1. Construction Joints: Locate and install construction joints so they do not impair strength or appearance of the structure, as acceptable to ESD Inspector.

2. Place construction joints perpendicular to main reinforcement. Continue reinforcement across construction joints except as indicated otherwise. Do not continue reinforcement through sides of slip joint placements.

3. Use bonding agent on existing concrete placement that will be joined with fresh concrete.

4. Waterstops: Provide waterstops in construction joints to form continuous diaphragm in each joint. Support and protect exposed waterstops during progress of Work. Field-fabricated joints in waterstops in accordance with waterstop manufacturer’s printed instructions.

5. Isolation Joints in Slabs-on-Grade: Construct isolation joints in slabs-on-grade at points of contact between slabs-on-grade and vertical surfaces, such as column pedestals, foundation walls, grade beams, and other locations as indicated.

6. Joint fillers and sealants will be as follows:

1. Self-expanding Cork Joint Filler: Preformed strips complying with ASTM

D 1752 for Type III.

2. Cork Joint Filler: Preformed strips complying with ASTM D 1752 for Type

II.

3. Sponge Rubber Joint Filler: Preformed strips complying with ASTM D

1752 for Type I.

4. Bituminous Fiber Joint Filler: Preformed strips complying with ASTM D

1751: Granulated cork with asphalt binder encased between two layers of saturated felt of glass-fiber felt of width and thickness indicated.

7. Joint sealers will be appropriate for their intended use and installations. Follow manufacturer’s instructions for use and installation. All joint sealers will be in accordance with ACI 504R.

H. Installing embedded Items:

1. General: Set and build into formwork anchorage devices and other embedded items required for other work that is attached to or supported by cast-in-place concrete. Use setting drawings, diagrams, instructions and directions provided by suppliers of items to be attached.

2. Forms for slabs and other flatwork: Set edge forms, bulkheads, and intermediate screed strips for slabs to achieve required elevations and contours in finished surfaces. Provide and secure units to support screed strips using strike-off templates or compacting-type screeds.

I. Preparing Form Surfaces:

1. General: Coat contact surfaces of forms with an approved, nonresidual, low-

VOC, form-coating compound before placing reinforcement.

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2. Do not allow excess form-coating material to accumulate in forms or come into contact with in-place concrete surfaces against which fresh concrete will be placed. Apply according to manufacturer’s instructions.

3. Coat steel forms with a nonstaining, rust-preventive material. Rust-stained steel formwork is not acceptable.

J. Concrete Placement:

1. Inspection: Before placing concrete, inspect and complete formwork installation, reinforcing steel, and items to be embedded or cast in. Notify other trades to permit preparation or installation of their Work.

Section 03300- Cast-In-Place Concrete Cont.

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

3. Ambient air temperatures and surface temperatures will be a minimum of 40 degrees and rising when placing concrete.

4. If Installer wants to deviate from this requirement, he must produce documentation in the form of ACI Guidelines as to the necessary adjustments and measures that must be taken in writing before proceeding with the placing of the concrete.

5. Deposit concrete continuously or in layers of such thickness that no new concrete will be placed on concrete that has hardened sufficiently to cause seams or planes of weakness. If a section cannot be placed continuously, provide construction joints as specified. Deposit concrete as not to cause segregation at its final location.

6. Placing Concrete in Forms: Deposit concrete in forms in horizontal layers no deeper than 24 inches and in a manner to avoid inclined construction joints.

Where placement consist of several layers, place each layer while proceeding layer is still plastic to avoid cold joints.

7. Consolidate placed concrete by mechanical vibrating equipment supplemented by hand-spading, rodding, or temping. Use equipment and procedures for consolidation of concrete complying with ACI 309.

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

A spare vibrator will be on-site for emergency use at all times.

9. Placing Concrete Slabs: Deposit and consolidate concrete slabs in a continuous operation, within limits of construction joints or expansion joints, until completing placement of a panel or section.

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

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11. Bring slab surfaces to correct level with a straightedge and strike-off. Use bull floats or darbies to smooth surface free of humps or hollows. Do not disturb slab surfaces prior to beginning finishing operations.

12. Maintain reinforcing in proper position on chairs during concrete placement.

13. Cold-Weather Placement: Comply with provisions of ACI 306. Protect concrete work from physical damage or reduced strength that could be caused by frost, freezing actions, or low temperatures.

a. When air temperature has fallen to or is expected to fall below 40 deg F, uniformly heat water and aggregates before mixing to obtain a concrete mixing temperature of not less than 50 deg F and not more than 80 deg F at time of placement.

Section 03300- Cast-In-Place Concrete Cont.

b. Do not use frozen materials or materials containing ice or snow. Do not place accelerators unless otherwise accepted in the mix designs. Calcium chloride will not be allowed.

14. Hot-Weather Placement: When hot-weather conditions exist that would impair quality or strength of concrete, place concrete complying with ACI 305 and as specified.

a. Cool ingredients before mixing to maintain concrete temperature at time of placement in accordance with ACI. Mixing water may be chilled or chopped ice may be used to control temperature, provided water equivalent of ice is calculated to total amount of mixing design water. Using liquid nitrogen to cool concrete is Contractor’s option.

b. Cover reinforcing steel with water-soaked burlap if it becomes too hot, so that steel temperature will not exceed the ambient air temperature immediately before placing concrete.

15. Fog spray forms, reinforcing steel, and subgrade just before placing concrete.

Keep subgrade moisture uniform without puddles or dry areas.

16. Use water-reducing retarding admixture when required by high temperatures, low humidity, or other adverse placing conditions, as acceptable to ESD

Inspector.

K. Finishing Formed Surfaces:

1. Rough-Formed Surfaces: Provide a rough-formed finish on formed concrete surface not exposed to view in the finished Work or concealed by other construction. This is the concrete surface having texture imparted by form-facing material used, with tie-holes and defective areas repaired and patched, or chipped off. Finish will be Class C in accordance with ACI 347.

2. Smooth-Formed Finish: Provide a smooth-formed finish on formed concrete surfaces exposed to view or to be covered with a coating material applied directly to concrete, or a covering material applied directly to concrete, such as waterproofing, damproofing, veneer plaster, painting, acid wash, or another similar system. This is an as-cast concrete surface obtained with selected form-facing material, arranged in an orderly and symmetrical manner with a minimum of seams. Repair and patch defective areas with fins or other

16 Division 03 - Concrete projections completely removed and smoothed. Finish will be Class A, in accordance with ACI 347.

3. Grout-Cleaned Finish: Provide grout-cleaned finish on scheduled concrete surfaces that have received smooth-formed finish treatment.

a. Combine one part Portland cement to one and one-half parts fine sand by volume, and a 50:50 mixture of acrylic or styrene butadiene-based bonding admixture and water to form the consistency of thick paint. Blend standard

Portland cement and white Portland cement in amounts determined by trial patches so that final color of dry grout will match adjacent surfaces.

b. Thoroughly wet concrete surfaces, apply grout to coat surfaces, and fill small holes. Remove excess grout by scraping and rubbing with clean burlap. Keep damp by fog spray for at least 36 hours after rubbing.

Section 03300- Cast-In-Place Concrete Cont.

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

L. Monolithic Slab Finishes:

1. The flatness of all slab surfaces will be such that the gap between a 10 foot long straight edge and the concrete surface is less than 1/4 inch. The surface will also meet ASTM E 1155 flatness values overall FF 38 (floor flatness) FT

25 (floor tolerance) and local FF 26 FT 17. Outdoor slabs will be sloped to drain a minimum of 1/8 inch per foot.

2. Float Finish: Apply float finish to monolithic slab surfaces to receive trowel, bull float, and other as specified; slab surfaces to be covered with a membrane or elastic waterproofing, membrane or elastic roofing, or sand-bed terrazzo, and where indicated.

a. After screeding, consolidating, and leveling concrete slabs, do not work surfaces until ready for floating. Begin floating, using float blades or float shoes only, when surface water has disappeared, or when concrete has stiffened sufficiently to permit operation of power-driven floats, or both.

Consolidate surface with power-driven floats or by hand-floating if area is small or inaccessible to power units. Finish surfaces to tolerances of FF 25 and FL 20 (floor levelness) measured in accordance with ASTM E 1155

(ASTM 1155M). Cut down high spots and fill low spots.

Uniformly slope surfaces to drains. Immediately after leveling, refloat surface to a uniform, smooth, granular texture. Class of surface will be

Class C in accordance with ACI 347R.

3. Nonslip Broom Finish: Apply a nonslip broom finish to exterior concrete platforms, steps, and ramps, and elsewhere as indicated.

a. Immediately after float finishing, slightly roughen concrete surface by brooming with fiber-bristle broom perpendicular to main traffic routes.

Coordinate required finish with ESD Inspector before application.

17 Division 03 - Concrete

4. Filling In: Fill in holes and opening left in concrete structures for passage of

Work by other trades, unless other shown or directed, after Work of other trades is in place.Mix, place, and cure concrete as specified to blend with in-place construction. Provide other miscellaneous concrete filling shown or required to compete Work. All grout used for filling will be non-shrinking.

5. Curbs: Provide monolithic finish to exterior curbs by stripping forms while concrete is still green and by steel-troweling surfaces to a hard, dense finish with corners, intersections, and terminations slightly rounded.

6. Equipment Pads and Foundations: Provide machine and equipment pad and foundations as shown on Drawings or at each piece of equipment specified. Set anchor bolts for machines and equipment to template at correct elevations, complying with diagrams or templates of manufacturer furnishing machines and equipment.

Section 03300- Cast-In-Place Concrete Cont.

7. Steel Pan Stairs: Provide concrete fill for steel pan stair treads, landings, and associated items. Cast-in safety inserts and accessories as required. Screed, tamp, and nonslip broom concrete surfaces.

M. Concrete Curing and Protection:

1. General: Protect freshly placed concrete from premature drying and excessive cold and hot temperatures. Protect concrete from rapid moisture loss before and during finishing operations in hot, dry, or windy weather with an evaporation-control material. Apply according to manufacturer’s instructions after screeding and bull floating, but before power floating and troweling.

2. Start initial curing as soon as free water had disappeared from concrete surface after placing and finishing. Keep concrete surface continuously moist for not less than 14 days as required due to weather.

3. Curing Methods: Cure concrete by moist curing, by moisture-retarding cover curing, or by combining these methods, as required.

a. Where the concrete is scheduled to receive a sealed concrete finish, the curing is to be accomplished by using an application of the “Ashford

Formula” in strict accordance with the manufacturer’s recommendations.

b. Provide moisture curing by the following methods:

1. Keep concrete surface continuously wet by covering with water.

2. Use continuous water-fog spray.

3. Cover concrete surface with specified absorptive cover, thoroughly saturate cover with water, and keep continuously wet. Place absorptive cover to provide coverage of concrete surfaces and edges, with a 4 inch lap over adjacent absorptive covers.

c. Provide moisture-retaining cover curing as follows:

1. Cover concrete with moisture-retaining cover for curing concrete, place in widest practical width with sides and ends lapped at least 3 inches and sealed with waterproof tape of adhesive. Immediately repair any holes or tears during curing period using cover material and waterproof tape.

18 Division 03 - Concrete

d. Curing Formed Surfaces: Cure formed concrete surfaces, including underside of beams, supported slabs, and other similar surfaces, by moist curing with forms in place for the full curing period. As soon as initial set has occurred, place a soil soaker hose along the tops of all walls to keep concrete forms wet during the curing period. If forms are removed, continue curing by methods specified above, as applicable, for the remainder of the curing period. If forms are removed before the end of the curing period, then concrete will be continuously moistened for the remainder of the curing period by fog spraying or covering with moist burlap.

e. Curing Uniformed Surfaces: Cure unformed surfaces, including slabs, floor topping, and other flat surfaces, by applying the appropriate curing method.

f. Final cure concrete surfaces to receive finished flooring with a moisture-retaining cover, unless otherwise directed.

N. Shores and Supports:

1. General: Comply with ACI 347 for shoring and reshoring in multistory construction, and as specified.

2. Extend shoring from ground to roof for structures four stories or less, unless otherwise permitted.

3. Keep reshores in place a minimum of 15 days, or longer if required, after placing upper tier, until concrete has attained its required 28-day strength and heavy loads due to construction operations have been removed.

O. Removing Forms:

1. Formwork, such as beam soffits, joists, walls, and other structural elements, may not be removed until concrete has attained at least seventy-five percent

(76%) of design minimum compressive strength at 28 days.

2. No earth loads or live loads will be placed against or on any poured structurally reinforced concrete until the concrete has reached its 28-day compressive strength of otherwise approved by Engineer. Determine potential compressive strength of in-place concrete by testing field-cured specimens’ representative of concrete locations or members.

3. Form-facing materials may be removed 4 days after placement of concrete only if shores and other vertical supports have been arranged to permit removal of form-facing materials without loosening or disturbing shores and supports.

P. Reusing Forms:

1. Clean and repair surfaces of forms to be reused in the Work. Split, frayed, delaminated, or otherwise damaged form-facing material will not be acceptable for exposed surfaces. Apply new form-coating compound as specified for new formwork.

2. When forms are extended for successive concrete placement, thoroughly clean surfaces, remove fins and laitance, and tighten to close joints. Align and secure joint to avoid offsets. Do not use patched forms for exposed concrete surfaces.

19 Division 03 - Concrete

Q. Concrete Surface Repairs:

1. Patching Defective Areas: Repair and patch defective areas with cement mortar immediately after removing forms.

2. Repairing formed Surfaces: Remove and replace concrete having defective surfaces if defects cannot be repaired to satisfaction of ESD. Surface defects include color and texture irregularities, cracks, spalls, air bubbles, honeycomb, rock pockets, fins and other projections in the surface, and stains and other discolorations that cannot be removed by cleaning. Make form tie holes flush and fill with dry-pack mortar or precast cement cone plugs secured in place with bonding agent.

3. Repair concealed formed surfaces, where possible, containing defects that affect the durability of the concrete. If defects cannot be repaired, remove and replace the concrete.

Section 03300- Cast-In-Place Concrete Cont.

4. Repairing Unformed Surfaces: Test uniformed surfaces, such as monolithic slabs, for smoothness and verify surface tolerances specified for each surface and finish. Correct low and high areas as specified. Test uniformed surfaces sloped to drains for trueness of slope and smoothness by using a template having the required slope.

5. Repair finished unformed surfaces containing defect that affect the concrete durability. Surface defects include crazing and cracks in excess of 0.01 inches wide or that penetrate to the reinforcement or completely through non-reinforced sections, regardless of width, spalling, popouts, honeycombs, rock pockets, and other objectionable conditions.

6. Correct high areas in unformed surfaces by grinding after concrete has cured at least 14 days.

7. Correct low areas in uniformed surfaces during or immediately after completing surface finishing operations by cutting out low areas and replacing with patching mortar. Finish repaired areas to blend into adjacent concrete.

Proprietary underlayment compounds may be used when acceptable to ESD

Inspections.

End of Section- 03300

20 Division 03 - Concrete

SECTION 03450- PLANT-PRECAST ARCHITECTURAL CONCRETE

PART 1 – GENERAL

A. Related Sections:

1. Division 7, Section “Sealants & Caulks”

2. Division 5, Section “Structural Steel”

3. Division 3, Section “Cast-in-place Concrete”

B. Performance Requirements:

1. Structural Performance: Provide precast architectural concrete units and connections capable of withstanding design loads within limits and under conditions indicated. See Code Summary and Drawing General Notes for design loads, design requirements, and durability requirements. Design loads as stated:

a. Members to withstand own weight, design loads due to pressure and suction of wind, erection forces, and live and dead loads.

b. Component connections to accommodate building movement. Provide adjustment to accommodate misalignment of structure without permanent distortion, damage to components, wracking of joint connection, breakage of seals or moisture penetration.

2. Architectural precast concrete contractor will design structural reinforcement required to resist handling and erection stresses and service loads.

3. Compressive strength of architectural concrete at transfer of pre-stressing force:

3500 psi, unless otherwise noted.

C. References:

1. American Concrete Institute (ACI).

a. ACI 362.1R-97, Guide for the Design of Durable Parking Structures

Recommendations, not specifications.

2. Prestressed Concrete Institute (PCI):

a. PCI MNL 116, “Manual for Quality for Plans and Production of Precast

Prestressed Concrete Products”.

b. PCI MNL 117, “Manual for Quality Control for Plants and Production of

Architectural Precast Concrete Products”.

c. PCI MNL 122, “Architectural Precast Design Handbook”.

3. American Welding Society (AWS):

a. AWS D1.1, “Structural Welding Code: Steel”.

b. AWS D1.4, “Structural Welding Code: Reinforcing Steel”.

c. AWS D19.0, “Welding Zinc-Coated Steel”.

D. Submittals:

1. Submittals: Submit in accordance with Division 1 requirements.

2. Design Mixes: For each type of concrete mix.

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

21 Division 03 - Concrete

Section 03450- Plant-Precast Architectural Concrete Cont.

4. Shop Drawings: Detail fabrication and installation of precast architectural concrete units. Indicate member locations, plans, elevations, dimensions, shapes, cross sections, limits of each finish, and types of reinforcement, including special reinforcement.

a. Indicate separate face and backup mix locations and thickness.

b. Indicate welded connections by AWS standard symbols. Detail loose and cast-in hardware, inserts, connections, and joints, including accessories and reinforcement.

c. Indicate bolted connections.

d. Indicate locations and details of anchorage devices to be embedded in other construction.

e. Comprehensive engineering analysis signed and sealed by the qualified professional engineer responsible for its preparation.

f. Indicate finishes and thickness of units.

g. Lift and erection inserts.

h. Show all caulked joints, including expansion joints (“soft” type) and grated joints (“rigid” type) and weep details and locations.

i. Indicate protective finishes for metal items including connections.

5. Samples: Submit samples approximately 12” x 12” x 2” to illustrate quality, color, and texture of surface finish.

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

7. Qualification Data: For firms and persons specified in “Quality Assurance”

Article this Section, to demonstrate their capabilities and experience. Include lists of completed projects, project names of similar size and scope.

a. Experience record of proposed supervisor for precast concrete erection.

8. Material Certificates: Signed by manufacturers certifying that each of the following items complies with requirements:

a. Concrete materials.

b. Reinforcing materials and prestressing tendon.

c. Admixtures.

d. Bearing pads.

e. Water-absorption test reports.

9. Plant Certification: Proof of architectural precast concrete supplier’s plant follows and is certified with Concrete Institute plant certification program prior to award of subcontract.

10. Engineering Certification: Provided drawings to be sealed by a structural engineer licensed in Kentucky indicating compliance with design requirements.

E. Quality Assurance:

1. Installer Qualifications:

a. Erection of precast panels will be performed by an established firm regularly engage for at least 5 years in the erection of precast concrete or stone panels of sizes similar to those required for this project.

22 Division 03 - Concrete

b. Perform erection of panels under the supervision of a foremen employed by the erection firm for this type of work.

2. Fabricator Qualifications: A firm that complies with the following requirements and is experienced in manufacturing precast architectural concrete units to those indicated for this Project and with a record of successful in-service performance.

a. Assumes responsibility for engineering precast architectural concrete units to comply with performance requirements. This responsibility includes the preparation of shop drawings and compressive engineering analysis by a qualified professional engineer.

b. Participates in PCI’s Plant Certification program and is designated a PCI-

Certified plant for Group A, Category A1- Architectural Cladding and

Load Bearing Units Concrete Products and is designated an APA-Certified plant.

c. Has a minimum 5 years continuous experience in the…