100-PrompII-Specs-Vol-II.pdf

IFB W912BU-09-B-0029

US Army Corps of Engineers Philadelphia District

RECOVERY

Spillway Modifications and Appurtenant Structures, Phase II

Prompton Dam Lackawaxen River Basin, PA

Construction Solicitation and Specifications

12 August 2009 Volume II

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Invitation for Bids

W912BU-09-B-0029

03230 STEEL STRESSING TENDONS AND ACCESSORIES FOR PRESTRESSED

CONCRETE

03300 CAST-IN-PLACE STRUCTURAL CONCRETE

03373 CONCRETE FOR SECANT WALL

03375 SHOTCRETE CONSTRUCTION FACING AND WALL DRAINAGE

03410 PRECAST PRESTRESSED CONCRETE GIRDERS

03413 PRECAST ARCHITECTURAL CONCRETE

DIVISION 04 - MASONRY

04200 MASONRY

DIVISION 05 - METALS

05120 STRUCTURAL STEEL

05480 BRIDGE EXPANSION JOINT ASSEMBLIES

05482 BRIDGE BEARINGS

05500 METAL: MISCELLANEOUS AND FABRICATIONS

DIVISION 06 - WOOD, PLASTICS, AND COMPOSITES

06100 ROUGH CARPENTRY

06200 FINISH CARPENTRY

06410 LAMINATE CLAD ARCHITECTURAL CASEWORK

DIVISION 07 - THERMAL AND MOISTURE PROTECTION

07212 MINERAL FIBER BLANKET INSULATION

07416 STRUCTURAL STANDING SEAM METAL ROOF (SSSMR) SYSTEM

07460 FIBER-CEMENT VERTICAL SIDING

07600 FLASHING AND SHEET METAL

07840 FIRESTOPPING

07920 JOINT SEALANTS

DIVISION 08 - OPENINGS

08110 STEEL DOORS AND FRAMES

08120 ALUMINUM DOORS AND FRAMES

08210 WOOD DOORS

08361 SECTIONAL OVERHEAD DOORS

08520 ALUMINUM WINDOWS

08710 DOOR HARDWARE

08800 GLAZING

08900 GLAZED CURTAIN WALL

DIVISION 09 - FINISHES

09100 METAL SUPPORT ASSEMBLIES

09250 GYPSUM BOARD

09310 CERAMIC TILE, QUARRY TILE, AND PAVER TILE

09510 ACOUSTICAL CEILINGS

09546 WOOD CEILING PANEL SYSTEM

09650 RESILIENT FLOORING

09900 PAINTS AND COATINGS

PROJECT TABLE OF CONTENTS Page 2

DIVISION 03 - CONCRETE

PROJECT TABLE OF CONTENTS - VOLUME II

10430 EXTERIOR SIGNAGE

10522 FIRE EXTINGUISHER AND CABINET

10800 TOILET ACCESSORIES

DIVISION 11 - EQUIPMENT

11401 ELECTRIC KITCHEN EQUIPMENT

DIVISION 12 - FURNISHINGS

12484 ENTRANCE MATS AND GRIDS

12490 WINDOW TREATMENT

DIVISION 13 - SPECIAL CONSTRUCTION

13080 SEISMIC PROTECTION FOR MISCELLANEOUS EQUIPMENT

13100 LIGHTNING PROTECTION SYSTEM

13280 ASBESTOS HAZARD CONTROL ACTIVITIES

13721 SMALL INTRUSION DETECTION SYSTEM

13851 FIRE DETECTION AND ALARM SYSTEM, ADDRESSABLE

DIVISION 15 - MECHANICAL

15070 SEISMIC PROTECTION FOR MECHANICAL EQUIPMENT

15080 THERMAL INSULATION FOR MECHANICAL SYSTEMS

15182 REFRIGERANT PIPING

15191 FACILITY GAS PIPING

15400 PLUMBING, GENERAL PURPOSE

15569 WATER HEATING; GAS

15700 UNITARY HEATING AND COOLING EQUIPMENT

15895 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEMS

15951 DIRECT DIGITAL CONTROL FOR HVAC

15990 TESTING, ADJUSTING, AND BALANCING OF HVAC SYSTEMS

15995 COMMISSIONING OF HVAC SYSTEMS

DIVISION 16 - ELECTRICAL

16070 SEISMIC PROTECTION FOR ELECTRICAL EQUIPMENT

16264 GENERATOR SET, STATIONARY 15-300 KW, STANDBY APPLICATIONS

16273 SINGLE-PHASE PAD-MOUNTED TRANSFORMERS

16375 ELECTRICAL DISTRIBUTION SYSTEM, UNDERGROUND

16402 INTERIOR DISTRIBUTION SYSTEM AND BRIDGE APPURTENANCES

16510 INTERIOR LIGHTING

16710 BUILDING TELECOMMUNICATIONS CABLING SYSTEM

16711 TELECOMMUNICATIONS OUTSIDE PLANT (OSP)

-- End of Project Table of Contents --

PROJECT TABLE OF CONTENTS Page 3

DIVISION 10 - SPECIALTIES

10201 METAL WALL LOUVERS

10260 CORNER GUARDS

SECTION 03230

STEEL STRESSING TENDONS AND ACCESSORIES FOR PRESTRESSED CONCRETE

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.

ACI INTERNATIONAL (ACI)

ACI 318/318R (2002) Building Code Requirements for Structural Concrete and Commentary

ACI SP-66 (2004) ACI Detailing Manual

ASTM INTERNATIONAL (ASTM)

ASTM A 416/A 416M (2002) Steel Strand, Uncoated Seven-Wire for Prestressed Concrete

ASTM A 421 (1998a) Uncoated Stress-Relieved Steel Wire for Prestressed Concrete

ASTM C 109/C 109M (2002) Compressive Strength of Hydraulic Cement Mortars (Using 2-in. [50-mm] Cube Specimens)

ASTM C 150 (2004a) Portland Cement

ASTM C 939 (2002) Flow of Grout for Preplaced-Aggregate Concrete (Flow Cone Method)

ASTM C 940 (1998a; R 2003) Expansion and Bleeding of Freshly Mixed Grouts for Preplaced-Aggregate Concrete in the Laboratory

1.2 LUMP SUM PRICES

1.2.1 Steel Stressing Tendons and Accessories for Prestressed Concrete

1.2.1.1 Payment

Payment shall constitute full compensation for furnishing all plant, labor, materials and equipment and performing all operations necessary for steel stressing tendons and accessories for prestressed concrete.

Section 03230 Page 1

1.2.1.2 Unit of Measure

Unit of measure: lump sum.

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. The following shall be submitted in accordance with Section 01330 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Installation Drawings; G, DO

Installation drawings for tendons and accessories shall be submitted and approved prior to commencing the work.

SD-03 Product Data

Prestressing Method and Equipment; G, DO

Descriptions of proposed prestressing method and equipment shall be submitted and approved prior to the start of prestressing operations.

Materials Disposition Records

Records which identify the incorporation of approved materials into the work shall be submitted before completion of the contract.

Prestressing Operations Records

Complete records of the prestressing operations shall be submitted before completion of the contract.

SD-06 Test Reports

Stressing Tendons and Accessories

Certified materials test reports shall be submitted for all required materials tests, note the specific standards followed in the performance of tests, show that materials comply with the applicable specifications, be submitted for each material shipment and be identified with specific lots prior to use of materials in the work.

SD-07 Certificates

Certification of Prestressing Technicians

Certificates for prestressing technicians shall be submitted prior to start of prestressing operations.

1.4 CERTIFICATION OF PRESTRESSING TECHNICIANS

Submitted certificates for prestressing technicians who will use the proposed system in the work shall certify by name that these technicians

Section 03230 Page 2 are thoroughly trained and skilled in the use of the system.

1.5 DELIVERY, STORAGE AND HANDLING OF MATERIALS

Materials shall be suitably wrapped, packaged or covered at the factory to prevent being affected by dirt, water and rust. Materials shall be protected against abrasion or damage during shipment and handling.

Materials stored at the site shall be placed above ground on elevated, covered platforms.

PART 2 PRODUCTS

2.1 MATERIALS

Stressing tendons and accessories shall conform to the requirements of ACI 318/318R except as specified.

2.1.1 Stressing Tendons

Stressing tendons shall be clean and free of loose rust, scale and pitting. Unbonded tendons shall be permanently protected from corrosion with an approved applied coating.

2.1.1.1 Seven-Wire Low-Relaxation Strand and Strand Assemblies

Seven-wire low-relaxation strand and strand assemblies shall conform to ASTM A 416/A 416M, Grade 270, uncoated, 1/2-inch strand diameter. Strand assemblies may be either shop or field assembled with anchor fittings positively attached to strands.

2.1.1.2 Stress-Relieved Wire and Wire Assemblies

Stress-relieved wire and wire assemblies shall conform to ASTM A 421, Type BA or WA, wire diameter as shown. Wire assemblies shall be shop assembled with anchor fittings positively attached to wires.

2.1.1.3 REINFORCEMENT

See Section 03300 CAST-IN-PLACE STRUCTURAL CONCRETE for reinforcement requirements for concrete.

2.1.2 Accessories

2.1.2.1 Ducts

Tendon ducts shall be of ferrous metal, capable of transmitting forces from grout to the surrounding concrete, flexible enough to conform to the tendon profile and strong enough to maintain their shape without deforming, sagging, or collapsing during concrete placement and vibration. The inside diameter of the ducts shall be large enough to provide an internal area at least twice the gross area of multiple wire, bar or strand assemblies and shall be at least 1/4-inch larger than the diameter of a single wire, bar or strand placed in the ducts. Ducts shall be designed for watertight connections with all fittings. Galvanized ducts will not be permitted.

2.1.2.2 Anchorages and Couplers

Anchorages and couplers shall be metal of proven corrosion resistance and compatible with the stressing tendons, capable of fully developing the

Section 03230 Page 3 minimum guaranteed ultimate strength of tendons without excessive slip and approved. Anchorages shall be the button-head, wedge, nut and thread, grip nut, thread-bar, threaded plate or other approved type and shall be provided with bearing plates bars, rings, bells or other positive-attaching anchor fittings. Couplers shall be provided with housings long enough to permit the necessary movements and fittings which allow complete grouting of all components.

2.1.2.3 Grout

Grout for grouting post-tensioned tendons shall consist of a mixture of Portland cement, shrinkage compensating admixture and potable water of which final proportions shall be based on test results of sample mixtures.

Cement shall conform to ASTM C 150, Type I or II. The shrinkage compensating admixture shall produce a 2 percent minimum and a 10 percent maximum unconfined expansion when tested in accordance with ASTM C 940, shall not contain aluminum powder, chlorides, fluorides or nitrates, may be dispensed in solid or liquid form and must be approved by the Contracting Officer prior to its use. The water content shall be the minimum necessary for proper placement but the water-cement ratio shall not exceed 0.50 by weight. The pumpability of grout shall be determined in accordance with ASTM C 939. The efflux time of a grout sample immediately after mixing shall not be less than 11 seconds. The minimum 7-day compressive strength of 2-inch grout cubes, molded, cured and tested in accordance with ASTM C 109/C 109M shall be 2500 psi.

2.2 TESTS, INSPECTIONS, AND VERIFICATIONS

The Contractor shall have required material tests performed on stressing tendons and accessories by an approved laboratory to demonstrate that the materials are in conformance with the specifications. These tests shall be at the Contractor's expense.

PART 3 EXECUTION

3.1 INSTALLATION

Stressing tendons and accessories shall be installed or placed as specified and as shown on contract and approved installation drawings. Installation details of stressing tendons and accessories not specified or shown shall be in accordance with ACI SP-66 or ACI 318/318R. Welding shall not be performed near or adjacent to stressing tendons. Stressing tendons shall not be installed until all welding has been completed on supports or any part which might be in contact with the tendons.

3.1.1 Prestressing Method and Equipment

Descriptions of the proposed prestressing methods and equipment indicating the manufacturer of all prestressing equipment, including tensioning jacks, stress measurement gages, dynamometers and load cells or other devices for measuring stressing loads, shall be provided by the contractor.

Descriptions shall include certified calibration records for each set of jacking equipment and testing curves for stress measurement gages which show that the gages have been calibrated for the jacks for which they are to be used.

3.1.2 Installation Drawings

Detailed installation drawings for stressing tendons and accessories

Section 03230 Page 4 showing the type and size of stressing tendons and anchorages, erection methods, sequence of stressing and stressing calculations shall be provided by the Contractor.

3.1.3 Anchorages

Anchorages must be set in a plane normal to the axis of the tendons such that uniform bearing on the concrete is assured. Positive connecting anchorages rather than gripping types shall be used for anchoring embedded ends of tendons. Anchorages and anchor fittings shall be permanently protected against corrosion. Parallel wire anchorage wedges or cores shall be recessed within the members.

3.1.4 Stressing Tendons and Ducts

Protective coverings and wrappings shall be removed and each stressing tendon shall be closely inspected to see that nicks, scoring, pits or other damage does not exist and high strength steel bars shall be closely inspected to assure that they are not bent and that threaded ends are in satisfactory condition immediately prior to installation. Strand, wire and bar tendons shall be shop or field assembled as required and positively attached to anchorages. Type WA wire assemblies shall be anchored only with wedge type anchorages. Stressing tendons and ducts shall be assembled to required shapes and dimensions and placed where indicated on drawings within specified tolerances and adequately supported. Ducts shall be securely fastened at close intervals and grout openings and vents must be securely anchored to ducts and to either the forms or reinforcing steel to prevent displacement during concrete placing. The ends of ducts shall be effectively protected to prevent entry of water, concrete, grout or debris. Wires of parallel-wire assemblies shall not be spliced. Steel bar tendons may be joined by couplers where shown or approved, provided they are capable of developing the guaranteed minimum ultimate strength of the bars. Strands to be spliced shall have the same lay or direction of twist and the ends shall be cut by shears or abrasive grinders. No more than one strand shall be spliced in any one member where single strand tensioning is employed. Strand splices shall be capable of developing the full ultimate strength of the strand. Slippage of the splice shall be checked and correction made for differential slippage. Where multiple strand tensioning is used, not more than 10 percent of the strands in any member shall be spliced.

3.1.5 Tensioning Tendons

Tensioning of stressing tendons shall be as specified and shown. The stress induced in the tendons by any method of tensioning shall be determined independently by both (1) measurement of tendon elongation and

(2) direct measurement of force using a pressure gauge or load cell. If the results of these two measurements do not check each other and the theoretical values within 5 percent, the operation shall be carefully checked and the source of error determined and corrected before proceeding further. Concrete cylinder tests shall indicate a breaking strength of at least 5,500 psi before transfer of stress to ensure that the concrete strength is adequate for the requirements of the anchorages or for transfer through bond as well as meet camber or deflection requirements. The final prestress load in each unit after seating shall be as shown. Safety measures shall be taken by the Contractor to prevent accidental injury caused by failure of a stressing tendon or tendon component. The exposed ends of stressing tendons and anchorages shall be protected from damage during stressing operations to prevent failure.

Section 03230 Page 5

3.1.5.1 Pretensioning

Strand tendons may be tensioned by jacking of groups of strands or may be tensioned individually by means of a single-strand jack. Before final tensioning, all tendons shall be brought to a uniform initial tension of approximately 1,000 pounds per strand per 200 feet of bed, with a minimum of 1,000 pounds and a maximum of 3,000 pounds per strand. The force corresponding to the initial tension shall be measured by a dynamometer or other approved method to aid in determining the final elongation. After this initial tensioning, the tendons shall be stressed to the total tension indicated on the drawings using hydraulic or mechanical equipment with gauges or dynamometers graduated and calibrated to accurately determine the load applied. Draped pretensioned strands shall be tensioned partially by jacking at the end of the bed and partially by uplifting or depressing strands, or they shall be held in their draped positions by means of rollers, pins or other approved methods and tensioned entirely by jacking.

Approved low-friction devices shall be used at all points of change in slope of draped strands while tensioning draped strands, regardless of the tensioning method used. Cable stress shall be maintained between anchorages until the concrete has reached the specified compressive strength.

3.1.5.2 Detensioning

Forces from pretensioned strands shall be transferred to the concrete by either the multiple-strand release or the single-strand release method.

The stress transfer shall not be performed until concrete strength, as indicated by test cylinders, has reached the specified transfer strength.

If concrete has been heat-cured, the detensioning shall be done immediately following the curing period while the concrete is still warm and moist.

During detensioning, the prestressing forces shall be kept nearly symmetrical about the vertical axis of the member and shall be applied in a manner that will minimize sudden loading. Eccentricity about the vertical axis shall be limited to one strand.

a. Multiple-Strand Release: In this method, all strands shall be detensioned simultaneously and the load transferred gradually to the concrete by hydraulic jacking.

b. Single-Strand Release: In this method, all strands shall be detensioned by slow heat-cutting the strands in accordance with a pattern and schedule as approved. The strands shall be heated using a low-oxygen flame until the metal gradually loses its strength, causing release of the strands to occur gradually. The low-oxygen flame shall be played along the strand for a minimum of five inches. Strands shall be so heated that the failure of the first wire in each strand shall occur after the torch has been applied for a minimum of five seconds.

3.1.6 Accuracy of Stress and Elongation Measurement

3.1.6.1 Stress Measurement

Hydraulic gauges, dynamometers, load cells or other devices for measuring stressing load shall have an accuracy of reading within two percent for stress measurement. Gauges are required to have been calibrated for the jacks for which they are used within a period not exceeding 12 months.

Recalibration shall be performed at any time that a gaging system shows indication of erratic results in the opinion of the Contracting Officer.

Section 03230 Page 6

Gauges shall indicate loads directly in pounds or be accompanied by a chart which converts dial readings into pounds.

3.1.6.2 Elongation Measurement

After the initial force has been applied to a tendon, reference points for measuring elongation due to additional tensioning forces shall be established. They shall be located according to the method of tensioning and type of equipment. The system used shall be capable of measuring the true elongation plus or minus 1/16-inch.

3.1.7 Prestressing Operations Records

The Contractor shall compile and submit complete prestressing operations records to the Contracting Officer. These records shall show the manufacturer, identification and description of materials and equipment including prestressing tendons and jacking and load measuring equipment;

location of prestressing tendons; initial design tensioning loads, final design tensioning loads and actual tensioning loads for tendons; dates tensioning loads applied; and theoretical and actual elongations for tendons.

3.2 INSPECTION

The Contractor's facilities shall be open for inspection by the Contracting Officer at any time.

3.3 MATERIALS DISPOSITION RECORDS

Accurate materials disposition records identifying all materials incorporated into the work and showing the disposition of specific lots of approved tested materials shall be compiled by the Contractor.

-- End of Section --

Section 03230 Page 7

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SECTION 03300

CAST-IN-PLACE STRUCTURAL CONCRETE

PART 1 GENERAL

1.1 SCOPE

This section covers the material, labor, equipment and plant requirements for the following concrete items: retaining wall Types B and D and wingwalls WA, WB and WC; bridge pier, abutments and caissons; approach slabs; building floor slab, piers, foundation wall and footings; equipment pads; control sill; scour apron; cast-in-place facing for mechanically stabilized earth (MSE) and soil nail walls; foundation for soil nail wall;

leveling pads for MSE walls; and curbs.

All concrete items not listed above are addressed in other applicable sections of the project specifications, as follows: 02455 SECANT WALL

CONSTRUCTION; 02630 STORM DRAINAGE; 02754 CONCRETE PAVEMENTS; 02821

FENCING; 03373 CONCRETE FOR SECANT WALL; 03410 PRECAST PRESTRESSED CONCRETE

GIRDERS.

1.2 REFERENCES

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

ACI INTERNATIONAL (ACI)

ACI 117 (1990; R 2002) Standard Tolerances for Concrete Construction and Materials & Commentary

ACI 211.1 (1991; R 2002) Standard Practice for Selecting Proportions for Normal, Heavyweight, and Mass Concrete

ACI 214.3R (1988; R 1997) Simplified Version of the Recommended Practice for Evaluation of Strength Test Results of Concrete

ACI 305R (1999) Hot Weather Concreting

ACI 318/318R (2002) Building Code Requirements for Structural Concrete and Commentary

ACI 347R (2003) Guide to Formwork for Concrete

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS

(AASHTO)

AASHTO M 182 (1991; R 2000) Burlap Cloth Made from Jute or Kenaf

Section 03300 Page 1

AMERICAN HARDBOARD ASSOCIATION (AHA)

AHA A135.4 (1995) Basic Hardboard

AMERICAN WELDING SOCIETY (AWS)

AWS D1.4 (1998) Structural Welding Code - Reinforcing Steel

ASTM INTERNATIONAL (ASTM)

ASTM A 185 (2002) Steel Welded Wire Reinforcement, Plain, for Concrete

ASTM A 36/A 36M (2004) Carbon Structural Steel

ASTM A 615/A 615M (2003a) Deformed and Plain Billet-Steel Bars for Concrete Reinforcement

ASTM C 1059 (1999) Latex Agents for Bonding Fresh to Hardened Concrete

ASTM C 1064/C 1064M (2004) Temperature of Freshly Mixed Portland Cement Concrete

ASTM C 1107 (2002) Packaged Dry, Hydraulic-Cement Grout(Nonshrink)

ASTM C 1240 (2004) Silica Fume Used in Cementitious Mixtures

ASTM C 1260 (2005) Potential Alkali Reactivity of Aggregates (Mortar-Bar Method)

ASTM C 136 (2004) Sieve Analysis of Fine and Coarse Aggregates

ASTM C 143/C 143M (2003) Slump of Hydraulic Cement Concrete

ASTM C 150 (2004a) Portland Cement

ASTM C 171 (2003) Sheet Materials for Curing Concrete

ASTM C 172 (2004) Sampling Freshly Mixed Concrete

ASTM C 173/C 173M (2001e1) Air Content of Freshly Mixed Concrete by the Volumetric Method

ASTM C 192/C 192M (2002) Making and Curing Concrete Test Specimens in the Laboratory

ASTM C 231 (2004) Air Content of Freshly Mixed Concrete by the Pressure Method

ASTM C 260 (2001) Air-Entraining Admixtures for Concrete

ASTM C 309 (2003) Liquid Membrane-Forming Compounds for Curing Concrete

Section 03300 Page 2

ASTM C 31/C 31M (2003a) Making and Curing Concrete Test Specimens in the Field

ASTM C 33 (2003) Concrete Aggregates

ASTM C 39/C 39M (2004) Compressive Strength of Cylindrical Concrete Specimens

ASTM C 42/C 42M (2004) Obtaining and Testing Drilled Cores and Sawed Beams of Concrete

ASTM C 494/C 494M (2004) Chemical Admixtures for Concrete

ASTM C 552 (2003) Cellular Glass Thermal Insulation

ASTM C 578 (2004) Rigid, Cellular Polystyrene Thermal Insulation

ASTM C 591 (2001) Unfaced Preformed Rigid Cellular Polyisocyanurate Thermal Insulation

ASTM C 595 (2003) Blended Hydraulic Cements

ASTM C 618 (2003) Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use as a Mineral Admixture in Concrete

ASTM C 78 (2002) Flexural Strength of Concrete (Using Simple Beam With Third-Point Loading)

ASTM C 881/C 881M (2002) Epoxy-Resin-Base Bonding Systems for Concrete

ASTM C 937 (2002) Grout Fluidifier for Preplaced-Aggregate Concrete

ASTM C 94/C 94M (2004a) Ready-Mixed Concrete

ASTM C 940 (1998a; R 2003) Expansion and Bleeding of Freshly Mixed Grouts for Preplaced-Aggregate Concrete in the Laboratory

ASTM C 989 (2004) Ground Granulated Blast-Furnace Slag for Use in Concrete and Mortars

ASTM D 5249 (1995; R 2000) Backer Material for Use with Cold-and Hot-Applied Joint Sealants in Portland-Cement Concrete and Asphalt Joints

ASTM D 5893 (2004) Cold Applied, Single Component, Chemically Curing Silicone Joint Sealant for Portland Cement Concrete Pavements

ASTM D 75 (2003) Sampling Aggregates

Section 03300 Page 3

ASTM E 96 (2000e1) Water Vapor Transmission of Materials

NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY (NIST)

NIST HB 44 (2004) NIST Handbook 44: Specifications, Tolerances, and other Technical Requirements for Weighing and Measuring Devices

NATIONAL READY MIXED CONCRETE ASSOCIATION (NRMCA)

NRMCA CPMB 100 (2000) Concrete Plant Standards

NRMCA QC 3 (2002) Quality Control Manual: Section 3, Plant Certifications Checklist:

Certification of Ready Mixed Concrete Production Facilities

NRMCA TMMB 100 (2001) Truck Mixer, Agitator and Front Discharge Concrete Carrier Standards

PENNSYLVANIA DEPARTMENT OF TRANSPORTATION (PennDOT)

PennDOT Publication 408 (2003, Chg 4) Specifications

U.S. ARMY CORPS OF ENGINEERS (USACE)

COE CRD-C 104 (1980) Method of Calculation of the Fineness Modulus of Aggregate

COE CRD-C 521 (1981) Standard Test Method for Frequency and Amplitude of Vibrators for Concrete

COE CRD-C 540 (2001) Standard Specification for Nonbituminous Inserts for Contraction Joints in Portland Cement Concrete Airfield Pavements, Sawable Type

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

COE CRD-C 94 (1966) Specification for Surface Retarders

U.S. DEPARTMENT OF COMMERCE (DOC)

PS1 (1995) Construction and Industrial Plywood

(APA V995)

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. The following shall be submitted in accordance with Section 01330 SUBMITTAL PROCEDURES:

NOTE: Any submittals classified as "SD-01 Preconstruction Submittals" require approval prior to mobilization to the contract work site. All other

Section 03300 Page 4 submittals, classified as "SD-02" through "SD-11," require approval prior to commencing the particular task to which the submittal is associated.

SD-01 Preconstruction Submittals

Work Plan for Spillway Structures; G, DO.

Submit a comprehensive work plan that includes a detailed description of the equipment, materials and methods to be used to construct the cast-in-place concrete for the scour apron, the control sill, the facing for the soil nail and mechanically stabilized earth (MSE) walls, the foundation for the soil nail wall and the levelling pads for the MSE wall, and to prepare surfaces upon which these structures are to be placed, including removal of the existing chain link fencing in the vicinity of the work. In addition to all other pertinent information, plan shall include a description of the methods and equipment for transporting concrete to the various work sites and for handling, depositing, consolidating and finishing the concrete.

Work Plan for Bridge Structures; G, DO.

Submit a comprehensive work plan that includes a detailed description of the equipment, materials and methods to be used to construct the cast-in-place concrete for the bridge pier, pier cap, abutments, caissons for east abutment, bridge deck and barrier (curb), wingwalls and approach slabs, and to prepare surfaces upon which these structures are to be placed. In addition to all other pertinent information, plan shall include a description of the methods and equipment for transporting concrete to the various work sites and for handling, depositing, consolidating and finishing the concrete. See applicable project specification sections for requirements of all items to be included in the work plan that are not addressed in this section.

Work Plan for Retaining Walls; G, DO.

Submit a comprehensive work plan that includes a detailed description of the equipment, materials and methods to be used to construct the cast-in-place concrete for the Type B and D retaining walls in the vicinity of the top of the dam, and to prepare surfaces upon which these structures are to be placed, including removal of existing chain link fencing. In addition to all other pertinent information, plan shall include a description of the methods and equipment for transporting concrete to the work site and for handling, depositing, consolidating and finishing the concrete.

Work Plan for Building Structures; G, DO.

Submit a comprehensive work plan that includes a detailed description of the equipment, materials and methods to be used to construct the cast-in-place concrete for the building, to include, but not be limited to the floor slabs, foundations wall, footings, piers and equipment pads, and to prepare surfaces upon which these structures are to be placed. In addition to all other pertinent information, plan shall include a description of the methods and equipment for transporting concrete to the various work sites and for handling, depositing, consolidating and finishing the concrete.

Section 03300 Page 5

SD-02 Shop Drawings

Waterstops; G, DO.

Shop drawings and fabrication drawings provided by the manufacturer or prepared by the Contractor.

Concrete Reinforcement System; G, DO.

Detail drawings showing reinforcing steel schedules, sizes, grades, and splicing and bending details. Drawings shall show support details including types, sizes and spacing.

Concrete Formwork for Spillway Structures; G, DO.

Concrete Formwork for Bridge Structures; G, DO.

Concrete Formwork for Retaining Walls; G, DO.

Concrete Formwork for Building Structures; G, DO.

For each submittal, provide drawings showing details of formwork including dimensions of fiber voids, joints, supports, studding and shoring, and sequence of form and shoring removal.

SD-03 Product Data

Mixture Proportions; G, DO

The results of trial mixture design studies along with a statement giving the maximum nominal coarse aggregate size and the proportions of ingredients that will be used in the manufacture of each type, strength or class of concrete required by Part 2 of this specification section, at least 21 days prior to commencing concrete placing operations. Aggregate weights shall be based on the saturated surface dry condition. The statement shall be accompanied by test results from an approved independent commercial testing laboratory, showing that mixture design studies have been made with materials proposed for the project and that the proportions selected will produce concrete mixes of the qualities indicated. No substitutions shall be made in the materials used in the mixture design studies without additional tests to show that the quality of the concrete is satisfactory.

Batch Plant; G, DO

Batch plant data to the Contracting Officer for review for conformance with applicable specifications.

Preformed Expansion Joint Filler; G, DO.

Sealant; G, DO.

Waterstops; G, DO.

Backer; G, DO.

Manufacturer's literature, including safety data sheets, for preformed fillers and the sealant used in their installation, waterstops, and backer material.

SD-04 Samples

Waterstops; G, DO.

Section 03300 Page 6

Waterstop materials shall be submitted for inspection and testing and shall be identified to indicate manufacturer, type of material, size and quantity of material and shipment represented.

Each material sample shall be a piece not less than 12 inches long cut from each 200 feet of finished waterstop furnished, but not less than a total of 4 linear feet of each type and size furnished.

Preformed Expansion Joint Filler; G, DO.

Backer; G, DO.

Samples of preformed filler and backer material shall be submitted for inspection and testing and shall be identified to indicate manufacturer, and type and size of material. Each material sample shall be a piece not less than 12 inches long

Surface Retarder

Sample of surface retarder material with manufacturer's instructions for application in conjunction with air-water cutting.

SD-06 Test Reports

Testing and Inspection for Contractor Quality Control; G, DO

Certified copies of laboratory test reports, including mill tests and all other test data, for portland cement, blended cement, pozzolan, ground granulated blast furnace slag, silica fume, aggregate, admixtures, and curing compound proposed for use on this project and all compressive strength testing conducted during construction operations.

Nonshrink Grout; G, DO.

Prepackaged material requiring only the addition of water will be accepted on the basis of certified laboratory test results showing that the material meets the strength requirements stated herein.

Aggregates; G, DO

Submit test results for aggregates in accordance with ASTM C 1260 for potential alkali-silica reactions.

SD-07 Certificates

CQC Personnel Qualifications

Written documentation for Contractor Quality Control personnel.

Welder Qualifications; G, COR

A list of names of qualified welders.

Delivery Tickets; G, COR.

Copies of certified delivery tickets for all concrete used in the construction shall be submitted to the Contracting Officer at the time of delivery to the work site.

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Cementitious Materials; G, DO.

Manufacturer's certification of compliance, accompanied by mill test reports attesting that the materials meet the requirements of the specification under which it is furnished, for portland cement, portland-pozzolan cement, portland blast-furnace slag cement, or portland cement in combination with pozzolan or ground granulated blast furnace slag or silica fume. No of these materials shall be used until notice of acceptance has been given.

Cementitious products may be subjected to check testing by the Government from samples obtained at the mill, at transfer points, or at the project site.

Nonshrink Grout; G, DO.

Descriptive literature of the grout proposed for use shall be furnished together with a certificate from the manufacturer stating that it is suitable for the application or exposure for which it is being considered. The literature shall also certify that the nonshrink grout will meet the specified strength within the specified time. Nonshrink grout containing metallic aggregate will not be permitted.

Preformed Expansion Joint Filler; G, DO.

Sealant; G, DO.

Waterstops; G, DO.

Backer; G, DO.

Certificates of compliance stating that the joint filler and sealant materials and waterstops conform to the requirements specified.

Reinforcing Steel; G, DO.

Certified copies of mill reports attesting that the reinforcing steel furnished meets the requirements specified, prior to the installation of reinforcing steel.

SD-08 Manufacturer's Instructions

Preformed Expansion Joint Filler; G, DO.

Sealant; G, DO.

Waterstops; G, DO.

Backer; G, DO.

Manufacturer's recommended instructions for installing preformed fillers, backer material and waterstops.

1.4 QUALIFICATIONS

Contractor Quality Control personnel assigned to concrete construction shall be American Concrete Institute (ACI) Certified Workmen in one of the following grades or shall have written evidence of having completed similar qualification programs:

Concrete Field Testing Technician, Grade I Concrete Laboratory Testing Technician, Grade I or II

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Concrete Construction Inspector, Level II

Concrete Transportation Construction Inspector or Reinforced Concrete Special Inspector, Jointly certified by American Concrete Institute (ACI), Building Official and Code Administrators International (BOCA), International Conference of Building Officials (ICBO), and Southern Building Code Congress International (SBCCI).

The foreman or lead journeyman of the flatwork finishing crew shall have similar qualification for ACI Concrete Flatwork Technician/Finisher or equal, with written documentation.

1.5 QUALIFICATIONS OF WELDERS

Welders shall be qualified in accordance with AWS D1.4.

1.6 FORMWORK DESIGN

Formwork shall be designed in accordance with the methodology of ACI 347R for anticipated loads, lateral pressures, and stresses. Forms shall be capable of producing a surface which meets the requirements of the class of finish specified in paragraph FINISHING FORMED SURFACES, and the construction tolerances specified in Table 1 at the end of this section and in paragraph GENERAL REQUIREMENTS. Forms shall be capable of withstanding the pressures resulting from placement and vibration of concrete.

1.7 SPECIAL REQUIREMENTS

A pre-installation meeting with the Contracting Officer will be required at least 10 days prior to start of construction on each of the four primary areas of concrete work (at a minimum) as follows: spillway structures;

bridge structures; retaining walls; building structures. The separation of work into these primary areas is not intended as a limitation on the order of work to be done. Work shall be done in accordance with the Government-approved work plans and the Contractor is expected to submit an overall project schedule and associated work plans that are best suited to meet the contract requirements. The number of pre-installation meetings to be held may be adjusted as directed by, or agreed to by, the Contracting Officeer. The Contractor shall be responsible for calling the meeting; the Project Superintendent and active installation personnel shall be present.

1.8 GENERAL REQUIREMENTS

1.8.1 Tolerances

Except as otherwise specified herein, tolerances for concrete batching, mixture properties, and construction as well as definition of terms and application practices shall be in accordance with ACI 117. Level and grade tolerance measurements of slabs shall be made as soon as possible after finishing; when forms or shoring are used, the measurements shall be made prior to removal.

1.8.1.1 Floors

For the purpose of this Section, the following terminology correlation between ACI 117 and this Section shall apply:

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Floor Profile Quality Classification From ACI 117 This Section

Conventional Bullfloated Same Conventional Straightedged Same Flat Float Finish or Trowel Finish

Levelness tolerance shall not apply where design requires floors to be sloped to drains or sloped for other reasons.

1.8.1.2 Floors by the Straightedge System

The flatness of the floors shall be carefully controlled and the tolerances shall be measured by the straightedge system as specified in paragraph

4.5.7 of ACI 117, using a 10 foot straightedge, within 72 hours after floor slab installation and before shores and/or forms are removed. The listed tolerances shall be met at any and every location at which the straightedge can be placed.

Bullfloated 1/8-inch Straightedged 1/8-inch Float Finish 1/8-inch Trowel Finish 1/8-inch

1.8.1.3 Tolerances for Formed Surfaces

Formed Surfaces - Except as modified by the COR, tolerances for the finished formed surfaces shall conform to the requirements of ACI 117.

Formwork - Forms shall be set true to line and grade and shall meet the construction tolerances shown in Table 1 at the end of this section.

1.8.2 Strength Requirements and w/c Ratio

1.8.2.1 Strength Requirements

Specified compressive strength (f'c) shall be as follows:

COMPRESSIVE STRENGTH STRUCTURE OR PORTION OF STRUCTURE

5000 psi at 28 days Retaining walls, Wingwalls

4000 psi at 28 days Bridge abutments, Bridge pier, Approach slabs, Drilled caissons, Control sill, Scour apron, Building floor slab, Facing for MSE and soil nail walls, Foundation for soil nail wall, Leveling pads for MSE walls

3000 psi at 28 days Building piers, foundation walls and footings, Equipment pads, Curbs, and other miscellaneous items

Concrete slabs on-grade shall have a 28-day flexural strength of 650 psi.

Concrete made with high-early strength cement shall have a 7-day strength equal to the specified 28-day strength for concrete made with Type I or II portland cement. Compressive strength shall be determined in accordance

Section 03300 Page 10 with ASTM C 39/C 39M. Flexural strength shall be determined in accordance with ASTM C 78.

a. Evaluation of Concrete Compressive Strength. Compressive strength specimens (6 by 12 inch cylinders) shall be fabricated by the Contractor and laboratory cured in accordance with ASTM C 31/C 31M and tested in accordance with ASTM C 39/C 39M. The strength of the concrete will be considered satisfactory so long as the average of all sets of three consecutive test results equals or exceeds the specified compressive strength f'c and no individual test result falls below the specified strength f'c by more than 500 psi. A "test" is defined as the average of two companion cylinders, or if only one cylinder is tested, the results of the single cylinder test. Additional analysis or testing, including taking cores and/or load tests may be required at the Contractor's expense when the strength of the concrete in the structure is considered potentially deficient.

b. Investigation of Low-Strength Compressive Test Results. When any strength test of standard-cured test cylinders falls below the specified strength requirement by more than 500 psi or if tests of field-cured cylinders indicate deficiencies in protection and curing, steps shall be taken to assure that the load-carrying capacity of the structure is not jeopardized. When the strength of concrete in place is considered potentially deficient, cores shall be obtained and tested in accordance with ASTM C 42/C 42M.

At least three representative cores shall be taken from each member or area of concrete in place that is considered potentially deficient. The location of cores will be determined by the Contracting Officer to least impair the strength (and aesthetics, where applicable) of the structure. Concrete in the area represented by the core testing will be considered adequate if the average strength of the cores is equal to at least 85 percent of the specified strength requirement and if no single core is less than 75 percent of the specified strength requirement.

Non-destructive tests (tests other than test cylinders or cores) shall not be used as a basis for acceptance or rejection. The Contractor shall perform the coring and repair the holes. Cores will be tested by the Government.

c. Load Tests. If the core tests are inconclusive or impractical to obtain or if structural analysis does not confirm the safety of the structure, load tests may be directed by the Contracting Officer in accordance with the requirements of ACI 318/318R.

Concrete work evaluated by structural analysis or by results of a load test as being understrength shall be corrected in a manner satisfactory to the Contracting Officer. All investigations, testing, load tests, and correction of deficiencies shall be performed by and at the expense of the Contractor and must be approved by the Contracting Officer, except that if all concrete is found to be in compliance with the drawings and specifications, the cost of investigations, testing, and load tests (as discussed in these Paragraphs b and c) will be at the expense of the Government.

d. Evaluation of Concrete Flexural Strength. Flexural strength specimens (beams) shall be fabricated by the Contractor and laboratory cured in accordance with ASTM C 31/C 31M and tested in accordance with ASTM C 78. The strength of the concrete will be

Section 03300 Page 11 considered satisfactory so long as the average of all sets of three consecutive test results equals or exceeds the specified flexural strength and no individual test result falls below the specified flexural strength by more than 50 psi. A "test" is defined as the average of two companion beams. Additional analysis or testing, including taking cores and/or load tests may be required at the Contractor's expense when the strength of the concrete in the slab is considered potentially deficient.

1.8.2.2 Water-Cement Ratio

Maximum water-cement ratio (w/c) for air-entrained normal weight concrete shall be as follows:

WATER-CEMENT RATIO, BY WEIGHT STRUCTURE OR PORTION OF STRUCTURE

0.40 Retaining walls and Wingwalls

0.48 Bridge abutments and pier, Approach

Slabs, Drilled caissons, Control sill, Scour apron, Building floor slab, Facing for MSE and soil nail walls, Foundation for soil nail wall, Leveling pads for MSE walls

0.54 Building piers, foundation walls and

footings, Equipment pads, Curbs, and other miscellaneous items

These w/c's may cause higher strengths than that required above for compressive or flexural strength. The maximum w/c required will be the equivalent w/c as determined by conversion from the weight ratio of water to cement plus pozzolan, silica fume, and ground granulated blast furnace slag (GGBF slag) by the weight equivalency method as described in ACI 211.1.

In the case where silica fume or GGBF slag is used, the weight of the silica fume and GGBF slag shall be included in the equations of ACI 211.1 for the term P which is used to denote the weight of pozzolan.

1.8.3 Air Entrainment

All normal weight concrete shall be air entrained to contain between 4 and 7 percent total air, except that when the nominal maximum size coarse aggregate is 3/4 inch or smaller it shall be between 4.5 and 7.5 percent.

Concrete with specified strength over 5000 psi may have 1.0 percent less air than specified above. Specified air content shall be attained at point of placement into the forms. Air content for normal weight concrete shall be determined in accordance with ASTM C 231.

1.8.4 Slump

Slump of the concrete, as delivered to the point of placement into the forms, shall be within the following limits. Slump shall be determined in accordance with ASTM C 143/C 143M.

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Slump Structural Element Minimum Maximum

Retaining walls, wingwalls and facing for 2 in. 4 in.

MSE and soil nail walls

All other structures included in the Scope of this spec section 1 in. 3 in.

Any structural concrete approved for placement by pumping:

At pump 2 in. 6 in.

At discharge of line 1 in. 4 in.

1.8.5 Concrete Temperature

The temperature of the concrete as delivered shall not exceed 90 degrees F.

When the ambient temperature during placing is 40 degrees F or less, or is expected to be at any time within 6 hours after placing, the temperature of the concrete as delivered shall be between 55 and 75 degrees F.

1.8.6 Size of Coarse Aggregate

The largest feasible nominal maximum size aggregate (NMSA) specified in paragraph AGGREGATES shall be used in each placement. However, nominal maximum size of aggregate shall not exceed any of the following:

three-fourths of the minimum cover for reinforcing bars, three-fourths of the minimum clear spacing between reinforcing bars, one-fifth of the narrowest dimension between sides of forms, or one-third of the thickness of slabs or toppings.

1.8.7 Special Properties and Products

Concrete may contain admixtures other than air entraining agents, such as water reducers, or set retarding agents to provide special properties to the concrete, if specified or approved. Any of these materials to be used on the project shall be used in the mix design studies.

1.8.8 Technical Service for Specialized Concrete

The services of a factory trained technical representative shall be obtained to oversee proportioning, batching, mixing, placing, consolidating, and finishing of specialized structural concrete, such as that containing silica fume. The technical representative shall be on the job full time until the Contracting Officer is satisfied that field controls indicate concrete of specified quality is furnished and that the Contractor's crews are capable of continued satisfactory work. The technical representative shall be available for consultation with, and advice to, Government forces.

1.9 MIXTURE PROPORTIONS

Concrete shall be composed of portland cement, other cementitious and pozzolanic materials as specified, aggregates, water and admixtures as specified.

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1.9.1 Proportioning Studies for Normal Weight Concrete

Trial design batches, mixture proportioning studies, and testing requirements for various classes and types of concrete specified shall be the responsibility of the Contractor. Except as specified for flexural strength concrete, mixture proportions shall be based on compressive strength as determined by test specimens fabricated in accordance with ASTM C 192/C 192M and tested in accordance with ASTM C 39/C 39M. Samples of all materials used in mixture proportioning studies shall be representative of those proposed for use in the project and shall be accompanied by the manufacturer's or producer's test reports indicating compliance with these specifications. Trial mixtures having proportions, consistencies, and air content suitable for the work shall be made based on methodology described in ACI 211.1, using at least three different water-cement ratios for each type of mixture, which will produce a range of strength encompassing those required for each class and type of concrete required on the project. The maximum water-cement ratios required in subparagraph Water-Cement Ratio will be the equivalent water-cement ratio as determined by conversion from the weight ratio of water to cement plus pozzolan, silica fume, and ground granulated blast furnace slag (GGBF slag) by the weight equivalency method as described in ACI 211.1. In the case where silica fume or GGBF slag is used, the weight of the silica fume and GGBF slag shall be included in the equations in ACI 211.1 for the term P, which is used to denote the weight of pozzolan. If pozzolan is used in the concrete mixture, the minimum pozzolan content shall be 15 percent by weight of the total cementitious material, and the maximum shall be 35 percent. Laboratory trial mixtures shall be designed for maximum permitted slump and air content. Separate sets of trial mixture studies shall be made for each combination of cementitious materials and each combination of admixtures proposed for use. No combination of either shall be used until proven by such studies, except that, if approved in writing and otherwise permitted by these specifications, an accelerator or a retarder may be used without separate trial mixture study.