9_TOR Maintenance Building_Cast in Place Concrete_03 30 00.pdf

MAINTENANCE BUILDING DEMOLITION AND DISPOSAL

WITH REPLACEMENT OPTIONS

Toronto Lake, Woodson County, Kansas

Section 03 30 00 // CAST-IN-PLACE CONCRETE

SECTION 03 30 00

CAST-IN-PLACE 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.

AMERICAN CONCRETE INSTITUTE (ACI)

ACI 117 (2010; Errata 2011) Specifications for

Tolerances for Concrete Construction and Materials and Commentary

ACI 121R (2008) Guide for Concrete Construction

Quality Systems in Conformance with ISO 9001

ACI 301 (2016) Specifications for Structural Concrete

ACI 302.1R (2015) Guide for Concrete Floor and Slab

Construction

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

ACI 305.1 (2014) Specification for Hot Weather

Concreting

ACI 305R (2010) Guide to Hot Weather Concreting

ACI 306.1 (1990; R 2002) Standard Specification for

Cold Weather Concreting

ACI 308.1 (2011) Specification for Curing Concrete

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

Concrete Inspection

ACI SP-15 (2011) Field Reference Manual: Standard

Specifications for Structural Concrete ACI 301-05 with Selected ACI References

AMERICAN HARDBOARD ASSOCIATION (AHA)

AHA A135.4 (1995; R 2004) Basic Hardboard

AMERICAN WELDING SOCIETY (AWS)

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

Steel

ASTM INTERNATIONAL (ASTM)

ASTM A53/A53M (2020) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

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

ASTM A706/A706M (2016) Standard Specification for Low-Alloy

Steel Deformed and Plain Bars for Concrete

ASTM A767/A767M (2016) Standard Specification for Zinc-Coated

(Galvanized) Steel Bars for Concrete

ASTM A780/A780M (2020) Standard Practice for Repair of

Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings

ASTM A884/A884M (2019) Standard Specification for Epoxy-

Coated Steel Wire and Welded Wire

ASTM A934/A934M (2016) Standard Specification for Epoxy-

Coated Prefabricated Steel Reinforcing Bars

ASTM A996/A996M (2016) Standard Specification for Rail-Steel and Axle-Steel Deformed Bars for Concrete

ASTM A1022/A1022M (2016b) Standard Specification for Deformed and Plain Stainless Steel Wire and Welded Wire for Concrete Reinforcement

ASTM A1060/A1060M (2016b) Standard Specification for Zinc-

Coated (Galvanized) Steel Welded Wire Reinforcement, Plain and Deformed, for Concrete

ASTM A1064/A1064M (2017) Standard Specification for Carbon-

Steel Wire and Welded Wire Reinforcement, Plain and Deformed, for Concrete

ASTM C31/C31M (2019a) Standard Practice for Making and

Curing Concrete Test Specimens in the Field

ASTM C33/C33M (2018) Standard Specification for Concrete

Aggregates

ASTM C39/C39M (2020) Standard Test Method for Compressive

Strength of Cylindrical Concrete Specimens

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

ASTM C78/C78M (2018) Standard Test Method for Flexural

Strength of Concrete (Using Simple Beam with Third-Point Loading)

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

ASTM C136/C136M (2019) Standard Test Method for Sieve

Analysis of Fine and Coarse Aggregates

ASTM C143/C143M (2020) Standard Test Method for Slump of

Hydraulic-Cement Concrete

ASTM C150/C150M (2020) Standard Specification for Portland

Cement

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

Mixed Concrete

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

ASTM C231/C231M (2017a) Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method

ASTM C260/C260M (2010a; R 2016) Standard Specification for

Air-Entraining Admixtures for Concrete

ASTM C311/C311M (2018) Standard Test Methods for Sampling and

Testing Fly Ash or Natural Pozzolans for Use in Portland-Cement Concrete

ASTM C330/C330M (2017a) Standard Specification for

Lightweight Aggregates for Structural

ASTM C494/C494M (2019) Standard Specification for Chemical

Admixtures for Concrete

ASTM C595/C595M (2020) Standard Specification for Blended

Hydraulic Cements

ASTM C618 (2019) Standard Specification for Coal Fly

Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

ASTM C803/C803M (2018) Standard Test Method for Penetration

Resistance of Hardened Concrete

ASTM C845/C845M (2018) Standard Specification for Expansive

Hydraulic Cement

ASTM C873/C873M (2015) Standard Test Method for Compressive

Strength of Concrete Cylinders Cast in Place in Cylindrical Molds

ASTM C900 (2015) Standard Test Method for Pullout

Strength of Hardened Concrete

ASTM C920 (2018) Standard Specification for Elastomeric

Joint Sealants

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

Cement for Use in Concrete and Mortars

ASTM C1012/C1012M (2018b) Standard Test Method for Length

Change of Hydraulic-Cement Mortars Exposed to a Sulfate Solution

ASTM C1017/C1017M (2013; E 2015) Standard Specification for

Chemical Admixtures for Use in Producing Flowing Concrete

ASTM C1074 (2019) Standard Practice for Estimating

Concrete Strength by the Maturity Method

ASTM C1077 (2017) Standard Practice for Agencies Testing

Concrete and Concrete Aggregates for Use in Construction and Criteria for Testing Agency Evaluation

ASTM C1107/C1107M (2020) Standard Specification for Packaged

Dry, Hydraulic-Cement Grout (Nonshrink)

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

ASTM C1218/C1218M (2020c) Standard Test Method for Water-

Soluble Chloride in Mortar and Concrete

ASTM C1240 (2020) Standard Specification for Silica Fume

Used in Cementitious Mixtures

ASTM C1260 (2014) Standard Test Method for Potential

Alkali Reactivity of Aggregates (Mortar-Bar Method)

ASTM C1293 (2008; R 2015) Standard Test Method for

Determination of Length Change of Concrete Due to Alkali-Silica Reaction

ASTM C1567 (2013) Standard Test Method for Potential

Alkali-Silica Reactivity of Combinations of Cementitious Materials and Aggregate (Accelerated Mortar-Bar Method)

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

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

ASTM D412 (2016) Standard Test Methods for Vulcanized

Rubber and Thermoplastic Elastomers - Tension

ASTM D471 (2016a) Standard Test Method for Rubber

Property - Effect of Liquids

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

ASTM D1752 (2018) Standard Specification for Preformed

Sponge Rubber, Cork and Recycled PVC Expansion Joint Fillers for Concrete Paving and Structural Construction

ASTM D2628 (1991; R 2016) Standard Specification for

Preformed Polychloroprene Elastomeric Joint Seals for Concrete Pavements

ASTM D2835 (1989; R 2017) Standard Specification for

Lubricant for Installation of Preformed Compression Seals in Concrete Pavements

ASTM D5759 (2012; R 2020) Characterization of Coal Fly

Ash and Clean Coal Combustion Fly Ash for Potential Uses

ASTM D6690 (2015) Standard Specification for Joint and

Crack Sealants, Hot Applied, for Concrete and Asphalt Pavements

ASTM E96/E96M (2016) Standard Test Methods for Water Vapor

Transmission of Materials

ASTM E329 (2020) Standard Specification for Agencies

Engaged in Construction Inspection, Testing, or Special Inspection

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

ASTM E1745 (2017) Standard Specification for Water Vapor

Retarders Used in Contact with Soil or Granular Fill under Concrete Slabs

CONCRETE REINFORCING STEEL INSTITUTE (CRSI)

CRSI 10MSP (2018) Manual of Standard Practice

CRSI RB4.1 (2016) Supports for Reinforcement Used in

NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY (NIST)

NIST PS 1 (2009) DOC Voluntary Product Standard PS 1-

07, Structural Plywood

U.S. ARMY CORPS OF ENGINEERS (USACE)

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

Modulus of Aggregate

COE CRD-C 513 (1974) Corps of Engineers Specifications for

Rubber Waterstops

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

Polyvinylchloride Waterstops

U.S. GREEN BUILDING COUNCIL (USGBC)

LEED NC (2009) Leadership in Energy and Environmental

Design(tm) New Construction Rating System

1.2 DEFINITIONS

a. "Cementitious material" as used herein must include all portland cement, pozzolan, fly ash, slag cement, and silica fume.

b. "Exposed to public view" means situated so that it can be seen from eye level from a public location after completion of the building. A public location is accessible to persons not responsible for operation or maintenance of the building.

c. "Chemical admixtures" are materials in the form of powder or fluids that are added to the concrete to give it certain characteristics not obtainable with plain concrete mixes.

d. "Supplementary cementing materials" (SCM) include coal fly ash, silica fume, slag cement, natural or calcined pozzolans, and ultra-fine coal ash when used in such proportions to replace the portland cement that result in improvement to sustainability and durability and reduced cost.

e. "Design strength" (f'c) is the specified compressive strength of concrete at time(s) specified in this section to meet structural design criteria.

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

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

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

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

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

j. "Workability (or consistence)" is the ability of a fresh (plastic) concrete mix to fill the form/mould properly with the desired work (vibration) and without reducing the concrete's quality. Workability depends on water content, chemical admixtures, aggregate (shape and size distribution), cementitious content and age (level of hydration).

1.3 SUBMITTALS

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

Submit the following in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:

SD-01 Preconstruction Submittals

Quality Control Plan; G, COR

Quality Control Personnel Certifications; G, COR

Quality Control Organizational Chart

Laboratory Accreditation; G

Form Removal Schedule; G, COR

Maturity Method Data

SD-02 Shop Drawings

Formwork

Reinforcing Steel; G, COR

SD-03 Product Data

Joint Sealants; (LEED NC)

Joint Filler; (LEED NC)

Formwork Materials

Recycled Aggregate Materials; (LEED NC)

Cementitious Materials; (LEED NC)

Vapor Retarder and Vapor Barrier

Concrete Curing Materials

Reinforcement; (LEED NC)

Liquid Chemical Floor Hardeners and Sealers

Admixtures

Reinforcing Fibers

Mechanical Reinforcing Bar Connectors

Waterstops

Local/Regional Materials; (LEED NC)

Biodegradable Form Release Agent

SD-05 Design Data

Concrete Mix Design; G, COR

SD-06 Test Reports

Concrete Mix Design; G, COR

Fly Ash

Pozzolan

Slag Cement

Aggregates

Fiber-Reinforced Concrete; G, COR

Compressive Strength Tests; G, COR

Air Content

Slump Tests

Water

SD-07 Certificates

Reinforcing Bars

Welder Qualifications

SD-08 Manufacturer's Instructions

Liquid Chemical Floor Hardeners and Sealers

Joint Sealants; (LEED NC)

Curing Compound

1.4 MODIFICATION OF REFERENCES

Accomplish work in accordance with ACI publications except as modified herein. Consider the advisory or recommended provisions to be mandatory.

Interpret reference to the "Building Official," the "Structural Engineer," and the "Architect/Engineer" to mean the Contracting Officer.

1.5 DELIVERY, STORAGE, AND HANDLING

Follow ACI 301, ACI 304R and ASTM A934/A934M requirements and recommendations. Do not deliver concrete until vapor retarder, vapor barrier, forms, reinforcement, embedded items, and chamfer strips are in place and ready for concrete placement. Do not store concrete curing compounds or sealers with materials that have a high capacity to adsorb volatile organic compound (VOC) emissions. Do not store concrete curing compounds or sealers in occupied spaces.

1.5.1 Reinforcement

Store reinforcement of different sizes and shapes in separate piles or racks raised above the ground to avoid excessive rusting. Protect from contaminants such as grease, oil, and dirt. Ensure bar sizes can be accurately identified after bundles are broken and tags removed.

1.6 QUALITY ASSURANCE

1.6.1 Design Data

1.6.1.1 Concrete Mix Design

Sixty days minimum prior to concrete placement, submit a mix design for each strength and type of concrete. Submit a complete list of materials including type; brand; source and amount of cement, supplementary cementitious materials, and admixtures; and applicable reference specifications. Submit mill test and all other test for cement, supplementary cementitious materials, aggregates, and admixtures. Provide documentation of maximum nominal aggregate size, gradation analysis, percentage retained and passing sieve, and a graph of percentage retained verses sieve size. Provide mix proportion data using at least three different water-cementitious material ratios for each type of mixture, which produce a range of strength encompassing those required for each type of concrete required. If source material changes, resubmit mix proportion data using revised source material. Provide only materials that have been proven by trial mix studies to meet the requirements of this specification, unless otherwise approved in writing by the Contracting Officer. Indicate clearly in the submittal where each mix design is used when more than one mix design is submitted. Resubmit data on concrete components if the qualities or source of components changes. For previously approved concrete mix designs used within the past twelve months, the previous mix design may be re-submitted without further trial batch testing if accompanied by material test data conducted within the last six months. Obtain mix design approval from the contracting officer prior to concrete placement.

1.6.2 Shop Drawings

1.6.2.1 Reinforcing Steel

Indicate bending diagrams, assembly diagrams, splicing and laps of bars, shapes, dimensions, and details of bar reinforcing, accessories, and concrete cover. Do not scale dimensions from structural drawings to determine lengths of reinforcing bars. Reproductions of contract drawings are unacceptable.

1.6.3 Control Submittals

1.6.3.1 Concrete Curing Plan

Submit proposed materials, methods and duration for curing concrete elements in accordance with ACI 308.1.

1.6.3.2 Finishing Plan

Submit proposed material and procedures to be used in obtaining the finish for the floors. Include qualification of person to be used for obtaining floor tolerance measurement, description of measuring equipment to be used, and a sketch showing lines and locations the measuring equipment will follow.

1.6.3.3 Safety Data Sheets

Submit Safety Data Sheets (SDS) for all materials that are regulated for hazardous health effects. SDS must be readily accessible during each work shift to employees when they are at the construction site.

1.6.4 Test Reports

1.6.4.1 Fly Ash and Pozzolan

Submit test results in accordance with ASTM C618 for fly ash and pozzolan.

Submit test results performed within 6 months of submittal date.

1.6.4.2 Slag Cement

Submit test results in accordance with ASTM C989/C989M for slag cement.

Submit test results performed within 6 months of submittal date.

1.6.4.3 Aggregates

Submit test results in accordance with ASTM C33/C33M, or ASTM C330/C330M for lightweight aggregate, and ASTM C1293 or ASTM C1567 as required in the paragraph titled ALKALI-AGGREGATE REACTION.

1.6.5 Field Samples

1.6.5.1 Slab Finish Sample

Install minimum of 10 foot by 10 foot slab. Slab finish sample must not be part of the final project. Finish as required by specification.

1.6.6 Quality Control Plan

Develop and submit for approval a concrete quality control program in accordance with the guidelines of ACI 121R and as specified herein. The plan must include approved laboratories. Provide direct oversight for the concrete qualification program inclusive of associated sampling and testing.

All quality control reports must be provided to the Contracting Officer, Quality Manager and Concrete Supplier. Maintain a copy of ACI SP-15 and CRSI 10MSP at project site.

1.6.7 Quality Control Personnel Certifications

The Contractor must submit for approval the responsibilities of the various quality control personnel, including the names and qualifications of the individuals in those positions and a quality control organizational chart defining the quality control hierarchy and the responsibility of the various positions. Quality control personnel must be employed by the Contractor.

Submit American Concrete Institute certification for the following:

a. CQC personnel responsible for inspection of concrete operations.

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

Curing Crews.

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

1.6.7.1 Quality Manager Qualifications

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

1.6.7.2 Field Testing Technician and Testing Agency

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

a. Work on concrete under this contract must be performed by an ACI

Concrete Field Testing Technician Grade 1 qualified in accordance with ACI SP-2 or equivalent. Equivalent certification programs must include requirements for written and performance examinations as stipulated in

ACI SP-2.

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

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

1.6.8 Laboratory Qualifications for Concrete Qualification Testing

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

1.6.9 Laboratory Accreditation

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

a. Aggregate Testing and Mix Proportioning: Aggregate testing and mixture proportioning studies must be performed by an accredited laboratory and under the direction of a registered professional engineer in a U.S.

state or territory competent in concrete materials who is competent in concrete materials and must sign all reports and designs.

b. Acceptance Testing: Furnish all materials, labor, and facilities required for molding, curing, testing, and protecting test specimens at the site and in the laboratory. Furnish and maintain boxes or other facilities suitable for storing and curing the specimens at the site while in the mold within the temperature range stipulated by ASTM C31/C31M.

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

1.7 ENVIRONMENTAL REQUIREMENTS

Provide space ventilation according to material manufacturer recommendations, at a minimum, during and following installation of concrete curing compound and sealer. Maintain one of the following ventilation conditions during the curing period or for 72 hours after installation:

a. Supply 100 percent outside air 24 hours a day.

b. Supply airflow at a rate of 6 air changes per hour, when outside temperatures are between 55 degrees F and 84 degrees F and humidity is between 30 percent and 60 percent.

c. Supply airflow at a rate of 1.5 air changes per hour, when outside air conditions are not within the range stipulated above.

1.7.1 Submittals for Environmental Performance

a. Provide data indication the percentage of post-industrial pozzolan (fly ash, slag cement) cement substitution as a percentage of the full product composite by weight.

b. Provide data indicating the percentage of post-industrial and post-consumer recycled content aggregate.

c. Provide product data indicating the percentage of post-consumer recycled steel content in each type of steel reinforcement as a percentage of the full product composite by weight.

d. Provide product data stating the location where all products were manufactured

e. For projects using FSC certified formwork, provide chain-of-custody documentation for all certified wood products.

f. For projects using reusable formwork, provide data showing how formwork is reused.

g. Provide SDS product information data showing that form release agents meet any environmental performance goals such as using vegetable and soy based products.

h. Provide SDS product information data showing that concrete adhesives meet any environmental performance goals including low emitting, low volatile organic compound products.

1.8 QUALIFICATIONS FOR WELDING WORK

Welding procedures must be in accordance with AWS D1.4/D1.4M.

Verify that Welder qualifications are in accordance with AWS D1.4/D1.4M for welding of reinforcement or under an equivalent qualification test approved in advance. Welders are permitted to do only the type of welding for which each is specifically qualified.

PART 2 PRODUCTS

2.1 FORMWORK MATERIALS

a. Form-facing material in contact with concrete must be lumber, plywood, tempered concrete-form-grade hardboard, metal, plastic, . Submit product information on proposed form-facing materials if different from that specified herein.

b. Design formwork, shores, reshores, and backshores to support loads transmitted to them and to comply with applicable building code requirements.

c. Design formwork and shoring for load redistribution resulting from stressing of post-tensioned reinforcement. Ensure that formwork allows movement resulting from application of prestressing force.

d. Design formwork to withstand pressure resulting from placement and vibration of concrete and to maintain specified tolerances.

e. Design formwork to accommodate waterstop materials in joints at locations indicated in Contract Documents.

f. Provide temporary openings in formwork if needed to facilitate cleaning and inspection.

g. Design formwork joints to inhibit leakage of mortar.

h. Limit deflection of facing materials for concrete surfaces exposed to view to 1/240 of center-to-center spacing of facing supports.

j. Submit product information on proposed form-facing materials if different from that specified herein.

k. Submit shop drawings for formwork, shoring, reshoring, and backshoring.

Shop drawings must be signed and sealed by a licensed design engineer.

m. Submit procedure for reshoring and backshoring, including drawings signed and sealed by a licensed design engineer. Include on shop drawings the formwork removal procedure and magnitude of construction loads used for design of reshoring or backshoring system. Indicate in procedure the magnitude of live and dead loads assumed for required capacity of the structure at time of reshoring or backshoring.

n. Submit manufacturer's product data on form liner proposed for use with each formed surface.

2.1.1 Wood Forms

Use lumber as specified in Section 06 10 00 ROUGH CARPENTRY and as follows.

Provide lumber that is square edged or tongue-and-groove boards, free of raised grain, knotholes, or other surface defects. Provide plywood that complies with NIST PS 1, B-B concrete form panels or better or AHA A135.4, hardboard for smooth form lining. Submit data verifying that composite wood products contain no urea formaldehyde resins. Virgin wood used must be FSC-certified.

2.1.1.1 Concrete Form Plywood (Standard Rough)

Provide plywood that conforms to NIST PS 1, B-B, concrete form, not less than 5/8-inch thick.

2.1.1.2 Overlaid Concrete Form Plywood (Standard Smooth)

Provide plywood that conforms to NIST PS 1, B-B, high density form overlay, not less than 5/8-inch thick.

2.1.2 Plastic Forms

Plastic lumber as specified in Section 06 10 00 ROUGH CARPENTRY. Provide plastic forms that contain a minimum of 50 percent post-consumer recycled content, or a minimum of 50 percent post-industrial recycled content.

2.1.3 Carton Forms

Moisture resistant treated paper faces, biodegradable, structurally sufficient to support weight of wet concrete until initial set. Provide carton forms that contain a minimum of 5 percent post-consumer recycled content, or a minimum of 20 percent post-industrial recycled content.

2.1.4 Steel Forms

Provide steel form surfaces that do not contain irregularities, dents, or sags.

2.2 FORMWORK ACCESSORIES

a. Use commercially manufactured formwork accessories, including ties and hangers.

b. Form ties and accessories must not reduce the effective cover of the reinforcement.

2.2.1 Form Ties

a. Use form ties with ends or end fasteners that can be removed without damage to concrete.

b. Where indicated in Contract Documents, use form ties with integral water barrier plates or other acceptable positive water barriers in walls.

c. The breakback distance for ferrous ties must be at least 2 in. for

Surface Finish-2.0 or Surface Finish-3.0, as defined in ACI 301.

d. If the breakback distance is less than 3/4 in., use coated or corrosion-resistant ties.

e. Submit manufacturer's data sheet on form ties.

2.2.2 Waterstops

Submit manufacturer's data sheet on waterstop materials and splices.

2.2.2.1 PVC Waterstop

Polyvinylchloride waterstops must conform to COE CRD-C 572.

2.2.2.2 Rubber Waterstop

Rubber waterstops must conform to COE CRD-C 513.

2.2.2.3 Thermoplastic Elastomeric Rubber Waterstop

Thermoplastic elastomeric rubber waterstops must conform to ASTM D471.

2.2.2.4 Hydrophilic Waterstop

Swellable strip type compound of polymer modified chloroprene rubber that swells upon contact with water must conform to the following requirements when tested in accordance to ASTM D412: Tensile strength 420 psi minimum;

ultimate elongation 600 percent minimum. Hardness must be 50 minimum on the type A durometer and the volumetric expansion ratio in distilled water at 70 degrees F must be 3 to 1 minimum.

2.2.3 Biodegradable Form Release Agent

a. Provide form release agent that is colorless, biodegradable, and rapeseed oil-based soy oil-based water-based, with a low (maximum of 55 grams/liter (g/l)) VOC content.

b. Provide product that does not bond with, stain, or adversely affect concrete surfaces and does not impair subsequent treatments of concrete surfaces.

c. Provide form release agent that reduces formwork moisture absorption, and does not contain diesel fuel, petroleum-based lubricating oils, waxes, or kerosene. Submit documentation indicating type of biobased material in product and biobased content. Indicate relative dollar value of biobased content products to total dollar value of products included in project.

d. Submit manufacturer's product data on formwork release agent for use on each form-facing material.

2.2.4 Chamfer Materials

Use lumber materials with dimensions of 3/4 x 3/4 in.

2.2.5 Construction and movement joints

a. Submit details and locations of construction joints in accordance with the requirements herein.

b. Locate construction joints within middle one-third of spans of slabs, beams, and girders. If a beam intersects a girder within the middle one-third of girder span, the distance between the construction joint in the girder and the edge of the beam must be at least twice the width of the larger member.

c. For members with post-tensioning tendons, locate construction joints where tendons pass through centroid of concrete section.

d. Locate construction joints in walls and columns at underside of slabs, beams, or girders and at tops of footings or slabs.

e. Make construction joints perpendicular to main reinforcement.

f. Provide movement joints where indicated in Contract Documents or in accepted alternate locations.

g. Submit location and detail of movement joints if different from those indicated in Contract Documents.

h. Submit manufacturer's data sheet on expansion joint materials.

i. Provide keyways where indicated in Contract Documents. Longitudinal keyways indicated in Contract Documents must be at least 1-1/2 in.

deep, measured perpendicular to the plane of the joint.

2.2.6 Other Embedded items

Use sleeves, inserts, anchors, and other embedded items of material and design indicated in Contract Documents.

2.3 CONCRETE MATERIALS

2.3.1 Cementitious Materials

2.3.1.1 Portland Cement

a. Unless otherwise specified, provide cement that conforms to ASTM C150/C150M Type I.

b. Use one brand and type of cement for formed concrete having exposed-to-view finished surfaces.

c. Supplier must certify that no hazardous waste is used in the fuel mix or raw materials.

d. Submit information along with evidence demonstrating compliance with referenced standards. Submittals must include types of cementitious materials, manufacturing locations, shipping locations, and certificates showing compliance.

e. Cementitious materials must be stored and kept dry and free from contaminants.

2.3.1.2 Fly Ash

a. ASTM C618, Class F, except that the maximum allowable loss on ignition must not exceed 3 percent.

b. If fly ash is used it shall range from 15 to 20 percent by weight of cementitious material, provided the fly ash does not reduce the amount of cement in the concrete mix below the minimum requirements of local building codes. Where the use of fly ash cannot meet the minimum level,it shall not be used. Report the chemical analysis of the fly ash in accordance with ASTM C311/C311M. Evaluate and classify fly ash in accordance with ASTM D5759.

2.3.1.3 Slag Cement

ASTM C989/C989M, Grade 100.

2.3.1.4 Silica Fume

Silica fume must conform to ASTM C1240, including the optional limits on reactivity with cement alkalis. Silica fume may be furnished as a dry, densified material or as slurry. Proper mixing is essential to accomplish proper distribution of the silica fume and avoid agglomerated silica fume which can react with the alkali in the cement resulting in premature and extensive concrete damage. Supervision at the batch plant, finishing, and curing is essential. Provide at the Contractor's expense the services of a manufacturer's technical representative, experienced in mixing, proportioning, placement procedures, and curing of concrete containing silica fume. This representative must be present on the project prior to and during at least the first 4 days of concrete production and placement using silica fume. A High Range Water Reducing admixture (HRWRA) must be used with silica fume.

2.3.1.5 Other Supplementary Cementitious Materials

Natural pozzolan must be raw or calcined and conform to ASTM C618, Class N, including the optional requirements for uniformity and effectiveness in controlling ASR and must have an ignition loss not exceeding 3 percent.

Class N pozzolan for use in mitigating ASR must have a Calcium Oxide (CaO) content of less than 13 percent and total equivalent alkali content less than 3 percent.

Ultra Fine Fly Ash (UFFA) and Ultra Fine Pozzolan (UFP) must conform to ASTM C618, Class F or N, and the following additional requirements:

a. The strength activity index at 28 days of age must be at least 95 percent of the control specimens.

b. The average particle size must not exceed 6 microns.

c. The sum of SiO2 + Al2O3 + Fe2O3 must be greater than 77 percent.

2.3.2 Water

a. Water or ice must comply with the requirements of ASTM C1602/C1602M.

b. Minimize the amount of water in the mix. Improve workability by adjusting the grading of the aggregate and using admixture rather than by adding water.

c. Water must be potable; free from injurious amounts of oils, acids, alkalis, salts, organic materials, or other substances deleterious to

d. Protect mixing water and ice from contamination during storage and delivery.

e. Submit test report showing water complies with ASTM C1602/C1602M.

2.3.3 Aggregate

2.3.3.1 Normal-Weight Aggregate

a. Aggregates must conform to ASTM C33/C33M unless otherwise specified in the Contract Documents or approved by the contracting officer.

b. Aggregates used in concrete must be obtained from the same sources and have the same size range as aggregates used in concrete represented by submitted field test records or used in trial mixtures.

c.

d. Store and handle aggregate in a manner that will avoid segregation and prevents contamination by other materials or other sizes of aggregates.

Store aggregates in locations that will permit them to drain freely.

Do not use aggregates that contain frozen lumps.

e. Submit types, pit or quarry locations, producers' names, aggregate supplier statement of compliance with ASTM C33/C33M, and ASTM C1293 expansion data not more than 18 months old.

2.3.3.2 Lightweight Aggregate

Lightweight aggregate in accordance with ASTM C330/C330M.

2.3.4 Admixtures

a. Chemical admixtures must conform to ASTM C494/C494M.

b. Air-entraining admixtures must conform to ASTM C260/C260M.

c. Chemical admixtures for use in producing flowing concrete must conform to ASTM C1017/C1017M.

d. Do not use calcium chloride admixtures unless approved by the contracting officer.

e.

f. Admixtures used in concrete must be the same as those used in the concrete represented by submitted field test records or used in trial mixtures.

g. Protect stored admixtures against contamination, evaporation, or damage.

h. To ensure uniform distribution of constituents, provide agitating equipment for admixtures used in the form of suspensions or unstable solutions. Protect liquid admixtures from freezing and from temperature changes that would adversely affect their characteristics.

i. Submit types, brand names, producers' names, manufacturer's technical data sheets, and certificates showing compliance with standards required herein.

2.4 MISCELLANEOUS MATERIALS

2.4.1 Concrete Curing Materials

Provide concrete curing material in accordance with ACI 301 Section 5 and ACI 308.1 Section 2. Submit product data for concrete curing compounds.

Submit manufactures instructions for placement of curing compound.

2.4.2 Nonshrink Grout

Nonshrink grout in accordance with ASTM C1107/C1107M.

2.4.3 Floor Finish Materials

2.4.3.1 Liquid Chemical Floor Hardeners and Sealers

a. Hardener must be a colorless aqueous solution containing a blend of inorganic silicate or siliconate material and proprietary components combined with a wetting agent; that penetrates, hardens, and densifies concrete surfaces. Submit manufactures instructions for placement of liquid chemical floor hardener.

b. Use concrete penetrating sealers with a low (maximum 100 grams/liter, less water and less exempt compounds) VOC content. Submit manufactures instructions for placement of sealers.

2.4.3.2 Abrasive Aggregate for Nonslip Aggregate Finish

2.4.3.3 Dry Materials for Colored Wear-Resistant Finish

2.4.4 Expansion/Contraction Joint Filler

ASTM D1751 or ASTM D1752 Type I or Type II. Material must be 1/2 inch thick.

2.4.5 Joint Sealants

Submit manufacturer's product data, indicating VOC content.

2.4.5.1 Horizontal Surfaces, 3 Percent Slope, Maximum

ASTM D6690 or ASTM C920, Type M, Class 25, Use T.

2.4.5.2 Vertical Surfaces Greater Than 3 Percent Slope

ASTM C920, Type M, Grade NS, Class 25, Use T ..

2.4.5.3 Preformed Polychloroprene Elastomeric Type

ASTM D2628.

2.4.5.4 Lubricant for Preformed Compression Seals

ASTM D2835.

2.4.6 Vapor Retarder and Vapor Barrier

ASTM E1745 Class C polyethylene sheeting, minimum 10 mil thickness or other equivalent material with a maximum permeance rating of 0.04 perms per ASTM E96/E96M.

Consider plastic vapor retarders and adhesives with a high recycled content, low toxicity low VOC (Volatile Organic Compounds) levels.

2.4.7 Dovetail Anchor Slot

Preformed metal slot approximately 1 inch by 1 inch of not less than 22 gage galvanized steel cast in concrete. Coordinate actual size and throat opening with dovetail anchors and provide with removable filler material.

2.5 CONCRETE MIX DESIGN

2.5.1 Properties and Requirements

a. Use materials and material combinations listed in this section and the contract documents.

b. Cementitious material content must be adequate for concrete to satisfy the specified requirements for strength, w/cm, durability, and finishability described in this section and the contract documents.

c. Selected target slump must meet the requirements this section, the contract documents, and must not exceed 9 in. Concrete must not show visible signs of segregation.

d. The target slump must be enforced for the duration of the project.

Determine the slump by ASTM C143/C143M. Slump tolerances must meet the requirements of ACI 117.

e. The nominal maximum size of coarse aggregate for a mixture must not exceed three-fourths of the minimum clear spacing between reinforcement, one-fifth of the narrowest dimension between sides of forms, or one-third of the thickness of slabs or toppings.

f. Concrete must be air entrained for members assigned to Exposure Class

F1, F2, or F3. The total air content must be in accordance with the requirements of the paragraph titled DURABILITY.

g. Measure air content at the point of delivery in accordance with ASTM

C173/C173M or ASTM C231/C231M.

h. Concrete for slabs to receive a hard-troweled finish must not contain an air-entraining admixture or have a total air content greater than 3 percent.

i. Concrete properties and requirements for each portion of the structure are specified in the table below. Refer to the paragraph titled DURABILITY for more details on exposure categories and their requirements.

Minimum f'c psi Exposure

Categories^ Miscellaneous Requirements

Footings 5000at 7 days S0 ;C0 ;W0 ;F0

Max. slump:6 in.

Slabs-on-ground 5000at 7 days S0 ;C0 ;W0 ;F0

Concrete Toppings 5000 at 7 days S0 ;C0 ;W0 ;F0

Max. slump: 6 in.

2.5.2 Durability

2.5.2.1 Alkali-Aggregate Reaction

Do not use any aggregate susceptible to alkali-carbonate reaction (ACR).

Use one of the three options below for qualifying concrete mixtures to reduce the potential of alkali-silica reaction (ASR):

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

b. For each aggregate used in concrete, the expansion result of the aggregate and cementitious materials combination determined in accordance with ASTM C1567 must not exceed 0.10 percent at an age of 16 days.

c. Alkali content in concrete (LBA) must not exceed 4 pounds per cubic yard for moderately reactive aggregate or 3 pounds per cubic yard for highly reactive aggregate. Reactivity must be determined by testing in accordance with ASTM C1293 and categorized in accordance with ASTM C1778. Alkali content is calculated as follows:

LBA = (cement content, pounds per cubic yard) × (equivalent alkali content of portland cement in percent/100 percent)

2.5.2.2 Freezing and Thawing Resistance

a. Provide concrete meeting the following requirements based on exposure class assigned to members for freezing-and-thawing exposure in Contract Documents:

Exposure class

Maximum w/cm*

Minimum f'c, psi Air content

Additional Requirements

F0 N/A 2500 N/A

F1 0.55 3500 Depends on aggregate size

N/A

F2 0.45 4500 Depends on aggregate size

See limits on maximum cementitious material by mass

F3 0.40 5000 Depends on aggregate size

See limits on maximum cementitious material by mass

F3 plain concrete

0.45 4500 Depends on aggregate size

See limits on maximum cementitious material by mass

*The maximum w/cm limits do not apply to lightweight concrete.

b. Concrete must be air entrained for members assigned to Exposure Class

F1, F2, or F3. The total air content must meet the requirements of the following table:

Nominal maximum aggregate size, in.

Total air content, percent*^

Exposure Class F2 and F3

Exposure Class F1

3/8 7.5 6.0

1/2 7.0 5.5

3/4 6.0 5.0

1 6.0 4.5

1-1/2 5.5 4.5

2 5.0 4.0

3 5.5 3.5

*Tolerance on air content as delivered must be plus/minus 1.5 percent.

^For f'c greater than 5000 psi, reducing air content by 1.0 percentage point is acceptable.

c. Submit documentation verifying compliance with specified requirements.

d. For sections of the structure that are assigned Exposure Class F3, submit certification on cement composition verifying that concrete mixture meets the requirements of the following table:

Cementitious material Maximum percent of total cementitious material by mass*

Fly ash or other pozzolans conforming to ASTM C618

Slag cement conforming to ASTM C989/C989M

Silica fume conforming to ASTM C1240 10

Total of fly ash or other pozzolans, slag cement, and silica fume

50^

Total of fly ash or other pozzolans and silica fume

35^

*Total cementitious material also includes ASTM C150/C150M, ASTM C595/C595M, ASTM C845/C845M, and ASTM C1157/C1157M cement. The maximum percentages above must include:

i. Fly ash or other pozzolans present in ASTM C1157/C1157M or ASTM C595/C595M Type IP blended cement.

ii. Slag cement present in ASTM C1157/C1157M or ASTM C595/C595M Type IS blended cement.

iii. Silica fume conforming to ASTM C1240 present in ASTM C1157/C1157M or ASTM C595/C595M Type IP blended cement.

^Fly ash or other pozzolans and silica fume must constitute no more than 25 percent and 10 percent, respectively, of the total mass of the cementitious materials.

2.5.2.3 Corrosion and Chloride Content

a. Provide concrete meeting the requirements of the following table based on the exposure class assigned to members requiring protection against reinforcement corrosion in Contract Documents.

b. Submit documentation verifying compliance with specified requirements.

c. Water-soluble chloride ion content contributed from constituents including water, aggregates, cementitious materials, and admixtures must be determined for the concrete mixture by ASTM C1218/C1218M at age between 28 and 42 days.

d. The maximum water-soluble chloride ion (Cl-) content in concrete, percent by mass of cement is as follows:

class

Maximum w/cm*

Minimum f'c, psi

Maximum water-soluble chloride ion (CL-) content in concrete, percent by mass of cement

Reinforced concrete

C0 N/A 2500 1.00

C1 N/A 2500 0.30

C2 0.4 5000 0.15

Prestressed concrete

C0 N/A 2500 0.06

C1 N/A 2500 0.06

C2 0.4 5000 0.06

2.5.2.4 Sulfate Resistance

on the exposure class assigned to members for sulfate exposure.

Exposurecla ss Maximumw/ cm Minimu m f'c,ps i

Required cementitious materials-types

Calcium chloride admixture

ASTM

C150/C15

0M

ASTM C595/C595M ASTM

C1157/C115

7M

S0 N/A 2500 N/A N/A N/A Norestrictio ns

S1 0.50 4000 II*^ IP(MS);IS(<70)(M

S); IT(MS)

MS Norestrictio ns

S2 0.45 4500 IV^ IP(HS);IS(<70)(H

S); IT(HS)

HS Notpermitted

S3 0.45 4500 V + pozzolan or slag cement**

IP(HS)+ pozzolan or slag cement^;

IS (<70)(HS) +

pozzolan or slag cement^; IT (HS) + pozzolan or slag cement**

HS +

pozzolan or slag cement**

Notpermitted

* For seawater exposure, other types of portland cements with tricalcium aluminate (C3A) contents up to 10 percent are acceptable if the w/cm does not exceed 0.40.

** The amount of the specific source of the pozzolan or slag cement to be used shall be at least the amount determined by test or service record to improve sulfate resistance when used in concrete containing Type V cement. Alternatively, the amount of the specific source of the pozzolan or slag used shall not be less than the amount tested in accordance with ASTM C1012/C1012M and meeting the requirements maximum expansion requirements listed herein.

^ Other available types of cement, such as Type III or Type I, are acceptable in exposure classes S1 or S2 if the C3A contents are less than 8 or 5 percent, respectively.

b. The maximum w/cm limits for sulfate exposure do not apply to lightweight concrete.

c. Alternative combinations of cementitious materials of those listed in this paragraph are acceptable if they meet the maximum expansion requirements listed in the following table:

^The 12-month expansion limit applies only when the measured expansion exceeds the 6-month maximum expansion limit.

2.5.2.5 Concrete Temperature

The temperature of concrete as delivered must not exceed 95°F.

2.5.2.6 Concrete permeability

on exposure class assigned to members requiring low permeability in the Contract Documents.

b. Submit documentation verifying compliance with specified requirements.

2.5.3 Contractor's Option for Material Only

At the option of the Contractor, those applicable material sections of DOT RBS for Class A strength concrete must govern in lieu of this specification for concrete. Do not change the selected option during the course of the work.

2.5.4 Trial Mixtures

Trial mixtures must be in accordance to ACI 301.

2.5.5 Ready-Mix Concrete

Provide concrete that meets the requirements of ASTM C94/C94M.

Ready-mixed concrete manufacturer must provide duplicate delivery tickets with each load of concrete delivered. Provide delivery tickets with the following information in addition to that required by ASTM C94/C94M:

a. Type and brand cement

b. Cement and supplementary cementitious materials content in 94-pound bags per cubic yard of concrete

c. Maximum size of aggregate

d. Amount and brand name of admixtures

e. Total water content expressed by water cementitious material ratio

2.6 REINFORCEMENT

a. Bend reinforcement cold. Fabricate reinforcement in accordance with fabricating tolerances of ACI 117.

b. When handling and storing coated reinforcement, use equipment and methods that do not damage the coating. If stored outdoors for more than 2 months, cover coated reinforcement with opaque protective material.

c. Submit manufacturer's certified test report for reinforcement.

d. Submit placing drawings showing fabrication dimensions and placement locations of reinforcement and reinforcement supports. Placing drawings must indicate locations of splices, lengths of lap splices, and details of mechanical and welded splices.

e. Submit request with locations and details of splices not indicated in

Contract Documents.

f. Submit request to place column dowels without using templates.

h. Submit request for field cutting, including location and type of bar to be cut and reason field cutting is required.

2.6.1 Reinforcing Bars

a. Reinforcing bars must be deformed, except spirals, load-transfer dowels, and welded wire reinforcement, which may be plain.

b. ASTM A615/A615M with the bars marked S, Grade 60; or ASTM A996/A996M with the bars marked R, Grade 50, or marked A, Grade 40. Cold drawn wire used for spiral reinforcement must conform to ASTM A1064/A1064M.

c. Submit mill certificates for reinforcing bars.

2.6.1.1 Galvanized Reinforcing Bars

a. Provide zinc-coated (galvanized) reinforcing bars that conform to ASTM A767/A767M, Class 1 as required by the contract Documents.

b. Coating damage incurred during shipment, handling, and placing of zinc-coated (galvanized) reinforcing bars must be repaired in accordance with ASTM A780/A780M. Damaged areas must not exceed 2 percent of surface area in each linear foot of each bar or bar must not be used.

The 2 percent limit on maximum allowed damaged coating area must include previously repaired areas damaged before shipment as required by ASTM A767/A767M.

2.6.2 Mechanical Reinforcing Bar Connectors

a. Provide 125 percent minimum yield strength of the reinforcement bar.

b. Mechanical splices for galvanized reinforcing bars must be galvanized or coated with dielectric material.

c. Mechanical splices used with epoxy-coated or dual-coated reinforcing bars must be coated with dielectric material.

d. Submit data on mechanical splices demonstrating compliance with this paragraph.

2.6.3 Wire

a. Provide flat sheets of welded wire reinforcement for slabs and toppings.

b. Plain or deformed steel wire must conform to ASTM A1064/A1064M.

c. Stainless steel wire must conform to ASTM A1022/A1022M.

d. Epoxy-coated wire must conform to ASTM A884/A884M. Coating damage incurred during shipment, storage, handling, and placing of epoxy-coated wires must be repaired. Repair damaged coating areas with patching material in accordance with material manufacturer's written recommendations. If damaged area exceeds 2 percent of surface area in each linear foot of each wire, wire must not be used. The 2 percent limit on damaged coating area must include repaired areas damaged before shipment as required by ASTM A884/A884M. Fading of coating color shall not be cause for rejection of epoxy-coated wire reinforcement.

2.6.4 Welded wire reinforcement

a. Use welded wire reinforcement specified in Contract Documents and conforming to one or more of the specifications given herein.

b. Plain welded wire reinforcement must conform to ASTM A1064/A1064M, with welded intersections spaced no greater than 12 in. apart in direction of principal reinforcement.

c. Deformed welded wire reinforcement must conform to ASTM A1064/A1064M, with welded intersections spaced no greater than 16 in. apart in direction of principal reinforcement.

d. Epoxy-coated welded wire reinforcement must conform to…