03_30_53.pdf

North Topeka and Units Improvements Topeka Levee System, KS

SECTION TABLE OF CONTENTS

DIVISION 03 - CONCRETE

SECTION 03 30 53

MISCELLANEOUS CAST-IN-PLACE CONCRETE

05/14

PART 1 GENERAL

1.1 SUMMARY

1.2 UNIT PRICES

1.3 REFERENCES

1.4 SUBMITTALS

1.5 QUALITY ASSURANCE

1.5.1 Regulatory Requirements

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

2.1.1 Strength

2.1.2 Construction Tolerances

2.1.3 Concrete Mixture Proportions

2.2 MATERIALS

2.2.1 Cementitious Materials

2.2.1.1 Portland Cement

2.2.1.2 Pozzolan

2.2.1.3 Nonshrink Grout

2.2.2 Aggregates

2.2.3 Admixtures

2.2.3.1 Air-Entraining Admixture

2.2.3.2 Water-Reducing or Retarding Admixture

2.2.4 Water

2.2.5 Reinforcing Steel

2.2.6 Expansion Joint Filler Strips, Premolded

2.2.7 Joint Sealants - Field Molded Sealants

2.2.8 Formwork

2.2.9 Form Coatings

2.2.10 Curing Materials

2.3 READY-MIX CONCRETE

2.4 ACCESSORIES

2.4.1 Curing Compound

PART 3 EXECUTION

3.1 PREPARATION

3.1.1 Embedded Items

3.1.2 Formwork Installation

3.1.3 Production of Concrete

3.1.3.1 Ready-Mixed Concrete

3.1.3.2 Concrete Made by Volumetric Batching and Continuous Mixing

3.1.3.3 Batching and Mixing Equipment

3.2 CONVEYING AND PLACING CONCRETE

3.2.1 Cold-Weather Requirements

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3.2.2 Hot-Weather Requirements

3.3 Nonshrink Grout Application

3.3.1 Mixing and Placing of Nonshrink Grout

3.3.2 Treatment of Exposed Surfaces

3.4 FINISHING

3.4.1 Temperature Requirement

3.4.2 Finishing Formed Surfaces

3.4.3 Finishing Unformed Surfaces

3.5 CURING AND PROTECTION

3.6 FORM WORK

3.6.1 Removal of Forms

3.7 STEEL REINFORCING

3.7.1 Fabrication

3.7.2 Splicing

3.7.3 Supports

3.8 EMBEDDED ITEMS

3.9 TESTING AND INSPECTING

3.9.1 Field Testing Technicians

3.9.2 Preparations for Placing

3.9.3 Sampling and Testing

3.9.4 Action Required

3.9.4.1 Placing

3.9.4.2 Air Content

3.9.4.3 Slump

-- End of Section Table of Contents --

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SECTION 03 30 53

MISCELLANEOUS CAST-IN-PLACE CONCRETE

05/14

PART 1 GENERAL

1.1 SUMMARY

Perform all work in accordance with ACI 318.

1.2 UNIT PRICES

1.3 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 INTERNATIONAL (ACI)

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

ACI 301 (2010; Errata 2011) Specifications for Structural Concrete

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

ACI 305R (2010) Guide to Hot Weather Concreting

ACI 306R (2010) Guide to Cold Weather Concreting

ACI 318 (2014; Errata 1-2 2014) Building Code Requirements for Structural Concrete and Commentary

ACI 347 (2004; Errata 2008; Errata 2012) Guide to Formwork for Concrete

ACI SP-66 (2004) ACI Detailing Manual

ASTM INTERNATIONAL (ASTM)

ASTM C1064/C1064M (2011) Standard Test Method for Temperature of Freshly Mixed Hydraulic-Cement Concrete

ASTM C1107/C1107M (2014) Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Nonshrink)

ASTM C143/C143M (2012) Standard Test Method for Slump of Hydraulic-Cement Concrete

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ASTM C150/C150M (2012) Standard Specification for Portland Cement

ASTM C1602/C1602M (2012) Standard Specification for Mixing Water Used in Production of Hydraulic Cement Concrete

ASTM C172/C172M (2014a) Standard Practice for Sampling Freshly Mixed Concrete

ASTM C173/C173M (2014) Standard Test Method for Air Content of Freshly Mixed Concrete by the Volumetric Method

ASTM C231/C231M (2014) Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method

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

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

ASTM C31/C31M (2012) Standard Practice for Making and Curing Concrete Test Specimens in the Field

ASTM C33/C33M (2013) Standard Specification for Concrete Aggregates

ASTM C39/C39M (2014a) Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

ASTM C494/C494M (2013) Standard Specification for Chemical Admixtures for Concrete

ASTM C618 (2012a) Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

ASTM C685/C685M (2011) Concrete Made by Volumetric Batching and Continuous Mixing

ASTM C920 (2014a) Standard Specification for Elastomeric Joint Sealants

ASTM C94/C94M (2014b) Standard Specification for Ready-Mixed Concrete

ASTM D1752 (2004a; R 2013) Standard Specification for Preformed Sponge Rubber Cork and Recycled PVC Expansion

ASTM D75/D75M (2014) Standard Practice for Sampling Aggregates

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

40 CFR 247 Comprehensive Procurement Guideline for Products Containing Recovered Materials

1.4 SUBMITTALS

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

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

SD-02 Shop Drawings

Installation Drawings; G, DO_

SD-03 Product Data

Air-Entraining Admixture

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

Batching and Mixing Equipment Conveying and Placing Concrete Formwork; G, RO Mix Design Data; G, RO_ Ready-Mix Concrete Curing Compound Nonshrink Grout

SD-06 Test Reports

Aggregates Concrete Mixture Proportions; G, RO_____

Compressive Strength Testing; G, RO_____ Slump; G, _RO____ Air Content Water

SD-07 Certificates

Cementitious Materials Pozzolan CPG for recycled materials or appropriate Waiver Form Aggregates Delivery Tickets

SD-08 Manufacturer's Instructions

Curing Compound

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1.5 QUALITY ASSURANCE

Indicate specific locations of Concrete Placement, Forms,Steel Reinforcement, Accessories, Expansion Joints,Construction Joints, Contraction Joints, Control Joints on installation drawings and include, but not be limited to, square feet of concrete placements, thicknesses and widths, plan dimensions, and arrangement of cast-in-place concrete section. All construction joints for new concrete should match the existing concrete construction joints.

1.5.1 Regulatory Requirements

The state statutory and regulatory requirements: Submit CPG for recycled materials or appropriate Waiver Form.

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

The Government retains the option to sample and test joint sealer, joint filler material, aggregates and concrete to determine compliance with the specifications. Provide facilities and labor as may be necessary to assist the Government in procurement of representative test samples. Obtain samples of aggregates at the point of batching in accordance with ASTM D75/D75M. Sample concrete in accordance with ASTM C172/C172M.

Determine slump and air content in accordance with ASTM C143/C143M and ASTM C231/C231M, respectively, when cylinders are molded. Prepare, cure, and transport compression test specimens in accordance with ASTM C31/C31M.

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

2.1.1 Strength

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

2.1.2 Construction Tolerances

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

2.1.3 Concrete Mixture Proportions

Concrete mixture proportions are the responsibility of the Contractor.

Mixture proportions must include the dry weights of cementitious material(s); the nominal maximum size of the coarse aggregate; the specific gravities, absorptions, and saturated surface-dry weights of fine and coarse aggregates; the quantities, types, and names of admixtures; and quantity of water per yard of concrete. Provide materials included in the

03 30 53 - 6 mixture proportions of the same type and from the same source as will be used on the project. The specified compressive strength f'c is 4,500 psi at 28 days (90 days if pozzolan is used). The maximum nominal size coarse aggregate shall be as recommended by the concrete manufactures's recommendations, and in accordance with ACI 304R. The air content must be between 4.5 and 7.5 percent with a slump between 2 and 5 inches. The maximum water-cementitious material ratio shall be as recommended by the concrete manufactures's recommendations. Submit the applicable test reports and mixture proportions that will produce concrete of the quality required, ten days prior to placement of concrete.

2.2 MATERIALS

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

2.2.1 Cementitious Materials

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

Provide cementitious materials that conform to the appropriate specifications listed:

2.2.1.1 Portland Cement

ASTM C150/C150M, Type I or II,

2.2.1.2 Pozzolan

Provide pozzolan that conforms to ASTM C618, Class F, including requirements of Tables 1A and 2A.

2.2.1.3 Nonshrink Grout

Nonshrink Grout shall conform to ASTM C1107/C1107M and a commercial formulation suitable for the application proposed. Submit descriptive literature of the Nonshrink Grout proposed for use together with a certificate from the manufacturer stating that it is suitable for the application or exposure for which it is being considered.

2.2.2 Aggregates

For fine and coarse aggregates meet the quality and grading requirements of ASTM C33/C33M. Submit certificates of compliance and test reports for aggregates showing the material(s) meets the quality and grading requirements of the specifications under which it is furnished.

2.2.3 Admixtures

Provide admixtures, when required or approved, in compliance with the appropriate specification listed. Retest chemical admixtures that have been in storage at the project site, for longer than 6 months or that have been subjected to freezing, at the expense of the Contractor at the request of the Contracting Officer and will be rejected if test results are not satisfactory.

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2.2.3.1 Air-Entraining Admixture

Provide air-entraining admixture that meets the requirements of

ASTM C260/C260M.

2.2.3.2 Water-Reducing or Retarding Admixture

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

2.2.4 Water

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

ASTM C1602/C1602M.

2.2.5 Reinforcing Steel

See Specification 03 20 00.00 10 Concrete Reinforcing.

2.2.6 Expansion Joint Filler Strips, Premolded

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

2.2.7 Joint Sealants - Field Molded Sealants

Conform to ASTM C920, Type M, Grade NS, Class 25, use NT for vertical joints and Type M, Grade P, Class 25, use T for horizontal joints. Provide polyethylene tape, coated paper, metal foil, or similar type bond breaker materials. The backup material needs to be compressible, nonshrink, nonreactive with the sealant, and a nonabsorptive material such as extruded butyl or polychloroprene foam rubber. Immediately prior to installation of field-molded sealants, clean the joint of all debris and further cleaned using water, chemical solvents, or other means as recommended by the sealant manufacturer or directed.

2.2.8 Formwork

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

2.2.9 Form Coatings

Provide form coating in accordance with ACI 301.

2.2.10 Curing Materials

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

2.3 READY-MIX CONCRETE

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

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

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a. Type and brand cement

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

c. Maximum size of aggregate

d. Amount and brand name of admixture

e. Total water content expressed by water cementitious material ratio

2.4 ACCESSORIES

2.4.1 Curing Compound

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

PART 3 EXECUTION

3.1 PREPARATION

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

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

3.1.1 Embedded Items

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

The embedding of wood in concrete is permitted only when specifically authorized or directed. Provide all equipment needed to place, consolidate, protect, and cure the concrete at the placement site and in good operating condition.

3.1.2 Formwork Installation

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

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

3.1.3 Production of Concrete

3.1.3.1 Ready-Mixed Concrete

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

3.1.3.2 Concrete Made by Volumetric Batching and Continuous Mixing

Conform to ASTM C685/C685M.

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3.1.3.3 Batching and Mixing Equipment

The option of using an on-site batching and mixing facility is available.

The facility must provide sufficient batching and mixing equipment capacity to prevent cold joints. Submit the method of measuring materials, batching operation, and mixer for review, and manufacturer's data for batching and mixing equipment demonstrating compliance with the applicable specifications. Provide an Onsite Plant conforming to the requirements of either ASTM C94/C94M or ASTM C685/C685M.

3.2 CONVEYING AND PLACING CONCRETE

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

3.2.1 Cold-Weather Requirements

Place concrete in cold weather in accordance with ACI 306R

3.2.2 Hot-Weather Requirements

Place concrete in hot weather in accordance with ACI 305R

3.3 Nonshrink Grout Application

Water content must be the minimum that will provide a flowable mixture and fill the space to be grouted without segregation, bleeding, or reduction of strength.

3.3.1 Mixing and Placing of Nonshrink Grout

Mix and place in accordance with the material manufacturer's instructions and as specified. Thoroughly dry-mix ingredients before adding water.

After adding water, mix the batch for 3 minutes. Size batches to allow continuous placement of freshly mixed grout. Discard grout not used within 30 minutes after mixing. Fill the space between the top of the concrete and the bottom of the hole with non-shrink grout. Use forms of wood or other equally suitable material for retaining the grout and remove after the grout has set. If grade "A" grout as specified in ASTM C1107/C1107M is used, form all surfaces to provide restraint. Work the placed grout to eliminate voids; however, avoid overworking and breakdown of the initial set. Do not be retemper or subject grout to vibration from any source.

Where clearances are unusually small, place under pressure with a grout pump. Maintain temperature of the grout, and of surfaces receiving the grout, at 65 to 85 degrees F until after setting.

3.3.2 Treatment of Exposed Surfaces

The exposed surface of nonshrink grout must have a smooth, dense finish.

3.4 FINISHING

3.4.1 Temperature Requirement

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

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3.4.2 Finishing Formed Surfaces

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

3.4.3 Finishing Unformed Surfaces

Finish unformed surfaces in accordance with ACI 301, Section 5.

3.5 CURING AND PROTECTION

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

3.6 FORM WORK

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

3.6.1 Removal of Forms

Remove forms in accordance with ACI 301, Section 2.

3.7 STEEL REINFORCING

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

3.7.1 Fabrication

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

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

3.7.2 Splicing

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

3.7.3 Supports

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

3.8 EMBEDDED ITEMS

Before placing concrete, take care to determine that all embedded items are firmly and securely fastened in place. Provide embedded items free of oil and other foreign matter, such as loose coatings of rust, paint and scale.

Embedding of wood in concrete is permitted only when specifically authorized or directed.

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3.9 TESTING AND INSPECTING

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

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

See Section 01 45 00.00 10 QUALITY CONTROL.

3.9.1 Field Testing Technicians

The individuals who sample and test concrete must have demonstrated a knowledge and ability to perform the necessary test procedures equivalent to the ACI minimum guidelines for certification of Concrete Field Testing Technicians, Grade I.

3.9.2 Preparations for Placing

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

3.9.3 Sampling and Testing

a. Obtain samples and test concrete for quality control during placement.

Sample fresh concrete for testing in accordance with ASTM C172/C172M.

Make six test cylinders.

b. Test concrete for compressive strength at 7 and 28 days for each design mix and for every 100 cubic yards of concrete. Test two cylinders at 7 days; two cylinders at 28 days; and hold two cylinders in reserve.

Conform test specimens to ASTM C31/C31M. Perform compressive strength testing conforming to ASTM C39/C39M.

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

d. Test air content for air-entrained concrete in accordance with ASTM C231/C231M. Test concrete using lightweight or extremely porous aggregates in accordance with ASTM C173/C173M. Check air content at least once during each shift that concrete is placed .

e. Determine temperature of concrete at time of placement in accordance with ASTM C1064/C1064M. Check concrete temperature at least once during each shift that concrete is placed .

3.9.4 Action Required

3.9.4.1 Placing

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

3.9.4.2 Air Content

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

03 30 53 - 12 concrete to forms.

3.9.4.3 Slump

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

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