Amendment_3_-_KC46_Body_Tank_Storage_-_Specs.pdf

B1837 Addition For Tank Storage JBMDLPTFL163008

SECTION 03 45 00

PRECAST ARCHITECTURAL CONCRETE

05/16

PART 1 GENERAL

1.1 REFERENCES

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

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS

(AASHTO)

AASHTO M 251 (2006; R 2011) Standard Specification for Plain and Laminated Elastomeric Bridge Bearings

AMERICAN CONCRETE INSTITUTE INTERNATIONAL (ACI)

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

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

ACI 301 (2016) Specifications for Structural Concrete

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

ACI 305R (2010) Guide to Hot Weather Concreting

ACI 306.1 (1990; R 2002) Standard Specification for Cold Weather Concreting

ACI 318 (2014; Errata 1-2 2014; Errata 3-5 2015;

Errata 6 2016; Errata 7-9 2017) Building Code Requirements for Structural Concrete (ACI 318-14) and Commentary (ACI 318R-14)

ACI SP-66 (2004) ACI Detailing Manual

AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE)

ASCE 7 (2017) Minimum Design Loads for Buildings and Other Structures

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2015; Errata 1 2015; Errata 2 2016) Structural Welding Code - Steel

SECTION 03 45 00 Page 1

ASME INTERNATIONAL (ASME)

ASME B18.21.1 (2009; R 2016) Washers: Helical Spring-Lock, Tooth Lock, and Plain Washers (Inch Series)

ASTM INTERNATIONAL (ASTM)

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

ASTM A153/A153M (2016) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware

ASTM A27/A27M (2017) Standard Specification for Steel Castings, Carbon, for General Application

ASTM A283/A283M (2013) Standard Specification for Low and Intermediate Tensile Strength Carbon Steel Plates

ASTM A36/A36M (2014) Standard Specification for Carbon Structural Steel

ASTM A449 (2014) Standard Specification for Hex Cap Screws, Bolts, and Studs, Steel, Heat Treated, 120/105/90 ksi Minimum Tensile Strength, General Use

ASTM A47/A47M (1999; R 2014) Standard Specification for Ferritic Malleable Iron Castings

ASTM A563 (2015) Standard Specification for Carbon and Alloy Steel Nuts

ASTM A615/A615M (2016) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

ASTM A666 (2015) Standard Specification for Annealed or Cold-Worked Austenitic Stainless Steel Sheet, Strip, Plate and Flat Bar

ASTM C1107/C1107M (2017) Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Nonshrink)

ASTM C1218/C1218M (2017) Standard Test Method for Water-Soluble Chloride in Mortar and Concrete

ASTM C143/C143M (2015) Standard Test Method for Slump of Hydraulic-Cement Concrete

ASTM C150/C150M (2018) Standard Specification for Portland Cement

SECTION 03 45 00 Page 2

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

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

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 C31/C31M (2018a) Standard Practice for Making and Curing Concrete Test Specimens in the Field

ASTM C311/C311M (2017) Standard Test Methods for Sampling and Testing Fly Ash or Natural Pozzolans for Use in Portland-Cement Concrete

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

ASTM C39/C39M (2018) Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

ASTM C42/C42M (2018) Standard Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete

ASTM C494/C494M (2017) Standard Specification for Chemical Admixtures for Concrete

ASTM C618 (2017a) Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

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

ASTM C94/C94M (2017a) Standard Specification for Ready-Mixed Concrete

ASTM D2240 (2015; E 2017) Standard Test Method for Rubber Property - Durometer Hardness

ASTM D5759 (2012) Characterization of Coal Fly Ash and Clean Coal Combustion Fly Ash for Potential Uses

PRECAST/PRESTRESSED CONCRETE INSTITUTE (PCI)

PCI MNL-117 (2013) Manual for Quality Control for Plants and Production of Architectural Precast Concrete Products, 3rd Edition

SECTION 03 45 00 Page 3

PCI MNL-122 (2007) Architectural Precast Concrete, 3rd Edition

1.2 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. Submittals with an "S" are for inclusion in the Sustainability eNotebook, in conformance with Section 01 33 29 SUSTAINABILITY REPORTING. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Pre-Installation Meeting

SD-02 Shop Drawings

Precast Drawings; G

SD-03 Product Data

Cast-In Embedded Items And Connectors; G

Connection Devices; G

Admixtures

Gasket

Bearing Pads

SD-04 Samples

Concrete Wall Panel Surface Finish; G

SD-05 Design Data

Design Calculations; G

Contractor-Furnished Mix Design; G

Concrete Mix Design for Repair of Surface Defects; G

SD-06 Test Reports

Strength Tests; G

Slump

Air Content

Test for Concrete Materials

Water

Testing Precast Units for Strength

SECTION 03 45 00 Page 4

SD-07 Certificates

Manufacturer's Qualifications; G

Fabricator Quality Certifications

Erector Certification

Erector's Post Audit Declaration

SD-08 Manufacturer's Instructions

Installation; G

Cleaning; G

SD-11 Closeout Submittals

Concrete Batch Ticket Information; G

Recycled Content for Fly Ash and Pozzolan;

Recycled Content for Ground Iron Blast-Furnace Slag;

Recycled Content for Silica Fume;

1.3 MODIFICATION OF REFERENCES

In the referenced ACI and PCI publications, consider the advisory provisions to be mandatory. Interpret reference to the "Building Official," the "Structural Engineer," and the "Architect/Engineer" to mean the Contracting Officer.

1.4 GENERAL REQUIREMENTS

Precast concrete units must be designed and fabricated by an experienced and certified precast concrete manufacturer. The manufacturer needs to have been regularly and continuously engaged in the manufacture of precast concrete work similar to that indicated on the drawings for at least 3 years. The Contractor must submit a statement detailing the Manufacturer's Qualifications. Coordinate precast work with the work of other trades.

1.5 DESIGN

1.5.1 Standards and Loads

Precast unit design must conform to ASCE 7, ACI 318 and PCI MNL-122.

Indicate design loads for precast concrete on the drawings. A differential temperature of 192 degrees F, between interior and exterior faces of the units, must be considered in the design. Stresses due to restrained volume change caused by shrinkage and temperature differential, handling, transportation and erection must be accounted for in the design.

1.5.2 Connections

Connection of units to other members, or to other units must be of the type and configuration indicated or as recommended by precast fabrications for application. The design and sizing of connections for all design loads will be completed by the Contractor.

SECTION 03 45 00 Page 5

1.5.3 Concrete Proportion

Base the selection of proportions for concrete on the methodology presented in ACI 211.1 for normal weight concrete. Develop the concrete proportion using the same type and brand of cement, the same type and gradation of aggregates, and the same type and brand of admixture that will be used in the manufacture of precast concrete units for the project. Do not use calcium chloride in precast concrete and admixtures containing chloride ions, nitrates, or other substances that are corrosive will not be used in prestressed concrete.

1.5.4 Design Calculations

Calculations for design of members, connections and embedments not shown must be made by a registered professional engineer experienced in the design of precast architectural concrete. Calculations prepared and sealed by a registered Professional Engineer will demonstrate compliance with indicated loading conditions. Calculation will include the analysis of member for lifting stresses and the sizing of the lifting inserts. Submit calculations for review and approval prior to fabrication, signed and sealed by the registered design professional who prepared the design.

1.6 DELIVERY, STORAGE, AND HANDLING

Deliver packaged materials, except for wall panels, to the project site in the original, unbroken packages or containers, each bearing a label clearly identifying manufacturer's name, brand name, weight or volume, and other pertinent information. Store packaged materials, and materials in containers, in a weathertight and dry place until ready for use.

Store products in manufacturer's unopened packaging in dry storage area, with ambient temperature between 30 degrees F and 120 degrees F, until installation.

1.7 STORAGE AND INSPECTION AT MANUFACTURER'S PLANT

Protect precast units temporarily stored at the manufacturer's plant from damage in accordance with PCI MNL-117 and PCI MNL-122. Immediately prior to shipment to the jobsite, all precast concrete units must be inspected for quality to insure all precast units conform to the requirements specified. Inspection for quality will include, but will not be limited to, the following elements: color, texture, dimensional tolerances, chipping, cracking, staining, warping and honeycombing. Replace or repair all defective precast concrete units as approved.

1.8 PLANT INSPECTION

At the option of the Contracting Officer, precast units may be inspected.

The Contractor is to give notice 14 days prior to the time the units will be available for plant inspection. Neither the exercise nor waiver of inspection at the plant will affect the Government's right to enforce contractual provisions after units are transported or erected.

1.8.1 Fabricator Quality Certifications

Plants must be certified by the PCI Plant Certification Program for Group A, Category A1, or Architectural Precast Association (APA) certification or National Precast Concrete Association (NPCA). When plants are not

SECTION 03 45 00 Page 6 currently enrolled in one of the three certification programs listed above then they must provide a product quality control system in accordance with PCI MNL-117 and perform concrete and aggregate quality control testing using an approved, independent commercial testing laboratory.

1.9 ERECTOR CERTIFICATION

Erector with erecting organization and all erecting crews certified and designated by PCI's Certificate of Compliance to erect Category A (Architectural Systems) for non-load-bearing members.

1.10 ERECTOR QUALIFICATIONS

A precast erector that is not certified by PCI who retains a PCI-Certified Field Auditor, at the erector's expense, to conduct a field audit of a project in the same category as this project prior to start of precast concrete erection and must submit the Erector's Post Audit Declaration to be considered qualified.

1.11 CONCRETE SAMPLING AND TESTING

1.11.1 Test for Concrete Materials

Sample and test concrete materials proposed for use in the work in accordance with PCI MNL-117.

Submit reports for each material sampled and tested prior to the start of work. Reports must contain the project name and number, date, name of Contractor, name of precast unit manufacturer, name of concrete testing service, source of concrete aggregates, generic name of aggregate, and values specified.

1.11.2 Quality Control Testing DuringFabrication

Sample and test concrete for quality control during fabrication as follows:

REQUIREMENT TEST METHOD NUMBER OF TESTS

Sampling fresh concrete ASTM C172/C172M except modified for slump per

ASTM C94/C94M

As required for each test

Slump test ASTM C143/C143M One for each concrete load at point of discharge and one for each set of compressive strength tests

Air Content by pressure method

ASTM C231/C231M One for each set of compressive strength tests

SECTION 03 45 00 Page 7

REQUIREMENT TEST METHOD NUMBER OF TESTS

Compressive test specimens

ASTM C31/C31M One set of six specimens for each Compressive Strength test, one set per day or for every 20 cubic yards of concrete placed, whichever is greater.

Compression test specimens may be either standard 6 by 12 inch cylinders or 4-inch cubes. Cubes may be molded individually or cut from slabs.

Preparation and testing of cube specimens must be as nearly consistent with the test methods specified as possible, with the exception that the concrete will be placed in a single layer.

Curing of compression test specimens must be the same as the curing method used for the precast concrete wall panels until panels are stripped of forms and then standard moist cure will continue.

REQUIREMENT TEST METHOD NUMBER OF TESTS

Concrete temperature

Each time a set of compression test specimens is made

Compressive strength tests

ASTM C39/C39M One set of facing strength tests mix and one set of backing mix for every ten panels or fraction thereof cast in any one day; two specimens in each set tested at 7 calendar days; three specimens in each set tested at 28 calendar days, and one specimen in each set retained in reserve for testing if required

Evaluate compression test results at 28 days in accordance with ACI 214R using a coefficient of variation of 20 percent. Evaluate the strength of concrete by averaging the test results (two specimens) of standard cylinders tested at 28 days. Not more than 20 percent of the individual tests can have an average compressive strength less than the specified ultimate compressive strength. Submit test reports on the same day that tests are made.

Reports for Compressive Strength tests need to contain the project name and number, date of concrete placement, name of Contractor, name of precast concrete wall panel manufacturer, name of concrete testing service, panel identification letter and number, use of concrete mixture (facing or

SECTION 03 45 00 Page 8 backing), design compressive strength at 28 calendar days, concrete-mix proportions and materials, and compressive breaking strength and type of break.

If 4-inch cubes are used for compressive strength specimens, average strength of the cubes at any test age must be multiplied by the factor of

0.8 to arrive at an estimate of the corresponding 6 by 12 inch cylinder strength. Report both of these values .

1.12 QUALITY ASSURANCE

1.12.1 Precast Drawings

Submit precast drawings with the following information:

a. Precast dimensions, cross-section, and edge details; location, size, and type of reinforcement, including reinforcement necessary for safe handling and erection of precast units and other embedded items. Comply with ACI SP-66.

b. Layout, dimensions, and identification of each precast unit, corresponding to installation sequence.

c. Setting drawings, instructions, and directions for installation of concrete inserts.

d. Location and details of anchorage devices and lifting devices embedded in panels, and connection details to building framing system.

1.12.2 Concrete Wall Panel Surface Finish Sample

Submit a concrete wall panel sample 12 inches by 12 inches by approximately 1 1/2 inches in thickness, to illustrate quality, color, and texture of both exposed-to-view surface finish and finish of panel surfaces that will be concealed by other construction.

After approval of the surface, Contractor must provide one full size sample Wall Panel. Approved sample may be used in construction when properly identified.

1.12.3 Required Records

ASTM C94/C94M. Submit mandatory batch ticket information for each load of ready-mixed concrete.

1.12.4 Pre-Installation Meeting

Hold a meeting at the job site with representative of the manufacturer and the applicator prior to application of water repellents and all other trades that may be effected by work of this section. Notify the Contracting Officer at least 3 days in advance of the time of the meeting.

1.13 TOLERANCES

Dimensions of the finished panel, at the time of erection in the structure, must conform to the tolerances for precast, non-prestressed elements in PCI MNL-117, unless otherwise specified by the Architect.

SECTION 03 45 00 Page 9

PART 2 PRODUCTS

2.1 CONCRETE

2.1.1 Contractor-Furnished Mix Design

ACI 211.1 and ACI 301. The Contractor must submit the mix design report giving the maximum nominal coarse aggregate size, the proportions of all ingredients and the type and amount of any admixtures that will be used in the manufacture of each strength and type of concrete, a minimum of sixty days prior to commencing operations. 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. Plot a curve for each concrete mixture, showing the relationships between water-cementitious material ratios and compressive strengths. Maximum permissible water-cementitious material ratio must be that value not exceeding the maximum water-cementitious material ratio specified, indicated by the curve to produce a design minimum laboratory compressive strength at 28 calendar days not less than that specified. The mix design report is to contain the project name and number, date, name of Contractor, name of precast concrete wall panel manufacturer, name of concrete testing service, use of concrete mixture (facing or backing), source of concrete aggregates for each mixture.

Submit 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, and aggregates. The statement must be accompanied by test results from an approved testing laboratory, certifying that the proportions selected will produce concrete of the properties required. Make no substitutions without additional tests to verify that the concrete properties are satisfactory. Concrete must have a 28-day compressive strength of 5000 psi. Air content of plastic concrete must be between 4 and 6 percent air by volume.

If, the compressive strength falls below that specified, adjust the mix proportions and water content and make necessary changes in the temperature, moisture, and curing procedures to secure the specified strength. Notify the Contracting Officer of all changes.

2.1.2 Backing Mixture

Provide the approved mix design.

2.2 MATERIALS

2.2.1 Material Sustainability Criteria

For products in this section, where applicable and to extent allowed by performance criteria, provide and document the following in accordance with Section 01 33 29 SUSTAINABILITY REQUIREMENTS:

a. Recycled content for fly ash and pozzolan

b. Recycled content for Ground Iron Blast-Furnace Slag

c. Recycled content for Silica Fume

2.2.2 Fine Aggregates

ASTM C33/C33M. The optional method of reducing the No. 50 and No. 100 sieve aggregates does not apply. The restriction to use only fine aggregates that do not contain any materials that are deleteriously

SECTION 03 45 00 Page 10 reactive with alkalis in cement does apply.

2.2.3 Coarse Aggregate

ASTM C33/C33M, Size No. 57, Class 5S. The restriction to use only coarse aggregates that do not contain any materials that are deleteriously reactive with alkalis in cement does apply. Aggregate must not contain slag or crushed concrete.

2.2.4 Cementitious Materials

For exposed concrete, use one manufacturer and one source for each type of cement, ground slag, fly ash, and pozzolan.

2.2.4.1 Fly Ash

ASTM C618, Class F, except that the maximum allowable loss on ignition must not exceed percent. Class F fly ash for use in mitigating Alkali-Silica Reactivity must have a Calcium Oxide (CaO) content of less than 8 percent and a total equivalent alkali content less than 1.5 percent.

Add with cement. Fly ash content must be a minimum of 15 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, provide the maximum amount of fly ash permittable that meets the code requirements for cement content. Report the chemical analysis of the fly ash in accordance with ASTM C311/C311M. Evaluate and classify fly ash in accordance with ASTM D5759.

2.2.4.2 Portland Cement

Provide cement that conforms to ASTM C150/C150M, Type I II, with tri-calcium aluminates (C3A) content less than 10 percent and a maximum cement-alkali content of 0.80 percent Na2Oe (sodium oxide) equivalent. Use one brand and type of cement for formed concrete having exposed-to-view finished surfaces.

2.2.5 Admixtures

ASTM C260/C260M for air-entraining admixtures. Other admixtures:

ASTM C494/C494M.

2.2.6 Water

Water must comply with the requirements of ASTM C1602/C1602M. Minimize the amount of water in the mix. Improve workability by adjusting the grading rather than by adding water. Water must be potable; free from injurious amounts of oils, acids, alkalis, salts, organic materials, or other substances deleterious to concrete. Submit test report showing water complies with ASTM C1602/C1602M.

2.2.7 Reinforcement

All exposed steel must be phosphate treated, primed, and coated to prevent rust.

2.2.7.1 Reinforcing Bars

ACI 301 unless otherwise specified. ASTM A615/A615M, Grade 60.

SECTION 03 45 00 Page 11

2.2.7.2 Welded Wire Reinforcement

ASTM A1064/A1064M.

2.2.7.3 Supports for Concrete Reinforcement

Include bolsters, chairs, spacers, and other devices necessary for proper spacing, supporting, and fastening in place in accordance with PCI MNL-117.

2.2.8 Tie Wire

Tie wire must be soft monel or 18-8 stainless steel.

2.2.9 Plates, Angles, Anchors and Embedment

ASTM A36/A36M, ferrous metal plate connectors for attachment to the structural framing using manufacturer standard construction procedures.

Headed studs will use 60,000 psi steel with construction conforming to AWS D1.1/D1.1M, Type B. Deformed bar anchors must conform to ASTM A1064/A1064M. Coat steel items, other than stainless, with a rust-inhibiting paint or provide hot-dip galvanized after fabrication in accordance with ASTM A153/A153M.

Furnish and install anchors, inserts, lifting devices, and other accessories which are to be embedded in the precast units in accordance with the approved detail drawings. Embedded items must be accurately positioned in their designed location, and have sufficient anchorage and embedment to satisfy design requirements.

2.2.10 Form Release Agent

Release agent must be manufacturer's standard non-staining type.

2.2.11 Grout

Packaged, nonmetallic, noncorrosive, nonstaining grout containing selected silica sands, portland cement, shrinkage-compensating agents, plasticizing and water-reducing agents, complying with ASTM C1107/C1107M, Grade A for drypack and Grades B and C for flowable grout and of consistency suitable for application within a 30-minute working time. Water-soluble chloride ion content less than 0.06 percent by weight of cement when tested according to ASTM C1218/C1218M.

2.3 CAST-IN EMBEDDED ITEMS AND CONNECTORS

2.3.1 Inserts

2.3.1.1 Threaded-Type Concrete Inserts

ASTM A47/A47M, Grade 32510 or 35018, or may be medium strength cast steel conforming to ASTM A27/A27M, Grade U-60-30. Provide galvanized ferrous casting having enlarged base with two nailing lugs minimum length less than the thickness of panel less 3/4 inch, and internally threaded to receive 3/4 inch diameter machine bolt. Ferrous castings must be ferritic malleable iron. Provide inserts hot-dip galvanized after fabrication in accordance with ASTM A153/A153M.

SECTION 03 45 00 Page 12

2.3.1.2 Wedge-Type Concrete Inserts

Provide galvanized, box-type ferrous castings with integral anchor loop at back of box to accept 3/4 inch diameter bolts having special wedge-shaped head. Provide ferrous castings ASTM A47/A47M, Grade 32510 or 35018, ferritic malleable iron or ASTM A27/A27M, Grade U-60-30, medium-strength cast steel. Provide inserts hot-dip galvanized after fabrication in accordance with ASTM A153/A153M.

2.3.1.3 Slotted-Type Concrete Inserts

Provide pressed steel plate, welded construction, box type with slot to receive 3/4 inch diameter square head bolt, and provide lateral adjustment of bolt. Length of insert body, less anchorage lugs, must be 4 1/2 inches minimum. Provide insert with knockout cover. Steel plate must be 1/8 inch minimum thickness, ASTM A283/A283M, Grade C. Provide inserts hot-dip galvanized after fabrication in accordance with ASTM A153/A153M.

2.3.1.4 Flashing Reglets

Reglets must be sheet metal open-type with continuous groove not less than 1-1/8 inches deep by 3/16-inch wide at opening and sloped upward, designed to anchor snap-lock counter flashing.

Metal must be minimum 0.011-inch thick conforming to ASTM A666, Type 302 or 304, No. 1 finish, soft temper.

2.3.2 Connection Devices

2.3.2.1 Clip Angles

ASTM A36/A36M steel, galvanized after fabrication in accordance with

ASTM A153/A153M.

2.3.2.2 Ferrous Casting Clamps

ASTM A47/A47M, Grade 32510 or Grade 35018 malleable iron or cast steel, or ASTM A27/A27M, Grade 60-30, cast steel casting, hot-dip galvanized in accordance with ASTM A153/A153M.

2.3.2.3 Threaded Fasteners

Provide galvanized machine bolts, washers and, when required, nuts.

a. Bolts: ASTM A449, 3/4 inch diameter machine bolts with hexagon head.

b. Washers: ASME B18.21.1, medium or heavy lock-spring washers.

c. Nuts: ASTM A563, Grade C, heavy, hexagon-type nuts.

d. Square Nuts: ASTM A563, Grade A, plain, square-type nuts where required for slotted-type concrete inserts.

2.4 PRECAST ELEMENT FABRICATION

2.4.1 Formwork and Fabrication Tolerances

Provide forms and form-facing materials of wood, metal, plastic, or other

SECTION 03 45 00 Page 13 approved material to produce concrete having the specified finish.

Construct forms mortar-tight and of sufficient strength to withstand all pressures due to concrete placing operations and temperature changes.

Brace and stiffen against deformation. Provide form liners where required to produce indicated finish. Provide dimensional tolerances per PCI MNL-117.

2.4.2 Reinforcement

ACI 301. Place reinforcing bars and welded wire reinforcement. Secure in position with tie wires, bar supports, and spacers.

2.4.3 Preparation for Placing Concrete

Remove hardened concrete, excess form parting compound, standing water, ice, snow, or other deleterious substances from form interiors and reinforcement before concrete placement. Secure reinforcement and embedded items.

2.4.4 Concrete Mixing and Conveying

2.4.4.1 Batch Plant, Mixer, Mixing, and Measuring of Materials

ASTM C94/C94M.

2.4.4.2 Conveying

Prevent segregation and loss of materials.

2.4.5 Concrete Placing

ACI 304R. Deposit concrete in the forms continuously or in layers of such thickness that no concrete will be placed on concrete which has hardened sufficiently to cause formation of seams or planes of weakness within the precast concrete units. Place concrete at a constant temperature of between 50 and 90 degrees F throughout fabrication of each unit. Make temperature of forms or molds the same as or close to the concrete temperature. For hot or cold weather, use methods recommended by ACI 305R and ACI 306.1.

Vibrate and consolidate concrete to prevent segregation and to produce a high-density concrete free of honeycomb and rock pockets. When specified, the exposed-to-view facing mixture is required to be a minimum thickness of 3/4 inches. Place backing mixture before facing mixture attains initial set.

2.4.6 Identification Markings

Permanently mark each precast unit to indicate pick-up points, location, orientation in the building, and date of casting. Identification markings need to correlate with approved detail drawings. Do not locate in exposed-to-view finished surfaces.

2.4.7 Finishing

2.4.7.1 Unformed Concealed Surfaces (Standard Smooth Finish)

Provide a trowel finish. Level surface with a straightedge, and strike off. After surface water has disappeared, float and trowel surface.

Provide smooth finished surface, free of trowel marks, and uniform in texture and appearance.

SECTION 03 45 00 Page 14

2.4.7.2 Smooth, Exposed-to-View Surfaces

Provide a standard smooth finish to all exposed-to-view surfaces of panels, unless otherwise indicated. Provide a concrete surface having the texture imparted by a steel form or other approved smooth surfaces form-facing material.

2.4.7.3 Other Surfaces

Surfaces of precast units not exposed to view or not otherwise indicated to be finished are to be finished in accordance with ACI 301 for a Surface Finish of 1.0.

2.4.8 Curing

Provide moist or steam curing or curing compound. Do not remove precast units from forms; prevent moisture loss and maintain 50 degrees F minimum for at least 24 hours after finishing. Maintain precast units in a surface damp condition at 50 degrees F minimum until concrete has attained 75 percent minimum of the design compressive strength. Do not use steam curing with wood forms.

2.4.9 Repair of Surface Defects

Cut out defective areas to solid concrete, with edges of cuts perpendicular to the surface of the concrete, and clean thoroughly. Dampen area to be patched and brush-coat with nonshrink grout or bonding agent. Patch the surface in accordance with procedures previously submitted by the Contractor and approved by the Contracting Officer. Where exposed to view, the patches, when dry, needs to be indistinguishable from the surrounding surfaces.

2.4.9.1 Smooth, Concealed Surfaces

Acceptable defective area will be limited to holes left by rods and other temporary inserts, and to honeycomb or rock pockets of 1/4 inch diameter maximum. Remove fins and other projections on the surfaces.

2.4.9.2 Exposed-to-View Surfaces

The combined area of acceptable defective areas must not exceed 0.2 percent of the exposed-to-view surface area and will be limited to holes of 1/4 inch diameter maximum.

2.4.10 Stripping

Do not remove precast concrete units from forms until units develop sufficient strength to safely strip the formwork and to remove the precast concrete units from the forms to prevent damage to the units from overstress or chipping.

2.4.11 Built-In Anchorage Devices

Accurately position and securely anchor all anchorage devices. Openings in anchorage devices must be filled temporarily to prevent entry of concrete.

2.4.12 Lifting Devices

Lifting devices must be provided, and designed for a safety factor of 4, SECTION 03 45 00 Page 15 which includes 100 percent impact. Do not use brittle material.

2.4.13 Finishing for Formed Surfaces

Upon removal of forms, repair and patch defective areas. Where the finished surface will be exposed to view, the combined area of defective areas must not exceed 0.2 percent of the surface and will be limited to honeycomb or rock pockets not deep enough to expose the reinforcement.

Where the finished surface will be concealed by other construction, defective areas are limited to holes left by the rods and other temporary inserts and honeycomb or rock pockets not deep enough to expose the reinforcement. Defective areas must be cut out to solid concrete, cleaned, and patched with grout. Where concrete surface will be exposed to view, the patches, when dry, must be indistinguishable from the surrounding surfaces.

Match the finish of the approved sample and existing panels.

2.5 BEARING PADS

Submit product data for all bearing pads being used, as recommended by recast fabricator application.

2.5.1 Elastomeric

AASHTO M 251, for plain neoprene bearings.

2.5.2 Random-Oriented, Fiber-Reinforced Elastomeric Pads

Preformed, randomly oriented synthetic fibers set in elastomer. Surface hardness of 70 to 90 Shore A durometer according to ASTM D2240. Capable of supporting a compressive stress of 3000 psi with no cracking, splitting or delaminating in the internal portion of the pad.

2.5.3 Cotton-Duck-Fabric-Reinforced Elastomeric Pads

Preformed, horizontally layered cotton-duck fabric bonded to an elastomer.

Surface hardness of 80 to 100 Shore A durometer according to ASTM D2240.

Conforming to Division II, Section 18.10.2 of AASHTO LRFD Bridge Design Specifications or Military Specification MIL-C-882E.

2.5.4 Frictionless Pads

Polytetrafluoroethylene (PTFE), glass-fiber reinforced, bonded to stainless or mild-steel plates, or random-oriented, fiber-reinforced elastomeric pads, of type required for in-service stress.

2.5.5 Sub Title

Multimonomer, nonleaching, plastic strip capable of supporting loads with no visible overall expansion.

PART 3 EXECUTION

3.1 PREPARATION

Deliver anchorage devices to the site in time to be installed before the start of concrete placing or during steel erection. Contractor must provide setting drawings, instructions, and directions for the installation

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3.2 EXAMINATION

Do not begin installation until supporting structures have been properly prepared.

Verify that all parts of the supporting structure are complete and ready to receive the precast units and that site conditions are conducive to proper installation.

If support structure is the responsibility of another installer, notify Contracting Officer of unsatisfactory preparation before proceeding.

3.3 INSTALLATION

Install precast concrete units and accessories in accordance with approve detail drawings and descriptive data, and as specified below.

3.3.1 Building Framing System

Provide supporting members, including anchorage items attached to or embedded in building structural elements, prior to placement of precast units.

3.3.2 Concrete Strength at Time of Precast Unit Installation

Do not install precast units until concrete has attained the minimum laboratory compressive strength at 28 calendar days specified.

Do not install precast units before 28 calendar days from the date of casting unless approval has been obtained to make one compressive strength test, ASTM C39/C39M, and one flexural strength test using simple beam with third-point loading, ASTM C78/C78M, on field cured concrete test specimens, ASTM C31/C31M, for each individual precast unit to determine the strength of the concrete.

3.3.3 Erection

rect precast units in accordance with the detail drawings and without damage to other units or to adjacent members. Set units true to alignment and level, with joints properly spaced and aligned both vertically and horizontally. Erection tolerances must be in accordance with the requirements of PCI MNL-117 and PCI MNL-122. As units are being erected, shims and wedges will be placed as required to maintain correct alignment.

After final attachment, grout precast units as shown. After erection, clean and touch-up welds and abraded surfaces of steel with a zinc-rich paint. Welds must be made by a certified welder in accordance with the manufacturer's erection drawings. Finish pickup points, boxouts, inserts, and similar items to match adjacent areas after erection. Erection of precast units must be supervised and performed by workmen skilled in this type of work. Welding and the qualifications of welders must be in accordance with AWS D1.1/D1.1M.

3.3.4 Erection Tolerances

Erect architectural precast concrete units level, plumb, square and in alignment without exceeding the noncumulative erection tolerances of PCI MNL-117, Appendix I.

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3.3.5 Joints

Joint widths between precast units will be as specified unless otherwise indicated.

3.3.5.1 Joint Sealing

Joint sealing will be as specified in Section 07 92 00 JOINT SEALANTS.

3.3.6 Protection

Protect exposed-to-view facing from staining and other damage from subsequent operations. Do not allow laitance to penetrate, stain, or harden on exposed surfaces.

3.4 DEFECTIVE WORK

Repair precast concrete units damaged during erection as soon after occurrence as possible or replaced, as directed, using approved procedures. All repairs to precast concrete units must match the adjacent surfaces in color and texture, as approved. Unless otherwise approved, repair procedures will conform to PCI MNL-117.

3.5 JOINTS AND GASKETS

Joints between precast units must be the width indicated and within limits of installation tolerances.

Install gaskets in joints as indicated, continuous throughout the joint length, and compressed at least 25 percent by volume.

3.6 INSPECTION AND ACCEPTANCE PROVISIONS

3.6.1 Dimensional Tolerances

Precast units having dimensions outside the limits for fabrication tolerances will be rejected.

3.6.2 Surface Finish Requirements

Precast units will be rejected for the following surface finish deficiencies:

Exposed-to-view surfaces that do not match the color, aggregate size and distribution, and texture of the approved sample

Exposed-to-view surfaces that contain defects that affect the appearance of the finish, such as cracks, spalls, honeycomb, rock pockets, or stains and discoloration of aggregate or matrix that cannot be removed by cleaning

Concealed surfaces that contain cracks in excess of 0.01 inch wide, cracks that penetrate to the reinforcement regardless of width, honeycomb, rock pockets, and spalls except minor breakage at corners and edges

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3.6.3 Strength of Precast Units

Strength of precast concrete units will be considered potentially deficient if the units fail to comply with the requirements that control the strength of the units, including the following conditions:

Failure to meet compressive strength tests

Reinforcement not conforming to the requirements specified

Concrete curing and protection of precast units against extremes of temperature during curing not conforming to the requirements specified

Precast units damaged during handling and erection

3.6.4 Testing Precast Units for Strength

When there is evidence that the strength of precast concrete units does not meet specification requirements, cores drilled from hardened concrete for compressive strength determination must be made in accordance with ASTM C42/C42M and as follows:

Take at least three representative cores from the precast-concrete units that are considered potentially deficient.

Test cores with the saturated surface dry.

Strength of cores will be considered satisfactory if their average is equal to or greater than 90 percent of the 28-day design compressive strength of 6 by 12 inch cylinders.

Submit test reports on the same day that tests are made. Reports must contain the project name and number, date, name of contractor, name of precast concrete wall units manufacturer, name of concrete-testing service, identification letter and number of units represented by core tests, nominal maximum size of aggregate, design compressive strength of concrete at 28 calendar days, compressive breaking strength and type of break, length of core test specimen before capping, compressive strength after correcting for length diameter ratio, direction of application of the load on the core test specimen with respect to the horizontal plane of the concrete as placed, and the moisture condition of the core test specimen at time of testing.

If the results of the core tests are unsatisfactory or if core tests are impractical to obtain, a static load tests of a precast unit will be evaluated in accordance with ACI 318.

Replace precast units used for core tests or static load tests with units that meet the requirements of this section.

3.7 SAMPLING AND TESTING

3.7.1 Rejection

Precast units in place may be rejected for any one of the following product defects or installation deficiencies remaining after repairs and cleaning have been accomplished. "Visible" means visible to a person with normal eyesight when viewed from a distance of 20 feet in broad daylight.

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a. Nonconformance to specified tolerances.

b. Air voids (bugholes or blowholes) larger than 3/8 inch diameter.

c. Visible casting lines.

d. Visible from joints.

e. Visible irregularities.

f. Visible stains on precast unit surfaces.

g. Visible differences between precast unit and approved sample.

h. Visible non-uniformity of textures or color.

i. Visible areas of backup concrete bleeding through the facing concrete.

j. Visible foreign material embedded in the face.

k. Visible repairs.

l. Visible reinforcement shadow lines.

m. Visible cracks.

n. Precast units that are damaged during construction operations.

3.7.2 Field Quality Control

Perform field inspection of precast unit connections. Notify the Contracting Officer in writing of defective welds, bolts, nuts and washers within 7 working days of the date of inspection. All defective connections or welds are to be removed and re-welded or repaired as required by the Contracting Officer.

3.7.2.1 Welded Connection Visual Inspection

AWS D1.1/D1.1M, furnish the services of AWS-certified welding inspector for erection inspections. Welding inspector must visually inspect all welds and identify all defective welds.

3.8 CLEANING

Clean exposed-to-view surfaces of precast units thoroughly with detergent and water; use a brush to remove foreign matter. Remove stains that remain after washing in accordance with recommendations of the precast manufacturer. Surfaces must be clean and uniform in color. Include precast concrete wall panel manufacturer's written recommendations for installation and cleaning.

-- End of Section --

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