SPECIFICATIONS_-_W912DW19B0008_-_2_of_2.pdf

FY19 Alki Coastal Erosion Control 18026 Seattle, WA W912DW19B0008

3.7 CLEANING

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SECTION 03 45 00 Page 3

SECTION 03 45 00

PRECAST 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 CONCRETE INSTITUTE (ACI)

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

ACI 201.2R (2016) Guide to Durable Concrete

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

ACI 211.2 (1998; R 2004) Standard Practice for Selecting Proportions for Structural Lightweight 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 364.3R (2009) Guide for Cementitious Repair Material Data Sheet

ACI SP-66 (2004) ACI Detailing Manual

AMERICAN WELDING SOCIETY (AWS)

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

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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 A1035/A1035M (2016b) Standard Specification for Deformed and Plain, Low-carbon, Chromium, Steel Bars for Concrete Reinforcement

ASTM A1055/A1055M (2010; E 2011) Standard Specification for Zinc and Epoxy Dual Coated Steel Reinforcing Bars

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 A276/A276M (2017) Standard Specification for Stainless Steel Bars and Shapes

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

ASTM A416/A416M (2017a) Standard Specification for Low-Relaxation, Seven-Wire for Prestressed Concrete

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 A706/A706M (2016) Standard Specification for Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement

ASTM A767/A767M (2016) Standard Specification for

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Zinc-Coated (Galvanized) Steel Bars for Concrete Reinforcement

ASTM A775/A775M (2017) Standard Specification for Epoxy-Coated Steel Reinforcing Bars

ASTM A882/A882M (2004a; R 2010) Standard Specification for Filled Epoxy-Coated Seven-Wire Prestressing Steel Strand

ASTM A886/A886M (2017) Standard Specification for Steel Strand, Indented, Seven-Wire Stress-Relieved for Prestressed Concrete

ASTM A934/A934M (2016) Standard Specification for Epoxy-Coated Prefabricated Steel Reinforcing Bars

ASTM A955/A955M (2018) Standard Specification for Deformed and Plain Stainless-Steel Bars for Concrete Reinforcement

ASTM C1077 (2017) Standard Practice for Laboratories Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Laboratory Evaluation

ASTM C1202 (2017a) Standard Test Method for Electrical Indication of Concrete's Ability to Resist Chloride Ion Penetration

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

ASTM C1064/C1064M (2017) Standard Test Method for Temperature of Freshly Mixed Hydraulic-Cement Concrete

ASTM C1231/C1231M (2014) Standard Practice for Use of Unbonded Caps in Determination of Compressive Strength of Hardened Concrete Cylinders

ASTM C1240 (2014) Standard Specification for Silica Fume Used in Cementitious Mixtures

ASTM C138/C138M (2017a) Standard Test Method for Density (Unit Weight), Yield, and Air Content (Gravimetric) of Concrete

ASTM C1582/C 1582M-11 Standard Specification for Admixtures to Inhibit Chloride-Induced Corrosion of Reinforcing Steel in Concrete

ASTM C1585 (2013) Standard Test Method for Measurement of Rate of Absorption of Water by Hydraulic-Cement Concretes

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ASTM C1610/C1610M (2017) Standard Test Method for Static Segregation of Self-Consolidating Concrete Using Column Technique

ASTM C1611/C1611M (2014) Standard Test Method for Slump Flow of Self-Consolidating Concrete

ASTM C1621/C1621M (2017) Standard Test Method for Passing Ability of Self-Consolidating Concrete by J-Ring

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

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

ASTM C157/C157M (2017) Standard Test Method for Length Change of Hardened Hydraulic-Cement Mortar and Concrete

ASTM C192/C192M (2018) Standard Practice for Making and Curing Concrete Test Specimens in the Laboratory

ASTM C1152/C1152M (2004; E 2012; R 2012) Standard Test Method for Acid-Soluble Chloride in Mortar and Concrete

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

ASTM C185 (2015) Standard Test Method for Air Content of Hydraulic Cement Mortar

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 (2018) 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

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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 C469/C469M (2014) Static Modulus of Elasticity and Poisson's Ratio of Concrete in Compression

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

ASTM C496/C496M (2017) Standard Test Method for Splitting Tensile Strength of Cylindrical Concrete Specimens

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

ASTM C642 (2013) Density, Absorption, and Voids in Hardened Concrete

ASTM C666/C666M (2015) Resistance of Concrete to Rapid Freezing and Thawing

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 C989/C989M (2017) Standard Specification for Slag Cement for Use in Concrete and Mortars

ASTM D1056 (2014) Standard Specification for Flexible Cellular Materials - Sponge or Expanded Rubber

ASTM D1149 (2007; R 2012) Standard Test Method for Rubber Deterioration - Surface Ozone Cracking in a Chamber

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

ASTM D635 (2014) Standard Test Method for Rate of Burning and/or Extent and Time of Burning of Self-Supporting Plastics in a Horizontal Position

ASTM D746 (2014) Standard Test Method for Brittleness Temperature of Plastics and Elastomers by Impact

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PRECAST/PRESTRESSED CONCRETE INSTITUTE (PCI)

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

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

U.S. ARMY CORPS OF ENGINEERS (USACE)

U.S. NAVAL FACILITIES ENGINEERING COMMAND (NAVFAC)

TR-NAVFAC ESC-CI-1215 (2012) Navy User's Guide for Quality Assurance of New Concrete Construction

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. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Pre-Installation Meeting

Concrete Qualification Program; G

SD-02 Shop Drawings

Precast Drawings; G

SD-03 Product Data

Cast-In Embedded Items And Connectors; G

Connection Devices and Lifting Eye; G

Admixtures

Gasket

Durability Modeling Report; G

Concrete Mixture Proportions; G

SD-04 Samples

Concrete Wall Panel Surface Finish; G

Full Size Sample Wall Panel

SD-05 Design Data

Contractor-Furnished Mix Design; G

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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

Fresh Concrete Properties

Hardened Concrete Properties

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; S

Recycled Content for Ground Iron Blast-Furnace Slag; S

Recycled Content for Silica Fume; S

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 for wall panels or laggings.

The manufacturer needs to have been regularly and continuously engaged in

SECTION 03 45 00 Page 10 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. The connection devices and lifting eye shall be the contractor responsibility

1.5 Concrete Proportion

Base the selection of proportions for concrete on the methodology presented in ACI 211.1 for normal weight concrete and ACI 211.2 for lightweight 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.

1.6 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.

Precast units must be inspected by the QC representative prior to being transported to the job site. 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 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.

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1.9 ERECTOR CERTIFICATION

Erector with erecting organization and all erecting crews certified and designated by PCI's Certificate of Compliance to erect Category S2 (Complex Structural Systems) for 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

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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

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(facing or 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.

e. Location of embedded brick work including joint locations, joint widths, brick coursing, brick coursing alignment across panel joints and reveal and false-joint locations and dimensions.

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.

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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.

1.14 CONCRETE DURABILITY

1.14.1 Concrete Mixture Proportions

At least 60 days prior to concrete placement, submit concrete mixture proportions, ingredient material certificates and test data, and trial batch test data for each class of concrete proposed for use on the project. Submittal shall clearly indicate where each mixture will be used when more than one mixture design is submitted. Obtain approval from Contracting Officer prior to placement. The contractor is to propose a design mix for a 75 years life of wall

1.14.2 Concrete Design Requirements

Proportion concrete mixtures to meet the requirements listed in Table 1 in accordance with the procedures outlined in ACI 201.2R and ACI 211.1 .

The mixture proportions for concrete shall be developed by the Contractor to produce the required compressive strength (f'cr), drying shrinkage, and constructability for mixtures that have the potential to accomplish a structure with the design service life.

Table 1 - Concrete Design Requirements

Prescriptive requirements Minimum Maximum

ASTM C666/C666M Method A Durability Factor at 300 cycles 90 --

Concrete ASTM C157/C157M Drying Shrinkage percent, as modified per ACI 364.3R at 28 days except for high volume fly ash (HVFA) at 56 days.

-- 0.05 percent

Initial acid-soluble chloride content in cast-in-place concrete per ASTM C1152/C1152M, percent/cement

-- 0.10

Initial acid-soluble chloride content in prestressed concrete determined following ASTM C1152/C1152M , percent/cement

-- 0.06

1.14.3 Concrete Mixture Qualifications

1.14.3.1 Previously Approved Concrete Mixtures

For identical concrete mixtures previously approved for use within the past 12 months, the previous mixture qualification submittal may be re-submitted without further trial batch testing if accompanied by:

a. A copy of the prior approvals indicating the project name, project number, and location.

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b. Ingredient material test data conducted within 6 months of the submittal date.

c. Copies of the previously approved trial batch test data, including the volume of permeable voids (phi), ionic diffusion coefficient (D oh), 50 percent saturation water content (S50 percent), permeability (K) and the specified effective diffusion coefficient (D spec ).

d. A log containing at least fifteen sequential test results with the calculated mean and standard deviation of the production concrete for air content, compressive strength, volume of permeable voids (phi), ionic diffusion coefficient (D oh)and the effective diffusion coefficient (D eff ).

If the Contractor changes material type, class, sources, or suppliers;

chemical composition; and/or mix proportions, provide a written opinion of the significance of the change(s). The change(s) may require additional testing at the discretion of the Contracting Officer in consultation with the agency's Subject Matter Expert in concrete materials.

1.14.3.2 New Concrete Mixtures

a. Submit complete ingredient material test data, including applicable reference specifications. Submit additional data regarding concrete aggregates if the source of aggregate changes.

b. Submit copies of test reports by independent test lab conforming to ASTM C1077 showing that the mixture has been successfully tested to produce concrete with the properties specified and that mixture will be suitable for the job conditions as described. Test reports shall be submitted along with the concrete mixture proportions. Obtain approval before concrete placement.

c. Test a minimum of three trial batches of production concrete to establish the tolerance limits and the specified effective diffusion coefficient (D spec ). If batching facilities are located such that the haul-time will exceed 30 minutes, a simulated haul time shall be included in the trial batch.

If the concrete mixture for construction is proposed to contain corrosion inhibitors then laboratory testing shall be accomplished and tested for transport properties with and without the corrosion inhibitor because they are known to distort the results of the service life modeling when compared to mixtures without corrosion inhibitors.

(1) Test and report fresh concrete property tests of each trial batch as follows:

(a) Slump in accordance with ASTM C143/C143M.

(b) Air content in accordance with ASTM C231/C231M or

ASTM C173/C173M.

(c) Unit weight in accordance with ASTM C138/C138M.

(d) Temperature in accordance with ASTM C1064/C1064M .

(2) Cast specimens, test, and report hardened concrete property tests of each trial batch as follows:

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(a) Compressive strength at 3, 7, 28, 56 and 90 days in accordance with ASTM C39/C39M. Use of unbonded caps in accordance with ASTM C1231/C1231M is permitted.

(b) Drying shrinkage may be determined from one batch.

(c) Tensile strength (if required) may be determined using specimens cast from one batch.

(d) Freeze-thaw durability factor (if required) shall be determined as the mean of six test specimens comprised of at least two specimens cast from each batch.

(e) Initial chloride ion content may be determined from one batch.

(3) Moist cure concrete intended for cast-in-place applications in accordance with the standard moist curing conditions described in ASTM C192/C192M unless otherwise specified. Moist cure concrete intended for precast applications in the manner proposed for use on the project.

(4) Cast twelve 4 by 8 inch cylinders, test and report ion transport properties as follows:

(a) Determine the porosity at 28-days and 90-days of standard moist curing. Calculate the mean porosity and standard deviation at each test age.

(b) Determine the D oh at 28-days and 90-days of standard moist curing. Calculate the mean D oh and standard deviation at each test age.

(c) Determine the MTC at 28-days of standard moist curing.

(d) Calculate the aging coefficient as the ratio of the mean 90-day, or longer, D oh to the mean 28-day standard moist cure D oh.

(e) Retain unused specimens in storage. These specimens may be tested later to refine the actual aging factor. This is advisable in the event that any production concrete falls short of the service life as it will provide evidence to better predict the service life.

(5) Special handling will be necessary for shipments of transport property specimens. These cylinders shall be wrapped completely with slightly damp paper towels with distilled water only. The wrapped cylinders shall be placed in either a vacuum package or double layers of sealed plastic bags. Package the test cylinders to prevent damage and ship to an approved testing laboratory.

d. Submit a Durability Modeling Report prepared by the STADIUM ® certified laboratory that addresses the service life of the proposed concrete system for each concrete mixture. As a minimum, the report shall contain:

(1) The concrete mixture proportions.

(2) The mean, standard deviation, and characteristic values for the

SECTION 03 45 00 Page 17 porosity, the 28-day D oh , the MTC, aging factor determined by testing and the specified effective diffusion coefficient (D spec ).

(3) The concrete cover to reinforcing steel. The cover to all reinforcing bars shall be clearly delineated with allowance for placement tolerances per ACI 117 .

(4) The environmental exposure conditions used for each type of concrete element.

(5) The effective diffusion coefficient (D eff ) that, for given specified exposure conditions and characteristics MTC values, satisfies the minimum required service life of the structural element.

(6) A narrative describing the modeling process including assumptions and recommendations to accomplish the service life using quality concrete and specified cover. In the event that locally available materials cannot be shown to accomplish the service life, prepare a proposal for review by the agency's Subject Matter Expert in Concrete Materials and approval by the Contracting Officer to use alternative sources of materials and/or supplemental corrosion protection methods.

(7) A signed and stamped cover letter certifying compliance with the required average compressive strength (f'cr), drying shrinkage, and constructability for mixtures that have the potential to accomplish a structure with the design service life.

(8) Letter regarding the certificate of completion for the STADIUM ® training and the UFGS Laboratory Certification letter for the accredited laboratory.

e. For concrete mixtures that are proposed to contain corrosion inhibitors, submit 28-day D oh values from at least three batches of the mixture with and without the admixture making appropriate adjustments to maintain constant water to cementitious ratio. The purpose is to establish a correlation with respect to an adjusted value for production D oh.

f. At the option of the Contractor, a revised service life submittal may be provided as a value engineering proposal using refined characteristic porosity and D oh values calculated from production data.

Extensions to corrosion propagation period may be reviewed by the agency's Subject Matter Expert in Concrete Materials and approved by the Contracting Officer based on evidence provided by the Contractor on a case-by-case basis.

1.14.4 Concrete Qualification Program

1.14.4.1 Fresh Concrete Properties

a. Air Content: Concrete that is air entrained shall conform to the air limits specified in ACI 301 for exposure and the aggregate size used and tested in accordance with ASTM C231/C231M. Variations outside the limits specified shall not be reason to reject the concrete in locations not subject to freeze-thaw conditions.

b. Slump: The concrete mixture shall be proportioned to have, at the

SECTION 03 45 00 Page 18 point of deposit, a maximum slump of 4 inches as determined by ASTM C143/C143M when admixtures that affect slump are not used. Where an ASTM C494/C494M, Type F or G admixture is used, the slump after the addition of the admixture shall not exceed 8 inches. Slump tolerances shall comply with the requirements of ACI 117 .

c. Self-Consolidating Concrete: When self-consolidating concrete is proposed for use, the mixture shall be proportioned and tested for qualification using:

(1) ASTM C1611/C1611M slump flow shall not be greater than 24 inches, with visual stability index not greater than one.

(2) ASTM C1621/C1621M Passing ability using the J-ring. Spread within one inch less than the slump flow.

(3) Passing ability using the L-Box between 4 and 8 seconds

(4) ASTM C1610/C1610M , static segregation shall be less than 4.0 percent.

For process control sampling, the slump flow limit as determined by ASTM C1611/C1611M shall be no greater than 24 inches and the visual stability index limit shall be no greater than 1.0.

d. Underwater concrete: When the concrete is intended for placement under water using the tremie technique, the concrete shall be proportioned to be cohesive and flow with minimal out segregation. Viscosity modifying admixtures are permitted for underwater concrete.

Proportioning guidance in ACI 304R shall be considered. Concrete mixtures shall be qualified for tremie placement methods based on a trial placement approved by the Contracting Officer.

1.14.4.2 Hardened Concrete Properties

a. Compressive Strength: The structural engineer shall specify the minimum compressive strength results at 28 days. Determine compressive strength (f'cr) for qualification of concrete mixtures and for quality acceptance testing. A compressive strength test result is defined as the mean of three properly conducted tests on 4 by 8 inch cylinders in accordance with ASTM C39/C39M. Alternatively and for concrete mixtures containing a maximum size aggregate greater than 1 inch, a strength test result shall be defined as the mean of two properly conducted 28-day tests on 6 by 12 inch cylindrical specimens in accordance with ASTM C39/C39M. In addition:

(1) Specified Compressive Strength: For structural concrete elements exposed in a marine environment, the minimum specified 28 day design strength is denoted as (f'c). Strength of concrete containing 50 percent or more fly ash shall be specified at a minimum of 56 days.

(2) Required Average Strength: The concrete shall be proportioned such that the minimum required average compressive strength (f'cr) exceeds the specified design strength (f'c) as per ACI 301.

(3) The average compressive strength may not exceed the specified strength at the same age by more than 20 percent unless approved by the Engineer of Record.

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(4) Strength of any individual concrete placement shall be considered satisfactory if both the following requirements are met:

(a) The arithmetic mean of any three consecutive lot strength tests is between 1.0 and 1.2f'c, and;

(b) No individual strength test result is less than 0.90 f'c.

(5) In the event that a placement is represented by single sampling lot, strength shall be considered satisfactory if either:

(a) The mean of the initial test is between 1.0 and 1.2 f'c, or;

(b) The mean of the initial test and retest is between 1.0 and 1.2 f'c, and neither strength test result is less than 0.90 f'c.

(6) For underwater concrete, cast compressive strength samples by placing concrete in four 5-gallon buckets below water using similar placement as the project. Permanently mark buckets as "3 days, 7 days, 28 days," and "Extra." Include date and station.

Provide specimen sets at every 100 cubic yards of concrete for the first 500 cubic yards, then every 500 cubic yards thereafter with a minimum of one set per day of underwater concrete placement.

(a) Retrieve buckets at specified intervals and extract three cores from each bucket. Conduct compressive strength test in accordance with ASTM C42/C42M.

(b) Strength of underwater concrete shall be satisfactory if the compressive strength result from extracted cores at the age of the specified strength is between 0.85 and 1.2 f'c with no individual strength test result less than 0.75 f'c.

b. Drying Shrinkage: Determine drying shrinkage for qualification of concrete mixtures prior to the fabrication of the Test Section and from samples made during the fabrication of the Test Section (see the subpart entitled "Test Section"). All test results shall not exceed

0.05 percent. A drying shrinkage test result shall be the mean value from three or more individual specimens constituting a test set. If an individual specimen's measurements deviate from the mean value by more than 0.009 percent length change the specimen's measurements shall be discarded and a new average established. Casting more than three specimens for each set is permitted. Test procedures and test specimens shall conform to the following:

Drying shrinkage specimens, typically 3 by 3 by 11.25 inch prisms for 1 inch maximum size aggregate or smaller, shall be fabricated, cured, dried, and measured at 28 days in the manner delineated in ASTM C157/C157M except as modified by ACI 364.3R . Mixtures containing 50 percent or more complementary cementing materials shall meet the shrinkage criteria at 56 days.

c. Tensile strength: Determine splitting-tensile strength of concrete only for qualification of concrete mixtures. Determine and report the splitting-tensile strength result of each class of concrete in accordance with ASTM C496/C496M as the mean of three properly conducted tests at the age specified for f'c and again at 90-days age for information only.

SECTION 03 45 00 Page 20

d. Elastic Modulus: Determine the elastic modulus of concrete only for qualification of concrete mixtures, per ASTM C469/C469M at the age specified for f'c if required by the Engineer of Record. Additional test ages should be specified for mass concrete.

e. Freeze-thaw durability: Determine the freeze-thaw durability factor of concrete for qualification of concrete mixtures, if required by environmental conditions. Determine and report the freeze-thaw durability factor of each class of concrete in accordance with ASTM C666/C666M Method-A. Start testing after 28 days of moist curing. The minimum acceptable durability factor after 300 cycles of rapid freezing and thawing is 90 percent.

f. Water Soluble Chloride Ion Content: Determine the chloride ion content only for qualification of concrete mixtures. Determine water soluble chloride ion content in accordance with ASTM C1218/C1218M . The limits for allowable water-soluble chloride ion concentrations in hardened concrete are listed in Table 3.

Table 3 - Maximum water soluble Chloride Ion Content for Corrosion Protection

Type of Member Maximum water soluble chloride ion in concrete, percent by weight of cement

Prestressed concrete 0.06 percent

Reinforced concrete exposed to chloride in service

0.08 percent

Reinforced concrete that will be dry or protected from moisture in Service

0.15 percent

Other reinforced concrete construction 0.30 percent

g. The use of silica fume is discouraged. Silica fume shall only be used for OCONUS projects where Class F fly ash and GGBF slag are not available, and when approved by the Contracting Officer. If justified by service life modeling the mixture may contain a maximum of 7 percent silica fume by mass. Concrete mixtures containing any percentage of silica fume shall be evaluated at every 100 cubic yards of concrete for the first 500 cubic yards, then every 500 cubic yards thereafter to ensure that the silica fume is properly dispersed in hardened concrete samples. A qualified laboratory shall microscopically examine a sectioned sample and document the results.

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.

h. Ion Transport Properties: Determine ion transport properties of the concrete in accordance with test procedures outlined by SIMCO, maker of STADIUM ® software. Ion Transport properties are required as inputs for service life modeling and include: the volume of permeable voids (porosity); the ion diffusion coefficient (D oh); the moisture transport coefficient (MTC), and an aging factor. A brief description of the test procedures is provided below. See TR-NAVFAC ESC-CI-1215 for

SECTION 03 45 00 Page 21 further details.

(1) Porosity: The volume of permeable voids (porosity) of concrete is determined in accordance with ASTM C642. Porosity is determined for qualification of concrete mixtures and for quality acceptance testing.

(2) Ion Diffusion Coefficient (D oh): This test is a modified version of ASTM C1202 and uses an electrical field to migrate chloride ions through a vacuum saturated concrete specimen for approximately 14 days. The electrical charge flowing through the concrete is related to the diffusion coefficient of ionic species in cementitious materials. A test is defined as the average of two specimens run together and whose results are analyzed together to produce a single D oh value. The service life modeling software uses the cementitious materials proportions and porosity measurements to analyze the electrical measurements and determine the D oh . The D oh is determined for qualification of concrete mixtures and for quality acceptance testing.

(3) Moisture Transport Test: This modified version of the ASTM C1585 test determines the drying rate of pre-saturated cementitious materials by measuring the evaporative mass loss of concrete slices with different thickness exposed to constant temperature and relative humidity environment. The moisture transport coefficient (MTC) is then determined by analyzing the mass loss data using the service life modeling software.

This test is only used for qualification of concrete mixtures, not for production concrete.

(4) Aging factor: The aging factor is a necessary value to estimate the change in diffusion coefficient over time. The aging factor is defined as the ratio of the ultimate D oh to the 28-day D oh per TR-NAVFAC ESC-CI-1215 . Since we cannot wait for two or more years to characterize project concrete, a surrogate aging factor is used in this specification. This surrogate aging factor is calculated as the ratio of 90-day, or longer, D oh to the 28-day D oh. The aging factor is determined only for qualification of concrete mixtures in compliance with TR-NAVFAC ESC-CI-1215 .

1.14.4.3 Reinforcing Steel Corrosion Properties

The corrosion properties of the reinforcing steel used for service life modeling shall be as follows unless otherwise approved by the Contracting Officer after review by the agency's Subject Matter Expert in Concrete Materials:

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Table 4 -Chloride Threshold Level and Corrosion Propagation Time

Description UNS Alloy

EN No. Chloride Threshold (CTH), ppm

Corrosion Propagation Period (Tp) max, years

ASTM A706/A706M (Low alloy carbon steel)

500 15

ASTM A615/A615M (Carbon steel) 500 15

ASTM A416/A416M (carbon steel 7-wire strand)

500 15

ASTM A882/A882M (indented 7-wire strand)*

ASTM A886/A886M (epoxy-filled 7-wire strand)*

ASTM A934/A934M (Purple Epoxy)*

ASTM A775/A775M (Green Epoxy) Not allowed

ASTM A767/A767M (Galvanized Class 1)*

ASTM A1035/A1035M (MMFX2 bars)*

ASTM A1055/A1055M (Z bars)*

ASTM A955/A955M (as applicable) XM Stainless Grades

XM-28 (Nitronic 32) S24100 500 15

XM-29 (Nitronic 33) S24000 500 15

XM-19 (Nitronic 50) S20910 500 15

ASTM A276/A276M

Austenitic Stainless 304L

S30403 1.4307 3000 15

ASTM A276/A276M

Duplex Stainless 2304

S32304 1.4362 4000 15

ASTM A955/A955M

Austenitic Stainless 316L

S31603 1.4404 5000 15

ASTM A955/A955M

Austenitic Stainless 316LN

S31653 1.4429 5000 15

ASTM A276/A276M

Duplex Stainless 2205

S31803 S32205

1.4462 5000 15

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Table 4 -Chloride Threshold Level and Corrosion Propagation Time

Description UNS Alloy

EN No. Chloride Threshold (CTH), ppm

Corrosion Propagation Period (Tp) max, years

*See TR-NAVFAC ESC-CI-1215

** All other reinforcement not listed require approval of agency's Subject Matter Expert in Concrete Materials

1.14.4.4 Supplemental Corrosion Protection

If the available materials in the region of the project cannot practically be made to meet the service life based on testing and service life modeling without the use of supplemental corrosion protection, prepare a recommendation on how to accomplish the service life using imported materials and/or supplemental corrosion protection. With input from the agency's Subject Matter Expert in Concrete Materials, the Contracting Officer shall consider approval of the Contractor's recommendation on a case-by-case basis.

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

SECTION 03 45 00 Page 24 must have a 28-day compressive strength of 5,000 psi. Air content of plastic concrete must be between 4 and 6 percent air by volume. Provide a dosage of air entraining agent which will produce 19 plus-or-minus 3 percent air in a 1 to 4 by weight standard sand mortar in accordance ASTM C185. Add inhibitors to the mix in accordance ASTM C1582/C 1582M-11 .

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:

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 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 Exposed Aggregate

In addition to the above, facing mixture aggregate, and aggregate for homogeneous panels with exposed aggregate finish, will be gravel of size and color to produce exposed surfaces to match the color and texture of the sample on file with the Contracting Officer.

Crush coarse aggregate by a means that will produce material of cubical shape with a minimum of elongated, thin, or partially fractured particles. Material or crushing methods that produce particles classified by petrographic examination as being weak, highly fractured or somewhat friable, or both, in excess of 16 percent of the particles in any whole sample will be rejected. Material for coarse aggregate must be free of substances that change color on oxidation. Obtain material used for the work from the same basic source and stratum. Quarry material to produce a uniformly colored aggregate that does not change color upon weathering.

During quarrying operations, the uniformity of rock face color must be verified by periodically comparing the rock face color to the approved coarse aggregate sample.

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Fine aggregate will be white quartz natural sand or stone screenings, or manufactured sand produced from white quartz. Aggregate must be free of substances that change color on oxidation. Color must conform to the approved sample.

2.2.5 Cementitious Materials

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

2.2.5.1 Fly Ash

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

2.2.5.2 Raw or Calcined Natural Pozzolan

Natural pozzolan must be raw or calcined and conform to ASTM C618, Class N, including the optional requirements for uniformity and effectiveness in controlling Alkali-Silica reaction and must have an ignition loss not exceeding 3 percent. Class N pozzolan for use in mitigating Alkali-Silica Reactivity must have a Calcium Oxide (CaO) content of less than 13 percent and total equivalent alkali content less than 3 percent.

2.2.5.3 Ultra Fine Fly Ash and Ultra Fine Pozzolan

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.

2.2.5.4 Ground Granulated Blast-Furnace Slag

ASTM C989/C989M, Grade 100. Slag content must be a minimum of 25 percent by weight of cementitious material.

2.2.5.5 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

SECTION 03 45 00 Page 26 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 Reducer (HRWR) must be used with silica fume.

2.2.5.6 Portland Cement

Provide cement that conforms to ASTM C150/C150M, Type I, low alkali 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.

2.2.6 Admixtures

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

ASTM C494/C494M. Certify that admixtures are free of chlorides.

2.2.7 Water

Water must comply with the requirements of ASTM C1602/C1602M . Minimize the amount of water in the mix.