A.07.24_Att_Technical_Specifications_(pg_349_update).pdf

SECTION 03 11 13.00 10

STRUCTURAL CONCRETE FORMWORK

04/06

PART 1 GENERAL

1.1 REFERENCES

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

ACI INTERNATIONAL (ACI)

ACI 347 (2004) Guide to Formwork for Concrete

AMERICAN HARDBOARD ASSOCIATION (AHA)

AHA A135.4 (2004) Basic Hardboard

APA - THE ENGINEERED WOOD ASSOCIATION (APA)

APA PS 1 (1995) Voluntary Product Standard for Construction and Industrial Plywood

ASTM INTERNATIONAL (ASTM)

ASTM C 578 (2007) Standard Specification for Rigid, Cellular Polystyrene Thermal Insulation

TURKISH STANDARDS

TS-46 Plywood, General Purpose

TS-500 Building Code Requirements for Reinforced Concrete

TS-3233 Building Code Requirements for Prestressed Concrete

TS-4645 Plywood-Exterior Use

TS-4520 Plywood for Building Purposes

If it will be approved by the Contracting Officer other applicable ASTM, BS, DIN, EN or equal TS-EN publications may also be used for the subject work. Under such circumstances English versions of the publications shall be furnished to the Contracting Officer for his/her review and approval.

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. The following shall be submitted in accordance with the provisions of the contract and Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Formwork ; G

Drawings showing details of formwork, including dimensions of fiber voids, joints, supports, studding and shoring, and sequence of form and shoring removal.

SD-03 Product Data

Design

Design analysis and calculations for form design and methodology used in the design.

Form Materials

Manufacturer's data including literature describing form materials, accessories, and form releasing agents.

Form Releasing Agents

Manufacturer's recommendation on method and rate of application of form releasing agents.

SD-04 Samples

Fiber Voids ; G

One sample unit of fiber voids prior to installation of the voids.

SD-07 Certificates

Fiber Voids

Certificates attesting that fiber voids conform to the specified requirements.

1.3 DESIGN

Formwork shall be designed in accordance with methodology of ACI 347 for anticipated loads, lateral pressures, and stresses. Forms shall be capable of producing a surface which meets the requirements of the class of finish specified in Section 03 31 00.00 10 CAST-IN-PLACE STRUCTURAL CONCRETE. Forms shall be capable of withstanding the pressures resulting from placement and vibration of concrete.

1.4 STORAGE AND HANDLING

Fiber voids shall be stored above ground level in a dry location. Fiber voids shall be kept dry until installed and overlaid with concrete.

PART 2 PRODUCTS

2.1 FORM MATERIALS

2.1.1 Forms For Class A and Class B Finish

Forms for Class A and Class B finished surfaces shall be plywood panels conforming to TS 46 Grade B-B concrete form panels, Class I or II.

Other form materials or liners may be used provided the smoothness and appearance of concrete produced will be equivalent to that produced by the plywood concrete form panels. Forms for round columns shall be the prefabricated seamless type.

2.1.2 Forms For Class C Finish

Forms for Class C finished surfaces shall be shiplap lumber; plywood conforming to APA PS 1 or TS 4520, Grade B-B concrete form panels, Class I or II; tempered concrete form hardboard conforming to AHA A135.4 or applicable European or Turkish Standards ; other approved concrete form material; or steel, except that steel lining on wood sheathing shall not be used. Forms for round columns may have one vertical seam.

2.1.3 Forms For Class D Finish

Forms for Class D finished surfaces, except where concrete is placed against earth, shall be wood or steel or other approved concrete form material.

2.1.4 Form Ties

Form ties shall be factory-fabricated metal ties, shall be of the removable or internal disconnecting or snap-off type, and shall be of a design that will not permit form deflection and will not spall concrete upon removal. Solid backing shall be provided for each tie. Except where removable tie rods are used, ties shall not leave holes in the concrete surface less than 6 mm nor more than 25 mm deep and not more than 25 mm in diameter. Removable tie rods shall be not more than 38 mm in diameter.

2.1.5 Form Releasing Agents

Form releasing agents shall be commercial formulations that will not bond with, stain or adversely affect concrete surfaces. Agents shall not impair subsequent treatment of concrete surfaces depending upon bond or adhesion nor impede the wetting of surfaces to be cured with water or curing compounds.

2.1.6 Fiber Voids

Fiber voids shall be the product of a reputable manufacturer regularly engaged in the commercial production of fiber voids. The voids shall be constructed of double faced, corrugated fiberboard. The corrugated fiberboard shall be fabricated of wet strength or standard kraft paper liners, impregnated with paraffin, and laminated with moisture resistant adhesive, and shall have a board strength of 20 kg/square centimeter.

Voids which are impregnated with paraffin after construction, in lieu of being constructed with paraffin impregnated fiberboard, are acceptable.

Voids shall be designed to support not less than 4900 kg/square meter.

To prevent separation during concrete placement fiber voids shall be assembled with steel or plastic banding at 1.22 m on center maximum, or by adequate stapling or gluing as recommended by the manufacturer.

Fiber voids placed under concrete slabs and that are 200 mm in depth may be heavy duty "waffle box" type, constructed of paraffin impregnated corrugated fiberboard.

2.2 FIBER VOID RETAINERS

2.2.1 Polystyrene Rigid Insulation

Polystyrene rigid insulation shall conform to ASTM C 578, or TS 11989 and TS 825. Size shall be 38 mm 2 cm thick, 60 cm wide and 120 cm in length, unless otherwise indicated or required.

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Formwork

Forms shall be mortar tight, properly aligned and adequately supported to produce concrete surfaces meeting the surface requirements specified in Section 03 31 00.00 10 CAST-IN-PLACE STRUCTURAL CONCRETE and conforming to construction tolerance given in TABLE 1. Where concrete surfaces are to have a Class A or Class B finish, joints in form panels shall be arranged as approved. Where forms for continuous surfaces are placed in successive units, the forms shall fit over the completed surface to obtain accurate alignment of the surface and to prevent leakage of mortar. Forms shall not be reused if there is any evidence of surface wear and tear or defects which would impair the quality of the surface. Surfaces of forms to be reused shall be cleaned of mortar from previous concreting and of all other foreign material before reuse.

Form ties that are to be completely withdrawn shall be coated with a nonstaining bond breaker.

3.1.2 Fiber Voids

Voids shall be placed on a smooth firm dry bed of suitable material, to avoid being displaced vertically, and shall be set tight, with no buckled cartons, in order that horizontal displacement cannot take place. Each section of void shall have its ends sealed by dipping in paraffin, with any additional cutting of voids at the jobsite to be field dipped in the same type of sealer, unless liners and flutes are completely impregnated with paraffin. Prior to placing reinforcement, the entire formed area for slabs shall be covered with a 1.22 x 2.44 m minimum flat sheets of fiber void corrugated fiberboard. Joints shall be sealed with a moisture resistant tape having a minimum width of 75 mm.

If voids are destroyed or damaged and are not capable of supporting the design load, they shall be replaced prior to placing of concrete.

3.1.3 Fiber Void Retainers

Fiber void retainers shall be installed, continuously, on both sides of fiber voids placed under grade beams in order to retain the cavity after the fiber voids biodegrade.

3.2 CHAMFERING

Except as otherwise shown, external corners that will be exposed shall be chamfered, beveled, or rounded by moldings placed in the forms.

3.3 COATING

Forms for Class A and Class B finished surfaces shall be coated with a form releasing agent before the form or reinforcement is placed in final position. The coating shall be used as recommended in the manufacturer's printed or written instructions. Forms for Class C and D finished surfaces may be wet with water in lieu of coating immediately before placing concrete, except that in cold weather with probable freezing temperatures, coating shall be mandatory. Surplus coating on form surfaces and coating on reinforcing steel and construction joints shall be removed before placing concrete.

3.4 REMOVAL OF FORMS

Forms shall be removed preventing injury to the concrete and ensuring the complete safety of the structure. Formwork for columns, walls, side of beams and other parts not supporting the weight of concrete may be removed when the concrete has attained sufficient strength to resist damage from the removal operation but not before at least 24 hours has elapsed since concrete placement. Supporting forms and shores shall not be removed from beams, floors and walls until the structural units are strong enough to carry their own weight and any other construction or natural loads. Supporting forms or shores shall not be removed before the concrete strength has reached 70 percent of design strength, as determined by field cured cylinders or other approved methods. This strength shall be demonstrated by job-cured test specimens, and by a structural analysis considering the proposed loads in relation to these test strengths and the strength of forming and shoring system. The job-cured test specimens for form removal purposes shall be provided in numbers as directed and shall be in addition to those required for concrete quality control. The specimens shall be removed from molds at the age of 24 hours and shall receive, insofar as possible, the same curing and protection as the structures they represent.

TABLE 1

TOLERANCES FOR FORMED SURFACES

1. Variations from the plumb: In any 3 m of length -------- 6 mm

a. In the lines and Maximum for entire length -- 25 mm surfaces of columns, piers, walls and in arises

b. For exposed corner In any 6 m of length -------- 6 mm columns, control-joint grooves, and other Maximum for entire length 13 mm conspicuous lines

2. Variation from the In any 3 m of length ------- 6 mm level or from the In any bay or in any 6 m of grades indicated on length -------------------- 10 mm the drawings:

a. In slab soffits, Maximum for entire length - 20 mm ceilings beam soffits, and in arises,measured before removal of supporting shores

b. In exposed lintels, In any bay or in any 6 m of sills,parapets, length --------------------- 6 mm horizontal grooves, Maximum for entire length - 13 mm and other conspicuous lines

3. Variation of the In any 6 m ---------------- 13 mm linear building Maximum ------------------- 25 mm lines from established position in plan

4. Variation of distance 6 mm per 3 m of distance, but

TABLE 1

TOLERANCES FOR FORMED SURFACES

between walls, columns, not more than 13 mm in any one partitions bay, and not more than 25 mm total variation

5. Variation in the sizes Minus --------------------- 6 mm and locations of Plus --------------------- 13 mm sleeves, floor openings, and wall opening

6. Variation in Minus -------------------- 6 mm cross-sectional Plus -------------------- 13 mm dimensions of columns and beams and in the thickness of slabs and walls

7. Footings:

a. Variation of Minus ------------------- 13 mm dimensions in Plus -------------------- 50 mm plan when formed or plus 75 mm when placed against unformed excavation

b. Misplacement of 2 percent of the footing width eccentricity in the direction of misplacement but not more than --------- 50 mm

c. Reduction in Minus ----------------- 5 percent thickness of specified thickness

8. Variation in steps: Riser ---------------------- 3 mm

a. In a flight of Tread ---------------------- 6 mm stairs

b. In consecutive Riser ---------------------- 2 mm steps Tread ---------------------- 3 mm

-- End of Section --

SECTION 03 11 14.00 10

FORMWORK FOR CONCRETE

04/06

PART 1 GENERAL

1.1 REFERENCES

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

ACI INTERNATIONAL (ACI)

ACI 347 (2004) Guide to Formwork for Concrete

APA - THE ENGINEERED WOOD ASSOCIATION (APA)

APA PS 1 (1995) Voluntary Product Standard for Construction and Industrial Plywood

ASTM INTERNATIONAL (ASTM)

ASTM C 1074 (2004) Standard Practice for Estimating Concrete Strength by the Maturity Method

ASTM C 1077 (2007) Standard Practice for Laboratories Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Laboratory Evaluation

ASTM C 31/C 31M (2006) Standard Practice for Making and Curing Concrete Test Specimens in the Field

ASTM C 39/C 39M (2005e1) Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

TURKISH STANDARDS

TS-46 Plywood, General Purpose

TS-500 Building Code Requirements for Reinforced Concrete

TS-3233 Building Code Requirements for Prestressed Concrete

TS-4645 Plywood-Exterior Use

TS-4520 Plywood for Building Purposes

If it will be approved by the Contracting Officer other applicable ASTM, BS, DIN, EN or equal TS-EN publications may also be used for the subject work. Under such circumstances English versions of the publications shall be furnished to the Contracting Officer for his/her review and approval.

1.2 DESIGN REQUIREMENTS

The design, engineering, and construction of the formwork shall be the responsibility of the Contractor. The formwork shall be designed for anticipated live and dead loads and shall comply with the tolerances specified in Section 03 31 01.00 10 CAST-IN-PLACE STRUCTURAL CONCRETE However, for surfaces with an ACI Class A surface designation, the allowable deflection for facing material between studs, for studs between walers and walers between bracing shall be limited to 0.0025 times the span. The formwork shall be designed as a complete system with consideration given to the effects of cementitious materials and mixture additives such as fly ash, cement type, plasticizers, accelerators, retarders, air entrainment, and others. The adequacy of formwork design and construction shall be monitored prior to and during concrete placement as part of the Contractor's approved Quality Control Plan.

1.3 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with the provisions of the contract and Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Shop Drawings

Drawings and design computations for all formwork required shall be submitted at least 15 days either before fabrication on site or before delivery of prefabricated forms. If reshoring is permitted, the method, including location, order, and time of erection and removal shall also be submitted for review.

SD-03 Product Data

Materials

Manufacturer's literature shall be submitted for plywood, concrete form hard board, form accessories, prefabricated forms, and form coating , and form-lining materials .

SD-04 Samples

Sample Panels; G

After shop drawings have been reviewed, sample panels for Class A finish with applied architectural treatment shall be built on the project site where directed.

SD-06 Test Reports

Inspection

The Contractor shall submit field inspection reports for concrete forms and embedded items.

Formwork Not Supporting Weight of Concrete ; G .

If forms are to be removed in less than 24 hours on formwork not supporting the weight of concrete, the evaluation and results of the control cylinder tests[ or maturity instrumentation] shall be submitted to and approved before the forms are removed.

1.4 SHOP DRAWINGS

The shop drawings and data submitted shall include the type, size, quantity, and strength of all materials of which the forms are made, the plan for jointing of facing panels, details affecting the appearance, and the assumed design values and loading conditions.

1.5 SAMPLE PANELS

Panels shall be of sufficient size to contain joints and shall be not less than 2 meters long and 1.5 meters wide. The panels shall be of typical wall thickness and constructed containing the full allocation of reinforcing steel that will be used in the structure, with the forming system that duplicates in every detail the one that will be used in construction of the structure. The same concrete mixture proportion and materials, the same placement techniques and equipment, and the same finishing techniques and timing shall be used that are planned for the structure. Construction of Class A finish will not be permitted until sample panels have been approved. Sample panels shall be protected from construction operations in a manner to protect approved finish, and are not to be removed until all Class A finish concrete has been accepted.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Forms and Form Liners

Forms and form liners shall be fabricated with facing materials that will produce a finish meeting the specified irregularities in formed surface requirements as defined in ACI 347. Forms and form liners shall be fabricated with facing materials as specified below.

2.1.1.1 Class "A" Finish

This class of finish shall apply to exposed concrete surfaces. The form facing material shall be composed of new, well-matched tongue-and-groove lumber or new plywood panels conforming to APA PS 1 or TS 4645, Grade B-B concrete form, Class I.

2.1.1.2 Class "B" Finish

This class of finish shall apply to all surfaces except those specified to receive Class A, Class C, Class D. The form facing material shall be composed of tongue-and-groove or shiplap lumber, plywood conforming to APA PS 1, Grade B-B concrete form, tempered concrete form hard board or steel. Steel lining on wood sheathing will not be permitted.

2.1.1.3 Class "C" Finish

This class of finish shall apply to surfaces that will be plastered or cladded. The form facing may be either tongue-and-groove lumber, plywood, concrete form hard board or steel. Wood form facing for curved or warped surfaces shall be composed of splines of lumber which can be bent to the required shape without splitting or cracking.

2.1.2 Form Coating

Form coating shall be commercial formulation that will not bond with, stain, cause deterioration, or any other damage to concrete surfaces.

The coating shall not impair subsequent treatment of concrete surfaces depending upon bond or adhesion nor impede the wetting of surfaces to be cured with water or curing compounds. If special form liners are to be used, the Contractor shall follow the recommendation of the form coating manufacturer.

2.2 ACCESSORIES

Ties and other similar form accessories to be partially or wholly embedded in the concrete shall be of a commercially manufactured type.

After the ends or end fasteners have been removed, the embedded portion of metal ties shall terminate not less than 50 mm from any concrete surface either exposed to view or exposed to water. Removable tie rods shall not be allowed in exposed locations. Plastic snap ties may be used in locations where the surface will not be exposed to view. Form ties shall be constructed so that the ends or end fasteners can be removed without spalling the concrete.

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Form Construction

Forms shall be constructed true to the structural design and required alignment. The form surface and joints shall be mortar tight and supported to achieve safe performance during construction, concrete placement, and form removal. The Contractor shall continuously monitor the alignment and stability of the forms during all phases to assure the finished product will meet the required surface class or classes specified in paragraph FORMS AND FORM LINERS and tolerances specified in paragraph DESIGN REQUIREMENTS. Failure of any supporting surface either due to surface texture, deflection or form collapse shall be the responsibility of the Contractor as will the replacement or correction of unsatisfactory surfaces. When forms for continuous surfaces are placed in successive units, care shall be taken to fit the forms over the completed surface to obtain accurate alignment of the surface and to prevent leakage of mortar. Forms shall not be re-used if there is any evidence of defects which would impair the quality of the resulting concrete surface. All surfaces of used forms shall be cleaned of mortar and any other foreign material before reuse.

3.1.2 Chamfering

All exposed joints, edges and external corners shall be chamfered by molding placed in the forms unless the drawings specifically state that chamfering is to be omitted or as otherwise specified. Chamfered joints shall not be permitted where earth or rockfill is placed in contact with concrete surfaces. Chamfered joints shall be terminated 300 mm outside the limit of the earth or rockfill so that the end of the chamfers will be clearly visible.

3.1.3 Coating

Forms for exposed or painted surfaces shall be coated with form oil or a form-release agent before the form or reinforcement is placed in final position. The coating shall be used as recommended in the manufacturer's instructions. Forms for unexposed surfaces may be wet with water in lieu of coating immediately before placing concrete, except that, in cold weather when freezing temperatures are anticipated, coating shall be mandatory. Surplus coating on form surfaces and coating on reinforcing steel and construction joints shall be removed before placing concrete.

3.2 FORM REMOVAL

Forms shall not be removed without approval. The minimal time required for concrete to reach a strength adequate for removal of formwork without risking the safety of workers or the quality of the concrete depends on a number of factors including, but not limited to, ambient temperature, concrete lift heights, type and amount of concrete admixture, and type and amount of cementitious material in the concrete.

It is the responsibility of the Contractor to consider all applicable factors and leave the forms in place until it is safe to remove them.

In any case forms shall not be removed unless the minimum time or minimum compressive strength or minimum time, minimum ambient temperature, and minimum compressive strength requirements below are met, except as otherwise directed or specifically authorized. When conditions are such as to justify the requirement, forms will be required to remain in place for a longer period. All removal shall be accomplished in a manner which will prevent damage to the concrete and ensure the complete safety of the structure. Where forms support more than one element, the forms shall not be removed until the form removal criteria are met by all supported elements. Evidence that concrete has gained sufficient strength to permit removal of forms shall be determined by tests on control cylinders. All control cylinders shall be stored in the structure or as near the structure as possible so they receive the same curing conditions and protection methods as given those portions of the structure they represent. Control cylinders shall be removed from the molds at an age of no more than 24 hours. All control cylinders shall be prepared and tested in accordance with ASTM C 31/C 31M and ASTM C 39/C 39M at the expense of the Contractor by an independent laboratory that complies with ASTM C 1077 and shall be tested within 4 hours after removal from the site. After obtaining approval, the Contractor may use maturity instrumentation instead of control cylinders to determine the compressive strength of the concrete. ASTM C 1074 procedures shall be used for estimating concrete strength by means of the maturity method. All expenses associated with instrumenting the concrete and evaluating the strength using maturity relationships shall be the responsibility of the Contractor.

3.2.1 Formwork Not Supporting Weight of Concrete

Formwork for walls, columns, sides of beams, gravity structures, and other vertical type formwork not supporting the weight of concrete shall not be removed in less than 24 hours after concrete placement is completed. Form removal before 24 hours will be allowed for simple floor slab, sidewalks, and driveways provided the ambient temperature during this period has not fallen below 10 degrees C at any time since placement and evidence from compressive tests on field-cured concrete control cylinders or maturity instrumentation indicate[s] that the concrete has attained a compressive strength of at least [_____] MPa.

Control cylinders shall be prepared for each set of forms to be removed before 24 hours. The stability of the concrete shall be evaluated by a structural engineer prior to removal of the forms.

3.2.2 Formwork Supporting Weight of Concrete

Formwork supporting weight of concrete and shoring shall not be removed until structural members have acquired sufficient strength to safely support their own weight and any construction or other superimposed loads to which the supported concrete may be subjected. As a minimum, forms shall be left in place until control concrete test cylinders or maturity instrumentation] indicate evidence the concrete has attained at least 80 percent of the compressive strength.

3.3 INSPECTION

Forms and embedded items shall be inspected in sufficient time prior to each concrete placement by the Contractor in order to certify to the Contracting Officer that they are ready to receive concrete. The results of each inspection shall be reported in writing.

SECTION 03 15 13.00 10

EXPANSION JOINTS, CONTRACTION JOINTS, AND WATERSTOPS

04/06

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 T 111 (1983; R 2004) Inorganic Matter or Ash in Bituminous Materials

AMERICAN HARDBOARD ASSOCIATION (AHA)

AHA A135.4 (2004) Basic Hardboard

ASTM INTERNATIONAL (ASTM)

ASTM A 1011/A 1011M (2007) Standard Specification for Steel, Sheet, and Strip, Hot-Rolled, Carbon, Structural, High-Strength Low-Alloy and High-Strength Low-Alloy with Improved Formability

ASTM A 109/A 109M (2003) Standard Specification for Steel, Strip, Carbon (0.25 Maximum Percent), Cold-Rolled

ASTM A 167 (1999; R 2004) Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip

ASTM A 480/A 480M (2006b) Standard Specification for General Requirements for Flat-Rolled Stainless and Heat-Resisting Steel Plate, Sheet, and Strip

ASTM B 152/B 152M (2006a) Standard Specification for Copper Sheet, Strip, Plate, and Rolled Bar

ASTM B 370 (2003) Standard Specification for Copper Sheet and Strip for Building Construction

ASTM C 919 (2002) Use of Sealants in Acoustical Applications

ASTM C 920 (2005) Standard Specification for Elastomeric Joint Sealants

ASTM D 1751 (2004) Standard Specification for

Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types)

ASTM D 1752 (2004a) Standard Specification for Preformed Sponge Rubber Cork and Recycled PVC Expansion

ASTM D 2628 (1991; R 2005) Standard Specification for Preformed Polychloroprene Elastomeric Joint Seals for Concrete Pavements

ASTM D 2835 (1989; R 2007) Lubricant for Installation of Preformed Compression Seals in Concrete Pavements

ASTM D 4 (1986; R 2004) Bitumen Content

ASTM D 412 (2006a) Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers - Tension

ASTM D 471 (2006) Standard Test Method for Rubber Property - Effect of Liquids

ASTM D 5249 (1995; R 2006) Backer Material for Use with Cold-and Hot-Applied Joint Sealants in Portland-Cement Concrete and Asphalt Joints

ASTM D 6 (1995; R 2006) Loss on Heating of Oil and Asphaltic Compounds

U.S. ARMY CORPS OF ENGINEERS (USACE)

COE CRD-C 513 (1974) Specifications for Rubber Waterstops

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

Applicable ASTM, BS, DIN, EN or equal TS-EN publications may also be used for the subject work. Under such circumstances English versions of the publications shall be furnished to the Contracting Officer for his/her review and approval.

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. The following shall be submitted in accordance with the provisions of the contract and Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Waterstops; G

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

SD-03 Product Data

Preformed Expansion Joint Filler Sealant Waterstops

Manufacturer's literature, including safety data sheets, for preformed fillers and the lubricants used in their installation;

field-molded sealants and primers (when required by sealant manufacturer); preformed compression seals; and waterstops.

Manufacturer's recommended instructions for installing preformed fillers, field-molded sealants; preformed compression seals; and waterstops; and for splicing non-metallic waterstops.

SD-04 Samples

Lubricant for Preformed Compression Seals

Specimens identified to indicate the manufacturer, type of material, size and quantity of material, and shipment or lot represented. Each sample shall be a piece not less than 3 m of 25 mm nominal width or wider seal or a piece not less than 4 m of compression seal less than 25 mm nominal width. One L of lubricant shall be provided.

Field-Molded Type

Four liters of field-molded sealant and one L of primer (when primer is recommended by the sealant manufacturer) identified to indicate manufacturer, type of material, quantity, and shipment or lot represented.

Non-metallic Materials

Specimens identified to indicate manufacturer, type of material, size, quantity of material, and shipment or lot represented. Each sample shall be a piece not less than 300 mm long cut from each 61 m of finished waterstop furnished, but not less than a total of 1 m of each type, size, and lot furnished.

One splice sample of each size and type for every 50 splices made in the factory and every 10 splices made at the job site.

The splice samples shall be made using straight run pieces with the splice located at the mid-length of the sample and finished as required for the installed waterstop. The total length of each splice shall be not less than 300 mm long.

SD-07 Certificates

Preformed Expansion Joint Filler Sealant Waterstops

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

1.3 DELIVERY AND STORAGE

Material delivered and placed in storage shall be stored off the ground and protected from moisture, dirt, and other contaminants. Sealants shall be delivered in the manufacturer's original unopened containers.

Sealants whose shelf life has expired shall be removed from the site.

PART 2 PRODUCTS

2.1 CONTRACTION JOINT STRIPS

Contraction joint strips shall be 3 mm thick tempered hardboard conforming to AHA A135.4, Class 1. In lieu of hardboard strips, rigid polyvinylchloride (PVC) or high impact polystyrene (HIPS) insert strips specifically designed to induce controlled cracking in slabs on grade may be used. Such insert strips shall have removable top section.

2.2 PREFORMED EXPANSION JOINT FILLER

Expansion joint filler shall be preformed material conforming to ASTM D 1751or ASTM D 1752. Unless otherwise indicated, filler material shall be 10 mm thick and of a width applicable for the joint formed.

Backer material, when required, shall conform to ASTM D 5249.

2.3 SEALANT

Joint sealant shall conform to the following:

2.3.1 Preformed Polychloroprene Elastomeric Type

ASTM D 2628.

2.3.2 Lubricant for Preformed Compression Seals

ASTM D 2835.

2.3.3 Field-Molded Type

ASTM C 920, Type M, Grade P or NS, Class 25, Use T or NT] for horizontal joints. Type M, Grade NS, Class 25, Use NT for vertical joints. Bond breaker material shall be polyethylene tape, coated paper, metal foil or similar type materials. The back-up material shall be compressible, non-shrink, nonreactive with sealant, and non-absorptive material type such as extruded butyl or polychloroprene rubber.

2.4 WATERSTOPS

Intersection and change of direction waterstops shall be shop fabricated.

2.4.1 Non-Metallic Materials`

Non-metallic waterstops shall be manufactured from a prime virgin resin;

reclaimed material is not acceptable. The compound shall contain plasticizers, stabilizers, and other additives to meet specified requirements. Rubber waterstops shall conform to COE CRD-C 513.

Polyvinylchloride waterstops shall conform to COE CRD-C 572.

Thermoplastic elastomeric rubber waterstops shall conform to ASTM D 471.

2.4.2 Non-Metallic Hydrophilic

Swellable strip type compound of polymer modified chloroprene rubber that swells upon contact with water shall conform to ASTM D 412 as follows: Tensile strength 2.9 MPa minimum; ultimate elongation 600 percent minimum. Hardness shall be 50 minimum on the type A durometer and the volumetric expansion ratio in distilled water at 20 degrees C shall be 3 to 1 minimum.

2.4.3 Preformed Elastic Adhesive

Preformed plastic adhesive waterstops shall be produced from blends of refined hydrocarbon resins and plasticizing compounds reinforced with inert mineral filler, and shall contain no solvents, asbestos, irritating fumes or obnoxious odors. The compound shall not depend on oxidizing, evaporating, or chemical action for its adhesive or cohesive strength.

2.4.3.1 Chemical Composition

The chemical composition of the sealing compound shall meet the requirements shown below:

PERCENT BY WEIGHT

COMPONENT MIN. MAX. TEST

Bitumen (Hydrocarbon plastic) 50 70 ASTM D 4 Inert Mineral Filler 30 50 AASHTO T 111 Volatile Matter 2 ASTM D 6

2.4.3.2 Adhesion Under Hydrostatic Pressure

The sealing compound shall not leak at the joints for a period of 24 hours under a vertical 2 m head pressure. In a separate test, the sealing compound shall not leak under a horizontal pressure of 65 kPa which is reached by slowly applying increments of 13 kPa every minute.

2.4.3.3 Sag of Flow Resistance

Sagging shall not be detected when tested as follows: Fill a wooden form 25 mm wide and 150 mm long flush with sealing compound and place in an oven at 58 degrees C in a vertical position for 5 days.

2.4.3.4 Chemical Resistance

The sealing compound when immersed separately in a 5% solution of caustic potash, a 5% solution of hydrochloric acid, 5% solution of sulfuric acid and a saturated hydrogen sulfide solution for 30 days at ambient room temperature shall show no visible deterioration.

PART 3 EXECUTION

3.1 JOINTS

Joints shall be installed at locations indicated and as authorized.

3.1.1 Contraction Joints

Contraction joints may be constructed by inserting tempered hardboard strips or rigid PVC or HIPS insert strips into the plastic concrete using a steel parting bar, when necessary, or by cutting the concrete with a saw after concrete has set. Joints shall be approximately 3 mm wide and shall extend into the slab one-fourth the slab thickness, minimum, but not less than 25 mm.

3.1.1.1 Joint Strips

Strips shall be of the required dimensions and as long as practicable.

After the first floating, the concrete shall be grooved with a tool at the joint locations. The strips shall be inserted in the groove and depressed until the top edge of the vertical surface is flush with the surface of the slab. The slab shall be floated and finished as specified. Working of the concrete adjacent to the joint shall be the minimum necessary to fill voids and consolidate the concrete. Where indicated, the top portion of the strip shall be sawed out after the curing period to form a recess for sealer. The removable section of PVC or HIPS strips shall be discarded and the insert left in place. True alignment of the strips shall be maintained during insertion.

3.1.1.2 Sawed Joints

Joint sawing shall be early enough to prevent uncontrolled cracking in the slab, but late enough that this can be accomplished without appreciable spalling. Concrete sawing machines shall be adequate in number and power, and with sufficient replacement blades to complete the sawing at the required rate. Joints shall be cut to true alignment and shall be cut in sequence of concrete placement. Sludge and cutting debris shall be removed.

3.1.2 Expansion Joints

Preformed expansion joint filler shall be used in expansion and isolation joints in slabs around columns and between slabs on grade and vertical surfaces where indicated. The filler shall extend the full slab depth, unless otherwise indicated. The edges of the joint shall be neatly finished with an edging tool of 3 mm radius, except where a resilient floor surface will be applied. Where the joint is to receive a sealant, the filler strips shall be installed at the proper level below the finished floor with a slightly tapered, dressed and oiled wood strip temporarily secured to the top to form a recess to the size shown on the drawings. The wood strip shall be removed after the concrete has set.

Contractor may opt to use a removable expansion filler cap designed and fabricated for this purpose in lieu of the wood strip. The groove shall be thoroughly cleaned of laitance, curing compound, foreign materials, protrusions of hardened concrete, and any dust which shall be blown out of the groove with oil-free compressed air.

3.1.3 Joint Sealant

Sawed contraction joints and expansion joints in slabs shall be filled with joint sealant, unless otherwise shown. Joint surfaces shall be clean, dry, and free of oil or other foreign material which would adversely affect the bond between sealant and concrete. Joint sealant shall be applied as recommended by the manufacturer of the sealant.

3.1.3.1 Joints With Preformed Compression Seals

Compression seals shall be installed with equipment capable of installing joint seals to the prescribed depth without cutting, nicking, twisting, or otherwise distorting or damaging the seal or concrete and with no more than 5 percent stretching of the seal. The sides of the joint and, if necessary, the sides of the compression seal shall be covered with a coating of lubricant. Butt joints shall be coated with liberal applications of lubricant.

3.1.3.2 Joints With Field-Molded Sealant

Joints shall not be sealed when the sealant material, ambient air, or concrete temperature is less than 4 degrees C. When the sealants are meant to reduce the sound transmission characteristics of interior walls, ceilings, and floors the guidance provided in ASTM C 919 shall be followed. Joints requiring a bond breaker shall be coated with curing compound or with bituminous paint. Bond breaker and back-up material shall be installed where required. Joints shall be primed and filled flush with joint sealant in accordance with the manufacturer's recommendations.

3.2 WATERSTOPS, INSTALLATION AND SPLICES

Waterstops shall be installed at the locations shown to form a continuous water-tight diaphragm. Adequate provision shall be made to support and completely protect the waterstops during the progress of the work. Any waterstop punctured or damaged shall be repaired or replaced.

Exposed waterstops shall be protected during application of form release agents to avoid being coated. Suitable guards shall be provided to protect exposed projecting edges and ends of partially embedded waterstops from damage when concrete placement has been discontinued.

Splices shall be made by certified trained personnel using approved equipment and procedures.

3.2.1 Non-Metallic

Fittings shall be shop made using a machine specifically designed to mechanically weld the waterstop. A miter guide, proper fixturing (profile dependant), and portable power saw shall be used to miter cut the ends to be joined to ensure good alignment and contact between joined surfaces. The splicing of straight lengths shall be done by squaring the ends to be joined. Continuity of the characteristic features of the cross section of the waterstop (ribs, tabular center axis, protrusions, etc.) shall be maintained across the splice.

3.2.1.1 Rubber Waterstop

Splices shall be vulcanized or shall be made using cold bond adhesive as recommended by the manufacturer. Splices for TPE-R shall be as specified for PVC.

3.2.1.2 Polyvinyl Chloride Waterstop

Splices shall be made by heat sealing the adjacent waterstop edges together using a thermoplastic splicing iron utilizing a non-stick surface specifically designed for waterstop welding. The correct temperature shall be used to sufficiently melt without charring the plastic. The spliced area, when cooled, shall show no signs of separation, holes, or other imperfections when bent by hand in as sharp an angle as possible.

3.2.1.3 Quality Assurance

Edge welding will not be permitted. Centerbulbs shall be compressed or closed when welding to non-centerbulb type. Waterstop splicing defects which are unacceptable include, but are not limited to the following:

1) Tensile strength less than 80 percent of parent section. 2) Free lap joints. 3) Misalignment of centerbulb, ribs, and end bulbs greater than 2 mm. 4) Misalignment which reduces waterstop cross section more than 15 percent. 5) Bond failure at joint deeper than 2 mm or 15 percent of material thickness. 6) Misalignment of waterstop splice resulting in misalignment of waterstop in excess of 13 mm in 3 m. 7) Visible porosity in the weld area, including pin holes. 8) Charred or burnt material. 9) Bubbles or inadequate bonding. 10) Visible signs of splice separation when cooled splice is bent by hand at a sharp angle.

3.2.2 Non-Metallic Hydrophilic Waterstop Installation

Ends to be joined shall be miter cut with sharp knife or shears. The ends shall be adhered with cyanacryiate (super glue) adhesive. When joining hydrophilic type waterstop to PVC waterstop, the hydrophilic waterstop shall be positioned as shown on the drawings. A liberal amount of a single component hydrophilic sealant shall be applied to the junction to complete the transition.

3.2.3 Preformed Plastic Adhesive Installation

The installation of preformed plastic adhesive waterstops shall be a prime, peel, place and pour procedure. Joint surfaces shall be clean and dry before priming and just prior to placing the sealing strips.

The end of each strip shall be spliced to the next strip with a 25 mm overlap; the overlap shall be pressed firmly to release trapped air.

During damp or cold conditions the joint surface shall be flashed with a safe, direct flame to warm and dry the surface adequately; the sealing strips shall be dipped in warm water to soften the material to achieve maximum bond to the concrete surface.

3.3 CONSTRUCTION JOINTS

Construction joints are specified in Section 03 31 00.00 10 CAST-IN-PLACE STRUCTURAL CONCRETE except that construction joints coinciding with expansion and contraction joints shall be treated as expansion or contraction joints as applicable.

SECTION 03 15 14.00 10

EXPANSION, CONTRACTION AND CONSTRUCTION JOINTS IN CONCRETE FOR CIVIL WORKS

04/06

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.

ASME INTERNATIONAL (ASME)

ASME BPVC SEC IX (2007) Boiler and Pressure Vessel Code;

Section IX, Welding and Brazing Qualifications

ASTM INTERNATIONAL (ASTM)

ASTM A 1011/A 1011M (2007) Standard Specification for Steel, Sheet, and Strip, Hot-Rolled, Carbon, Structural, High-Strength Low-Alloy and High-Strength Low-Alloy with Improved Formability

ASTM A 109/A 109M (2003) Standard Specification for Steel, Strip, Carbon (0.25 Maximum Percent), Cold-Rolled

ASTM A 167 (1999; R 2004) Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip

ASTM B 152/B 152M (2006a) Standard Specification for Copper Sheet, Strip, Plate, and Rolled Bar

ASTM C 920 (2005) Standard Specification for Elastomeric Joint Sealants

ASTM D 1751 (2004) Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types)

ASTM D 1752 (2004a) Standard Specification for Preformed Sponge Rubber Cork and Recycled PVC Expansion

ASTM D 2628 (1991; R 2005) Standard Specification for Preformed Polychloroprene Elastomeric Joint Seals for Concrete Pavements

ASTM D 2835 (1989; R 2007) Lubricant for

Installation of Preformed Compression Seals in Concrete Pavements

U.S. ARMY CORPS OF ENGINEERS (USACE)

COE CRD-C 513 (1974) Specifications for Rubber Waterstops

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

Applicable ASTM, BS, DIN, EN or equal TS-EN publications may also be used for the subject work. Under such circumstances English versions of the publications shall be furnished to the Contracting Officer for his/her review and approval.

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. The following shall be submitted in accordance with the provisions of the contract and Section 01 33 00 SUBMITTAL PROCEDURES:

SD-03 Product Data

Splicing Waterstops ; G

Procedures for splicing waterstops shall be submitted for approval.

SD-04 Samples

Field Molded Sealants and Primer

Four L of field-molded sealant and 1 L of primer (when primer is recommended by the sealant manufacturer) shall be provided for testing.

Waterstops ; G

Waterstop materials and splice samples shall be submitted for inspection and testing and shall be identified to indicate manufacturer, type of material, size and quantity of material and shipment represented. Each materials sample shall be a piece not less than 300 mm long cut from each 60 m of finished waterstop furnished, but not less than a total of 1.2 linear meters of each type and size furnished. For spliced segments of waterstops to be installed in the work, one spliced sample of each size and type for every 50 splices made in the factory and every 10 splices made at the job site shall be furnished for inspection and testing. The spliced samples shall be made using straight run pieces with the splice located at the mid-length of the sample and finished as required for the installed waterstop. The total length of each spliced sample shall be not less than 300 mm long.

SD-06 Test Reports

Premolded Expansion Joint Filler Strips Compression Seals and Lubricant

Metallic Waterstops

Certified manufacturer's test reports shall be provided for premolded expansion joint filler strips, compression seals and lubricant, and metallic waterstops to verify compliance with applicable specification.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Premolded Expansion Joint Filler Strips

Premolded expansion joint filler strips shall conform to ASTM D 1751 or ASTM D 1752, Type I, or resin impregnated fiberboard conforming to the physical requirements of ASTM D 1752.

2.1.2 Joint Seals and Sealants

2.1.2.1 Field Molded Sealants and Primer

Field molded sealants and primer shall conform to ASTM C 920, Type M, Grade NS orP, Class 25, Use T or NT for horizontal joints and Type M, Grade NS, Class 25, Use NT for vertical joints. Bond breaker material shall be polyethylene tape, coated paper, metal foil or similar type materials. The back-up material shall be compressible, nonshrink, nonreactive with sealant, and nonabsorptive material type such as extruded butyl or polychloroprene foam rubber.

2.1.2.2 Compression Seals and Lubricant

Compression seals shall conform to ASTM D 2628; lubricant for installation shall conform to ASTM D 2835.

2.1.3 Waterstops

2.1.3.1 Non-Metallic Waterstops

Rubber waterstops shall conform to COE CRD-C 513. Polyvinylchloride waterstops shall conform to COE CRD-C 572.

2.2 TESTS, INSPECTIONS, AND VERIFICATIONS

2.2.1 Materials Tests

2.2.1.1 Field-Molded Sealants

Samples of sealant and primer, when use of primer is recommended by the manufacturer, as required in paragraph FIELD MOLDED SEALANTS AND PRIMER, shall be tested by and at the expense of the Government for compliance with paragraph FIELD MOLDED SEALANTS AND PRIMER. If the sample fails to meet specification requirements, new samples shall be provided and the cost of retesting will be the responsibility of the contractor.

2.2.1.2 Non-Metallic Waterstops

Samples of materials and splices as required in paragraph WATERSTOPS shall be visually inspected and tested by and at the expense of the Government for compliance with COE CRD-C 513 or COE CRD-C 572 as applicable. If a sample fails to meet the specification requirements, new samples shall be provided and the cost of retesting will be the responsibility of the contractor.

2.2.2 Splicing Waterstops

2.2.2.1 Procedure and Performance Qualifications

Procedure and performance qualifications for splicing waterstops shall be demonstrated in the presence of the Contracting Officer.

2.2.2.2 Non-Metallic Waterstops

Procedure and performance qualifications for splicing non-metallic waterstops shall be demonstrated by the manufacturer at the factory and the Contractor at the job site by each making three spliced samples of each size and type of finished waterstop.

PART 3 EXECUTION

3.1 INSTALLATION

Joint locations and details, including materials and methods of installation of joint fillers and waterstops, shall be as…