B.08.03 19R4000 Amendment 1 Precast Concrete Cyst Specs 12-23-2019.pdf

Pre-Cast Concrete Burial Crypts 03 48 21-1

SECTION 034821

PRECAST CONCRETE BURIAL CRYPTS

(Double Depth Lawn Crypt)***6-30-10

PART 1 - GENERAL

1.1 DESCRIPTION

A. The work covered by this Section includes fabrication, handling, delivery to the site, storage and installation of precast concrete burial crypts; hereafter referred to as units or crypts, subbase foundation and drainage, placement of the units, backfilling, grading, fine grading and turf establishment, and other, all as shown on the plans or specified herein. In addition contractor to provide:

1. Three (3) crypt lid lifting apparatus.

2. Four (4) extra concrete crypt lids.

3. A device to retrieve and lower the inside shelf without Owner entering the crypt.

B. The design of the units shall be as described in this Section and their installation layout shall be as illustrated on the plans. All perimeter crypts shall be structurally designed for overhead and lateral soil pressure plus live loads specified hereafter. All designs will require that the manufacturer provide fabrication drawings stamped by a

Professional Engineer indicating that the design meets or exceeds the structural requirements contained herein. The Contractor may propose alternative designs of the corresponding components if all the following requirements are met.

1. Any proposed alternative design shall comply with the design criteria and the functional tests of this specification.

2. All provisions of this specification shall apply to any proposed alternative design.

3. The Government may accept or reject part or all of any proposed alternative design. The Contractor will pay for all cost for alternate designs, submittals, and reviews.

1.2 RELATED WORK

A. Excavation and Backfill: Section 312000 EARTHWORK.

B. Materials Testing and Inspection during Fabrication and Construction:

Section 014529, TESTING LABORATORY SERVICES.

1.3 QUALITY ASSURANCE

A. Manufacturer’s Qualifications: With submittal of bid documents, Contractor shall submit documentation regarding the manufacture of the units. Contractor shall provide evidence that manufacturer has a minimum of three years experience with pre-casting units of similar

03 48 21-2 Pre-Cast Concrete Burial Crypts type, and provide evidence that the manufacturer plant(s) used are certified by the National Precast Concrete Association (NPCA).

B. Precast concrete manufacturer shall provide a licensed Structural

Engineer to certify that the units conform to specified requirements.

C. Erector Qualifications: Regularly engaged for at least three years in erection of pre-cast concrete similar to this project.

D. Fabricate crypts to the interior dimensions described below. Replace or repair units that do not comply with the individual dimensions and tolerances.

E. Before starting full scale production of units, furnish at the site, two perimeter crypt units and a single interior crypt unit to demonstrate quality of construction of completed units and in-field load testing.

Commence production of units only after submittal and field load testing approval has been obtained.

F. Design Criteria (Double Depth Crypt):

1. The units shall be of the following type, style, and size:

a. Type: Precast concrete.

b. Style: One-piece box with separate outer lid, and a removable one-piece inside shelf.

c. Crypt interior size: Interior minimum dimensions are as follows: 30” minimum width at the inside bottom floor and for the full height of the crypt; 86” minimum length along the inside bottom floor and for the full height of the crypt; 25” minimum clear height from the highest part of the inside shelf to the underside of the lid and; 25” minimum clear height from the lowest part of the inside shelf to the top of the casket risers and; 3/4” minimum height casket risers from the crypt floor spaced 20” from crypt centerline to eliminate pinching of the lowering straps during removal.

Four risers required.

d. Crypt height and wall thickness: Exterior maximum height dimension: 60" including the lid. Crypt wall thickness: 2-inches plus or minus ½ inch. Perimeter crypts may exceed wall thickness dimension.

e. Layout: Crypts shall fit in a 3-foot by 8-foot plot or a lesser plot size as noted on the plans. The lesser plot size shall govern. If the contractor’s layout or crypt size dimensions differ, the Contractor at no cost to the Owner shall submit a Layout/Size Plan for approval by the Resident

Engineer.

Pre-Cast Concrete Burial Crypts 03 48 21-3

2. Units shall be designed for a burial depth with soil cover as indicated on the plans, and be capable of structurally withstanding passage of a wheel axle load of 12,000 lbs after burial, and a center point load of 6,000 lbs.

3. The Contractor shall submit to the Resident Engineer for approval five sets of design documentation showing structural design of the units. Contractor to provide one set to NCA Crypt Specialist. This documentation shall include dimensions, methods of construction, and calculations. All design calculations and drawings shall be signed and sealed by qualified licensed Structural Engineer.

4. The concrete lid shall be designed to be removable and replaceable.

Lid lifting shall be from top positioned galvanized anchors (4-required per lid) with a removable anchor covers to prevent dirt from entering the anchor bowl as specified in Sec 2.2 and installed in such a manner as not to be hit by excavating equipment when scraping backfill off the top of the lid. The Contractor shall furnish the cemetery with three (3) OSHA approved lifting devices for removing the lid. Inside shelf will be one piece rigid construction, fully conceal the lower casket with a rigid barrier, weigh 40 lbs. or less, allow for easy casket lowering belt removal, and capable of holding

400 lbs indefinitely. The entire inside shelf should be rigid, non-brittle and non-deteriorating. Provide a tool that Owner can easily retrieve and install the shelf from ground level without entering the crypt.

5. The concrete lid shall be beveled along the entire top perimeter.

Chamfer top edge of lid with a 1:1 chamfer beginning 3/4” down from top.

6. Through the use of spaced concrete chairs or other means, the design of casket risers shall allow the casket to rest above the inside bottom of the crypt and above the top of the inside shelf in order that the casket lowering straps can be removed without pinching from around the casket.

7. There shall be two 1” diameter drain holes in the bottom at opposite ends of each crypt to allow for drainage.

8. The crypt lifting wire/cable shall be designed for transport and installation along with provisions for removal/abandonment of crypt lifting wire/cable once crypt has been installed.

G. Design Criteria (Quad Crypt):

1. An alternate concrete Quad unit (one piece) may be used as an approved equal in lieu of two (2) double depth lawn crypt units. The Quad units shall conform to all other specified herein including:

03 48 21-4 Pre-Cast Concrete Burial Crypts

a. The shared interior wall thickness may be increased to allow for a gap between lids as deemed appropriate to meet layout requirements.

H. Functional Load Test: A functional on-site load test will be made at the

Contractor’s expense to insure the units are capable of supporting loads stated. The functional test will consist of following loading condition:

1. Confined Loading: An interior unit between two perimeter units shall be placed in a hole dug in the ground on site and covered with 24 inches of soil or covered to the maximum depth as shown on the plans, which ever is greater. The soil will be compacted to

95% density at optimum moisture content along the sides and over the lid. An axle load of 12,000 lbs. will then be passed over the covered crypts for a minimum of 20 times in repetition, in a manner that causes maximum lateral pressure due to wheel load on the sides of the crypts. The crypts shall then be fully excavated, exposed and the lid removed to allow careful examination inside and outside. The crypts must not show any signs of stress or cracking.

2. Concurrent with Confined Loading, the inside shelve of the interior crypt shall be loaded with one worker with a minimum weight of 200 lbs. Worker shall walk on individual supports to confirm structural integrity and load bearing capability. Worker shall adhere to all safety regulations while performing test. Upon uncovering and load removal, the shelf shall be removed and must not show any signs of stress, cracking or deflection.

1.4 ALLOWABLE TOLERANCES

A. Tolerances of individual units shall be as follows:

1. Variation in overall crypt outside dimensions of unit (height, length and width): 1/8” plus or minus. There is zero tolerance for any lesser crypt inside minimum clear dimensions.

2. Variation in thickness of precast panels and elements: 1/16” plus or minus.

3. Maximum height differential in final placement in the ground: 1/4” above or below design grade.

4. Cracks greater than 1/32nd inch in width may be cause for crypt rejection or repair at the discretion of the Resident Engineer at

Pre-Cast Concrete Burial Crypts 03 48 21-5 no cost to VA. Any cracking that extends completely thru wall or lid will be rejected and the crypt replaced at no cost to VA.

1.5 SUBMITTALS

A. In accordance with Section 013323, SAMPLES AND SHOP DRAWINGS, within 45 days of the approval of the shop drawings, Contractor shall furnish the following:

1. Samples: deliver to the site for testing and inspection:

a. Two perimeter crypts and one interior crypt.

B. Shop Drawings:

1. Erection Narrative:

a. Method of transportation.

b. Method of handling and placement.

2. Production Drawings:

a. Elevation view of each unit.

b. Plan view of unit.

c. Sections and details to show quantities, sizes and position of reinforcing steel, inserts, and essential embedded hardware for fabrication, handling, transportation and installation.

d. Section, details and location of specialty lid lifting anchors, caps, and lid lifting system.

e. Dimensions and finishes.

C. Product Design Data:

1. Self Consolidated Concrete mix design calculations of units, performed by a licensed Structural Engineer.

2. Loadings for Design Calculations:

a. Initial handling and erection stresses.

b. Dead and live loads specified.

c. Other loads specified for units as applicable.

d. Deflection of precast members.

e. Product test reports:

1). The concrete shall be tested for the compressive strength and beam flexural strength as specified herein. An approved independent, commercial testing laboratory shall perform tests. Certified copies of test reports, including test data and results shall be

03 48 21-6 Pre-Cast Concrete Burial Crypts submitted to the Resident Engineer immediately after the strength tests have been completed. The tests shall be as specified herein.

2). The Resident Engineer may request more frequent testing to ensure quality of the product.

3. Manufacturer’s Literature and Data:

a. Each type of anchorage, angle, and fastener.

1.6 PRODUCT DELIVERY, STORAGE AND HANDLING

A. Delivery and Handling: Units shall be transported, stored and handled so as to prevent damage to surfaces, edges and corners and to prevent development of stresses and cracks. The Contractor shall provide temporary bracing protection devices and measures as necessary to prevent damage to the units during handling, transportation and storage.

Contractor is responsible for transportation, storage and handling of units such that any negligence on the Contractor’s part shall be corrected at the Contractor’s expense. Use the designed crypt lifting cable to transport crypts. On the job site, forklift handling of crypts may be approved by the VA upon demonstration that no crypt damage will be incurred.

B. Storage:

1. Units may be stored at designated locations(s) on site.

C. Markings and Identifications:

1. Markings, including logos, trademarks and proprietary information are prohibited on surfaces of crypts.

2. Date of manufacture (month, day, year) shall be written on the box and lid with permanent ink or an equivalent marking.

1.7 COORDINATION

A. Coordinate the manufacture, delivery, storage and installation of the units with related work.

1.8 GUARANTEE

A. After erection, completed work will be, subject to terms of Article, GUARANTEE in Section 010000, GENERAL CONDITIONS, except guarantee period is extended to five years.

Pre-Cast Concrete Burial Crypts 03 48 21-7

PART 2 - PRODUCTS

2.1 MATERIALS

A. Precast Concrete: All crypts including lids shall be of concrete with a minimum 28 days compressive strength of 5,000 psi, be Self Consolidated

Concrete (SCC) containing structural fiber with an inverted slump between 22” and 28” and meet the following requirements:

1. Hydraulic Cement: ASTM C150 or ASTM C1157 or ASTM C595

2. Normalweight Aggregates: ASTM C 33

3. Water: ASTM C1602

4. Chemical Admixtures:

a. Water reducers, accelerating and retarding: ASTM C 494

b. Air Entraining: ASTM C260

c. Admixtures for flowing concrete: ASTM C1017

d. Admixtures with no standard designation shall be used only with approval of VA.

5. Prohibited Admixtures: Calcium Chloride thyocyanates or admixtures containing more than 0.1 percent chloride ions.

B. Reinforcement:

1. Welded Steel Wire Fabric: ASTM A185.

2. Steel Wire Reinforcement: ASTM A82, cold drawn.

3. Steel Reinforcement: ASTM A615 Grade 60, deformed.

4. Inserts, Anchors, Dowels and Accessories: Steel, ASTM A36, zinc coated ASTM A153 hot-dipped galvanized finish G90.

5. Fiber: Macrofiber complying with ASTM C1116

C. Form Coatings:

1. Use commercial formulation form-coating compounds that will not bond with, stain, or adversely affect concrete surfaces.

D. Paint:

2. Use commercial Concrete & Garage Floor Epoxy Acrylic Paint for crypt concrete lid & inside wall surface numbering. Paint as manufactured by BEHR Deep Base #930 or approved equal.

2.2 FABRICATION

A. General:

1. Units shall be fabricated in accordance with the minimum interior dimensions and tolerances indicated herein, with concrete surfaces that are smooth and free of irregularities.

03 48 21-8 Pre-Cast Concrete Burial Crypts

B. Finishes:

1. Surface holes (1/4” and smaller) caused by air bubbles, normal color variations, normal form joint marks, small chips (1/4” and smaller) and spalling (no more than one square foot total per unit) are permitted.

2. Exposed steel reinforcing, honeycomb, bugholes, and thruwall cracks are not permitted.

3. The lid lifting system shall be top mounted and consist of hot dip galvanized steel anchors (four per lid) each in a 2-1/2” diameter minimum recessed bowl of depth sufficient to easily connect lifting device as designated compatible by anchor manufacturer.

Anchors to be installed at locations to ensure maximum lid lifting stability. A removable plastic cap secured to the anchor will prevent fill material from entering the anchor bowl. Cap to be flush mounted to ensure the entire assembly is not an obstruction for crypt excavating equipment.

4. Concrete shall have no evidence of segregation of materials.

C. Reinforcement:

1. Provide steel and fiber reinforcing as required for casting, handling, erection loads, lateral and overhead fill, and equipment live loads.

2. Reinforcing steel shall be free of dirt, mill scale, rust, oil, grease, ice, snow, water and placed within approved tolerances in accordance with ACI 318. Careful placement of reinforcing is required to avoid overlapping at thin points of the units.

D. Concrete Placement:

1. Porosity, strength, weight and gradation of coarse aggregate shall be as required to produce specified characteristics.

2. Units shall be cast in steel forms designed to suit shape and finish required. Each element of the unit shall be cast as an integral piece free of joints and seams.

E. Curing:

1. 95 percent of specified concrete compressive strength shall be attained before transportation of units to the cemetery or storage site.

2. Units shall be cured as required to develop specified structural characteristics and shall be stored in a manner that will permit all surfaces to cure equally.

3. Units shall be properly cured in accordance with the applicable

Pre-Cast Concrete Burial Crypts 03 48 21-9 provisions of the current ACI Manual of Concrete Practice.

F. Surface Treatment and Corrective Work:

1. Units that have minor chipping of edges and corners shall be repaired by a method approved by the Resident Engineer.

2. Cracked/damaged units exceeding tolerances shall be removed by the contractor at no cost to the government.

2.3 TESTING AND INSPECTION

A. Contractor’s Responsibility for Inspection: The Contractor is responsible for the performance of all inspection requirements including the removal of lids, number painting inside crypts, and replacement of the lids for inspection by the Resident Engineer. The Resident Engineer reserves the right to perform any of the inspections set forth in the specification when deemed necessary to assure that the units conform to prescribed requirements.

PART 3 - EXECUTION

3.1 CRYPT FIELD QUALITY ASSURANCE

A. Testing: The contractor shall procure an independent qualified testing agency to perform concrete tests during crypt production and prepare test reports.

1. Concrete Cylinder testing for compressive strength: Three cylinders per day of crypt production to be taken in accordance to

ASTM C172 as applicable to SCC. Strength to exceed 5000 psi after

28 days curing in accordance to ASTM C31 & C39. Test inverted slump when cylinders are made.

2. Beam testing to confirm design flexure strength: Once at the beginning of crypt production, a minimum of three beams with fiber shall be taken for testing of Flexural Performance of Fiber-

Reinforced Concrete in accordance with ASTM C78 and C1399. All beams’ flexural strength shall exceed the crypt design flexural strength requirements and residual strength of fiber reinforced concrete, and shall exceed capacity of conventionally reinforced concrete wall design as submitted by the Structural Engineer and approved by VA. Fiber Manufacturer shall verify type and dosage rate of the test beams are identical in crypt production.

3.2 GENERAL LAYOUT CONTROL

A. A professional registered Land Surveyor shall establish and control

03 48 21-10 Pre-Cast Concrete Burial Crypts horizontal and vertical alignment of units.

3.3 PREPARATION

B. Before beginning installation, inspect work of other trades insofar as it affects the work of this section. Commencing installation of units will be construed as accepting as suitable the work of other trades.

C. Verify by survey, grading of subgrade and aggregate base for proper installation of units.

D. Verify by testing, compaction of prepared subgrade and subbase.

E. Verify by survey locations and elevations of units relative to control points indicated on plans. Submit new control point layout if a crypt size other than specified is used.

3.4 HANDLING AND INSTALLATION

A. Handling:

1. Units shall be handled in a vertical plane at all times and stacked vertically on wood supports of adequate strength, until erected. On the job site, use the designed lifting cable to transport crypts from the truck to storage to the final installation.

2. Lift units with suitable lifting devices at points provided by manufacturer.

3. Provide temporary wood bracing to comply with manufacturer’s recommendations to keep crypt bottom off ground during storage.

B. Installation:

1. Install units by competent erector crews trained and certified as competent by manufacturer.

2. Use all means necessary to protect units from being damaged in transport and during and after installation. Lids that show damage from bouncing during transport shall be replaced by the contractor at no cost to the Owner.

3. Accurately install by aligning and leveling units in accordance with plans. Assure that crypts are in straight horizontal alignment.

4. After crypt installation and prior to backfill, the contractor shall remove lids with the specified lifting apparatus for crypt inspection by the Resident Engineer and numbering. Numbers furnished by NCA shall be painted by the contractor on the outside of the crypt lids and on the upper inside crypt short wall, both

Pre-Cast Concrete Burial Crypts 03 48 21-11 at the headstone end. Numbers shall be permanent paint as specified and twelve inches high. After completion of inspection and marking, the Contractor shall replace the lids. Any damage to lids or crypts will be the responsibility of the contractor. Prior to lid replacement on all ‘‘perimeter’’ crypts, the contractor shall notify and allow for inspection by the NCA Crypt Specialist.

5. Place crypts on minimum 6 inch depth of compacted crushed aggregate size ¾ inches to Number 4 or as designated on the plans.

Protect aggregate from disturbance from equipment.

3.5 PROTECTION OF WORK

A. Use all means necessary to protect units from being damaged during and after installation.

3.6 REPLACEMENT AND REPAIR

A. Remove and replace units that the Resident Engineer has determined are damaged, cracked, broken, improperly fabricated, or otherwise defective and are structurally unsound and unacceptable.

B. Units having minor defects not affecting serviceability or appearance may be repaired when approved by Resident Engineer.

C. Repair work shall be sound, permanent, and flush with adjacent surfaces.

D. Replacements and repairs shall be done at no additional cost to the

Government.

3.7 BACKFILLING AND MATERIAL STORAGE

A. Protect installed crypt units during backfill operations.

B. Install approved backfill against outside walls of all units, insuring no voids are remaining. Approved backfill shall contain no material that will cause a concentrated point load. The perimeter wall backfill shall be compacted to 95% density to the level equal to the top of the crypts.

C. Install an approved fine fill material (sand or pea gravel) into gaps between crypts leaving no voids. Use rod or water to assure no bridging occurs and void areas are eliminated.

D. Pea gravel shall be a naturally occurring rounded coarse aggregate gravel (non crushed). Maximum size of gravel shall be 3/8” diameter.

Gravel shall meet either of the following gradations:

03 48 21-12 Pre-Cast Concrete Burial Crypts

Aggregate

Size No

Grading Requirements - Amounts finer than Each Sieve (Square

Openings), Mass Percent

1/2” 3/8” No. 4 No. 8 No. 16 No. 50

8 100 85 to 100 10 to 30 0 to 10 0 to 5

89 100 90 to 100 20 to 55 5 to 30 0 to 10 0 to 5

E. Install backfill on top of units and compact. Backfill on top of units working from bottom up consists of 2 inches of sand, soil to specified level, and 4 inches of topsoil as the final layer. The entire backfill atop the units shall be compacted to 85% density.

F. No equipment over the crypts should exceed crypt design loads as specified herein (12,000lbs axle), which includes compacting equipment.

No vibratory compaction equipment over the crypts unless impact loads are shown not to exceed crypt design loads.

G. After backfilling over crypts, contractor to immediately mark the crypt field edges with temporary driven lathes & signage for easy identification by topsoil, compost, sod trucks and other vehicles.

Signage shall state ‘‘12,000-lb axle load maximum’’

H. Finish grading and prepare topsoil as indicated on plans.

I. The contractor shall not store or stockpile any stone, sand, backfill or any other material or loaded equipment within ten (10) yards of or on top of installed crypts. All costs to inspect affected crypts for possible damages will be at contractor’s expense.

3.8 INSPECTION AND ACCEPTANCE

A. Final inspection and acceptance will be by Resident Engineer.

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