W912HV-16-B-0003_Zama_HS_Specifications_Vol_II_of_III.pdf

DoDEA Schools RTA Submittal

Specifications - Volume II of III

FY 13 DoDEA MILCON Renovate Zama High School Camp Zama, Japan 18 March 2016

Woolpert – KZF JV 4454 Idea Center Boulevard

Dayton, OH 45430

SPECIFICATION TABLE OF CONTENTS

VOLUME I – DIVISIONS 00-02

VOLUME II – DIVISIONS 03-22

VOLUME III – DIVISIONS 23-33

Renovate Zama High School RTA Submittal 18 March 2016 Camp Zama, Japan

PROJECT TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

01 01 50 PHASING OF WORK

01 10 26.20 33 CONTRACT ADMINISTRATION DATA (KANAGAWA RO)

01 11 00.20 33 GENERAL CONTRACT REQUIREMENTS

01 14 00 WORK RESTRICTIONS

01 20 00.00 20 PRICE AND PAYMENT PROCEDURES

01 32 01.00 10 PROJECT SCHEDULE

01 33 00 SUBMITTAL PROCEDURES

01 33 29 LEED(TM) DOCUMENTATION

01 35 29.70 33 SAFETY AND OCCUPATIONAL HEALTH REQUIREMENTS

01 42 00 SOURCES FOR REFERENCE PUBLICATIONS

01 42 00.00 33 ACCEPTABLE ALTERNATIVES FOR JAPANESE STANDARDS

01 45 00.00 10 QUALITY CONTROL

01 45 00.10 10 QUALITY CONTROL SYSTEM (QCS)

01 45 35 SPECIAL INSPECTION FOR SEISMIC-RESISTING SYSTEMS

01 57 20.00 10 ENVIRONMENTAL PROTECTION

01 62 35 RECYCLED / RECOVERED MATERIALS

01 74 19 CONSTRUCTION AND DEMOLITION WASTE MANAGEMENT

01 78 00 CLOSEOUT SUBMITTALS

01 78 23 OPERATION AND MAINTENANCE DATA

01 78 23.30 33 OPERATION AND MAINTENANCE COMMISSIONING REQUIREMENTS

01 91 00.00 40 GENERAL COMMISSIONING REQUIREMENTS

01 91 00.10 40 CONSTRUCTION CHECKLISTS COMMISSIONING REQUIREMENTS

01 91 00.20 40 FUNCTIONAL PERFORMANCE TESTING COMMISSIONING REQUIREMENTS

01 91 00.30 40 DEMONSTRATION AND TRAINING COMMISSIONING REQUIREMENTS

01 91 10 COMMISSIONING REQUIREMENTS

DIVISION 02 - EXISTING CONDITIONS

02 41 00 DEMOLITION

02 82 14.00 10 ASBESTOS HAZARD CONTROL ACTIVITIES

02 83 13.00 20 LEAD IN CONSTRUCTION

02 84 16 HANDLING OF LIGHTING BALLASTS AND LAMPS CONTAINING PCBs

AND MERCURY

DIVISION 03 - CONCRETE

03 11 13.00 10 STRUCTURAL CAST-IN-PLACE CONCRETE FORMING

03 15 00.00 10 CONCRETE ACCESSORIES

03 20 00.00 10 CONCRETE REINFORCING

03 30 00.00 10 CAST-IN-PLACE CONCRETE

03 35 00.00 10 CONCRETE FINISHING

03 39 00.00 10 CONCRETE CURING

03 54 16 SELF LEVELING UNDERLAYMENT

DIVISION 05 - METALS

05 12 00 STRUCTURAL STEEL

05 50 13 MISCELLANEOUS METAL FABRICATIONS

05 52 00 METAL RAILINGS

DIVISION 06 - WOOD, PLASTICS, AND COMPOSITES

06 20 00 FINISH CARPENTRY

06 41 16.00 10 LAMINATE CLAD ARCHITECTURAL CASEWORK

06 61 16 SOLID POLYMER (SOLID SURFACING) FABRICATIONS

PROJECT TABLE OF CONTENTS Page 1

DIVISION 07 - THERMAL AND MOISTURE PROTECTION

07 21 13 BOARD AND BLOCK INSULATION

07 21 16 MINERAL FIBER BLANKET INSULATION

07 21 20 SPRAY FOAM INSULATION

07 58 00 ELASTOMERIC ROOFING

07 60 00 FLASHING AND SHEET METAL

07 84 00 FIRESTOPPING

07 92 00 JOINT SEALANTS

DIVISION 08 - OPENINGS

08 11 13 STEEL DOORS AND FRAMES

08 11 16 ALUMINUM DOORS AND FRAMES

08 11 16.01 BLAST RESISTANT ALUMINUM DOORS AND FRAMES

08 14 00 WOOD DOORS

08 31 13 ACCESS DOORS AND FRAMES

08 41 13 ALUMINUM-FRAMED ENTRANCES AND STOREFRONTS

08 41 13.01 BLAST RESISTANT ALUMINUM-FRAMED ENTRANCES AND STOREFRONTS

08 45 23 TRANSLUCENT WALL PANELS

08 51 14.00 10 ALUMINUM AND ENVIRONMENTAL CONTROL ALUMINUM WINDOWS

08 71 00 DOOR HARDWARE

08 81 00 GLAZING

08 91 00 METAL WALL LOUVERS

DIVISION 09 - FINISHES

09 22 00 SUPPORTS FOR PLASTER AND GYPSUM BOARD

09 29 00 GYPSUM BOARD

09 30 00 CERAMIC TILE, QUARRY TILE, AND PAVER TILE

09 51 00 ACOUSTICAL CEILINGS

09 65 00 RESILIENT FLOORING

09 68 00 CARPET

09 83 13 ACOUSTICAL WALL AND CEILING TREATMENT

09 90 00 PAINTS AND COATINGS

09 90 20 ACRYLIC RESIN COATINGS

DIVISION 10 - SPECIALTIES

10 10 00 VISUAL COMMUNICATIONS SPECIALTIES

10 14 02 INTERIOR SIGNAGE

10 21 13 TOILET COMPARTMENTS

10 28 13 TOILET ACCESSORIES

10 51 13 METAL LOCKERS

DIVISION 11 - EQUIPMENT

11 60 00 STAGE CURTAIN

DIVISION 12 - FURNISHINGS

12 65 00 FIXED SEATING

DIVISION 13 - SPECIAL CONSTRUCTION

13 48 00 SEISMIC PROTECTION FOR MISCELLANEOUS EQUIPMENT

13 48 00.00 10 SEISMIC PROTECTION FOR MECHANICAL EQUIPMENT

PROJECT TABLE OF CONTENTS Page 2

DIVISION 14 - CONVEYING EQUIPMENT

14 24 00 HYDRAULIC ELEVATORS

DIVISION 21 - FIRE SUPPRESSION

21 13 13.00 10 WET PIPE SPRINKLER SYSTEM, FIRE PROTECTION

21 30 00 FIRE PUMPS

DIVISION 22 - PLUMBING

22 00 00 PLUMBING, GENERAL PURPOSE

22 08 00.00 10 PLUMBING SYSTEMS COMMISSIONING REQUIREMENTS

DIVISION 23 - HEATING, VENTILATING, AND AIR CONDITIONING (HVAC)

23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEMS

23 01 30.41 HVAC SYSTEM CLEANING

23 03 00.00 20 BASIC MECHANICAL MATERIALS AND METHODS

23 05 15 COMMON PIPING FOR HVAC

23 05 48.00 40 VIBRATION AND SEISMIC CONTROLS FOR HVAC PIPING AND

EQUIPMENT

23 05 93 TESTING, ADJUSTING, AND BALANCING FOR HVAC

23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS

23 08 00.00 10 COMMISSIONING OF HVAC SYSTEMS

23 09 23 LONWORKS DIRECT DIGITAL CONTROL FOR HVAC AND OTHER

BUILDING CONTROL SYSTEMS

23 09 24 ENERGY METERING SYSTEMS COMMISSIONING REQUIREMENTS

23 22 13.35 40 STEAM TRAPS

23 22 26.00 20 STEAM SYSTEM AND TERMINAL UNITS

23 29 23 VARIABLE FREQUENCY DRIVE SYSTEMS UNDER 600 VOLTS

23 64 10 WATER CHILLERS, VAPOR COMPRESSION TYPE

23 64 26 CHILLED, CHILLED-HOT, AND CONDENSER WATER PIPING SYSTEMS

23 65 00 COOLING TOWERS

DIVISION 26 - ELECTRICAL

26 05 48.00 10 SEISMIC PROTECTION FOR ELECTRICAL EQUIPMENT

26 20 00 INTERIOR DISTRIBUTION SYSTEM

26 23 00 SWITCHBOARDS

26 51 00 INTERIOR LIGHTING

DIVISION 27 - COMMUNICATIONS

27 21 00.00 40 INTERCOMMUNICATION SYSTEM

27 41 00 AUDITORIUM SOUND SYSTEM

27 50 00 DOOR ANSWERING SYSTEM

27 53 13.00 22 MASTER CLOCK SPECIFICATION

DIVISION 28 - ELECTRONIC SAFETY AND SECURITY

28 31 76 INTERIOR FIRE ALARM AND MASS NOTIFICATION SYSTEM

DIVISION 31 - EARTHWORK

31 00 00 EARTHWORK

31 11 00 CLEARING AND GRUBBING

DIVISION 32 - EXTERIOR IMPROVEMENTS

PROJECT TABLE OF CONTENTS Page 3

32 05 33 LANDSCAPE ESTABLISHMENT

32 10 00 BITUMINOUS CONCRETE PAVEMENT

32 11 24 GRADED CRUSHED AGGREGATE BASE COURSE FOR FLEXIBLE PAVEMENT

32 16 13 CONCRETE SIDEWALKS AND CURBS AND GUTTERS

32 17 24.00 10 PAVEMENT MARKINGS

32 31 13 CHAIN LINK FENCES AND GATES

32 92 19 SEEDING

32 93 00 EXTERIOR PLANTS

DIVISION 33 - UTILITIES

33 11 00 WATER DISTRIBUTION

33 40 00 STORM DRAINAGE UTILITIES

33 71 02 UNDERGROUND ELECTRICAL DISTRIBUTION

-- End of Project Table of Contents --

PROJECT TABLE OF CONTENTS Page 4

SECTION TABLE OF CONTENTS

DIVISION 03 - CONCRETE

SECTION 03 11 13.00 10

STRUCTURAL CAST-IN-PLACE CONCRETE FORMING

PART 1 GENERAL

1.1 REFERENCES

1.1.1 ACCEPTABLE ALTERNATIVES FOR JAPANESE STANDARDS

1.2 SYSTEM DESCRIPTION

1.3 SUBMITTALS

1.4 QUALITY ASSURANCE

PART 2 PRODUCTS

2.1 FORM MATERIALS

2.1.1 Forms For Class A Finish

2.1.2 Forms For Class B Finish

2.1.3 Forms For Class C Finish

2.1.4 Forms For Class D Finish

2.1.5 Form Ties

2.1.6 Form Releasing Agents

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Formwork

3.2 CHAMFERING

3.3 COATING

3.4 FORM REMOVAL

3.4.1 Formwork Not Supporting Weight of Concrete

3.4.2 Formwork Supporting Weight of Concrete

3.5 INSPECTION

-- End of Section Table of Contents --

SECTION 03 11 13.00 10 Page 1

SECTION 03 11 13.00 10

STRUCTURAL CAST-IN-PLACE CONCRETE FORMING

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. Contractor may substitute compatible JIS / JASS standards for non-Japanese standards, as approved by the Contracting Officer's representative.

AMERICAN CONCRETE INSTITUTE INTERNATIONAL (ACI)

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

AMERICAN HARDBOARD ASSOCIATION (AHA)

AHA A135.4 (1995; R 2004) Basic Hardboard

APA - THE ENGINEERED WOOD ASSOCIATION (APA)

APA L870 (2010) Voluntary Product Standard, PS 1-09, Structural Plywood

ASTM INTERNATIONAL (ASTM)

ASTM C1077 (2011c) Standard Practice for Laboratories Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Laboratory Evaluation

ASTM C31/C31M (2010) Standard Practice for Making and Curing Concrete Test Specimens in the Field

ASTM C39/C39M (2012) Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

1.1.1 ACCEPTABLE ALTERNATIVES FOR JAPANESE STANDARDS

In addition to the American Standards and criteria referenced in this specification section, certain Japanese Standards have been determined by the Contracting Officer to be acceptable alternatives to the listed US Standards. See Section 01 42 00.00 33 ACCEPTABLE ALTERNATIVES FOR JAPANESE STANDARDS for a listing of these acceptable Japanese Standards and information on the use of Japanese Standards not explicitly listed in Section 01 42 00.00 33.

1.2 SYSTEM DESCRIPTION

The design, engineering, and construction of the formwork is the

SECTION 03 11 13.00 10 Page 2 responsibility of the Contractor. Design formwork in accordance with methodology of ACI 347 for anticipated loads, lateral pressures, and stresses, and capable of withstanding the pressures resulting from placement and vibration of concrete. Comply with the tolerances specified in paragraph CONSTRUCTION TOLERANCES. However, for surfaces with an ACI Class A surface designation, limit the allowable deflection for facing material between studs, for studs between walers and walers between bracing to 0.0025 times the span. Design the formwork 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. Monitor the adequacy of formwork design and construction prior to and during concrete placement as part of the Contractor's approved Quality Control Plan.

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

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

SD-02 Shop Drawings

Formwork; G

SD-03 Product Data

Design Form Materials Form Releasing Agents

SD-04 Samples

Sample Panels; G

SD-06 Test Reports Inspection Formwork Not Supporting Weight of Concrete; G .

1.4 QUALITY ASSURANCE

Sample 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. Use the same concrete mixture proportion and materials, the same placement techniques and equipment, and the same finishing techniques and timing that are planned for the structure.

Construction of Class A finish will not be permitted until sample panels have been approved. Protect sample panels 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. After shop drawings have been reviewed, submit sample panels for Class A finish with applied architectural treatment; panels shall be built on the project site where

SECTION 03 11 13.00 10 Page 3 directed.

PART 2 PRODUCTS

2.1 FORM MATERIALS

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

2.1.1 Forms For Class A Finish

Forms for Class A finished surfaces shall be plywood panels conforming to APA L870 , 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 B Finish

This class of finish shall apply to all surfaces except those specified to receive Class A, Class C, and Class D. Forms for Class B finished surfaces shall be plywood panels conforming to APA L870 , 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. Steel lining on wood sheathing will not be permitted.

2.1.3 Forms For Class C Finish

Forms for Class C finished surfaces shall be shiplap lumber; plywood conforming to APA L870 , Grade B-B concrete form panels, Class I or II;

tempered concrete form hardboard conforming to AHA A135.4 ; 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.

2.1.4 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.

2.1.5 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. Provide solid backing for each tie. Terminate the embedded portion of metal ties not less that 50 mm from any concrete surface exposed to water. Plastic snap ties may be used in locations where the surface will not be exposed to view.

2.1.6 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

SECTION 03 11 13.00 10 Page 4 adhesion nor impede the wetting of surfaces to be cured with water or curing compounds. If special form liners are to be used, follow the recommendation of the form coating manufacturer. Submit manufacturer's recommendation on method and rate of application of form releasing agents.

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Formwork

Forms shall be constructed true to the structural design and required alignment. Forms shall be mortar tight, properly aligned and adequately supported to produce concrete surfaces meeting the surface requirements specified in Section 03 30 00.00 10 CAST-IN-PLACE CONCRETEand conforming to construction tolerance given in TABLE 1. 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. 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. Where concrete surfaces are to have a Class A or Class B finish, joints in form panels shall be arranged as approved. 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.

Form ties that are to be completely withdrawn shall be coated with a nonstaining bond breaker. Submit drawings showing details of formwork, joints, supports, studding and shoring, and sequence of form and shoring removal.

3.2 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.

3.3 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 FORM REMOVAL

Forms shall not be removed without approval. The minimal time required

SECTION 03 11 13.00 10 Page 5 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 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. Form removal shall be scheduled so that all necessary repairs can be performed as specified in Section 03 35 00.00 10. 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 C31/C31M and ASTM C39/C39M at the expense of the Contractor by an independent laboratory that complies with ASTM C1077 and shall be tested within 4 hours after removal from the site.

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

3.4.2 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 indicate evidence the concrete has attained at least 75 percent of the compressive strength required for the structure in accordance with the quality and location requirements.

3.5 INSPECTION

Forms and embedded items shall be inspected in sufficient time prior to each concrete placement 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. Submit field inspection reports for concrete forms and embedded items.

SECTION 03 11 13.00 10 Page 6

TABLE 1

TOLERANCES FOR FORMED SURFACES

1. Variations from the plumb:

a. In the lines and surfaces of columns, piers, walls and in arises

6 mm in any 3 m of length Maximum for entire length -- 25 mm

b. For exposed corner columns, control-joint grooves, and other conspicuous lines

6 mm in any 6 m of length Maximum for entire length -- 13 mm

2. Variation for the level or from the grades indicated on the drawings:

a. In slab soffits, ceilings beam soffits, and in arises,measured before removal of supporting shores

6 mm in any 3 m of length 10 mm in any bay or in any 6 m of length Maximum for entire length -- 20 mm

b. In exposed lintels, sills, parapets, horizontal grooves, and other conspicuous lines

6 mm in any bay or in any 6 m of length Maximum for entire length -- 13 mm

3. Variation of the linear building lines from established position in plan

13 mm in any 6 m 25 mm maximum

4. Variation of distance between walls, columns, partitions

6 mm per 3 m of distance, but not more than 13 mm in any one bay, and not more than 25 mm total variation

5. Variation in the sizes and locations of sleeves, floor openings, and wall opening

Minus 6 mm, Plus 13 mm

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

Minus 6 mm, Plus 13 mm

7. Footings:

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

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

SECTION 03 11 13.00 10 Page 7

TABLE 1

TOLERANCES FOR FORMED SURFACES

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

8. Variation in steps:

a. In a flight of stairs Riser -- 3 mm Tread -- 6 mm

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

-- End of Section --

SECTION 03 11 13.00 10 Page 8

SECTION TABLE OF CONTENTS

DIVISION 03 - CONCRETE

SECTION 03 15 00.00 10

CONCRETE ACCESSORIES

PART 1 GENERAL

1.1 REFERENCES

1.1.1 ACCEPTABLE ALTERNATIVES FOR JAPANESE STANDARDS

1.2 SYSTEM DESCRIPTION

1.2.1 Recycled Content and Regional Materials (LEED NC)

1.3 SUBMITTALS

1.4 DELIVERY, STORAGE, AND HANDLING

PART 2 PRODUCTS

2.1 CONTRACTION JOINT STRIPS

2.2 PREFORMED EXPANSION JOINT FILLER

2.3 SEALANT

2.3.1 Preformed Polychloroprene Elastomeric Type

2.3.2 Lubricant for Preformed Compression Seals

2.3.3 Field-Molded Type

2.4 TESTS, INSPECTIONS, AND VERIFICATIONS

2.4.1 Materials Tests

2.4.1.1 Field-Molded Sealants

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Contraction Joints

3.1.1.1 Joint Strips

3.1.1.2 Sawed Joints

3.1.1.3 Bond Breaker

3.1.2 Expansion Joints

3.1.3 Joint Sealant

3.1.3.1 Joints With Preformed Compression Seals

3.1.3.2 Joints With Field-Molded Sealant

3.2 CONSTRUCTION JOINTS

SECTION 03 15 00.00 10 Page 1

SECTION 03 15 00.00 10

CONCRETE ACCESSORIES

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. Contractor may substitute compatible JIS / JASS standards for non-Japanese standards, as approved by the Contracting Officer's representative.

AMERICAN HARDBOARD ASSOCIATION (AHA)

AHA A135.4 (1995; R 2004) Basic Hardboard

ASTM INTERNATIONAL (ASTM)

ASTM C919 (2008) Use of Sealants in Acoustical Applications

ASTM C920 (2011) Standard Specification for Elastomeric Joint Sealants

ASTM D1751 (2004; R 2008) Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types)

ASTM D1752 (2004a; R 2008) Standard Specification for Preformed Sponge Rubber Cork and Recycled PVC Expansion

ASTM D2628 (1991; R 2011) Standard Specification for Preformed Polychloroprene Elastomeric Joint Seals for Concrete Pavements

ASTM D2835 (1989; R 2007) Lubricant for Installation of Preformed Compression Seals in Concrete Pavements

ASTM D5249 (2010) Backer Material for Use with Cold-and Hot-Applied Joint Sealants in Portland-Cement Concrete and Asphalt Joints

1.1.1 ACCEPTABLE ALTERNATIVES FOR JAPANESE STANDARDS

In addition to the American Standards and criteria referenced in this specification section, certain Japanese Standards have been determined by the Contracting Officer to be acceptable alternatives to the listed US Standards. See Section 01 42 00.00 33 ACCEPTABLE ALTERNATIVES FOR JAPANESE STANDARDS for a listing of these acceptable Japanese Standards and

SECTION 03 15 00.00 10 Page 2 information on the use of Japanese Standards not explicitly listed in Section 01 42 00.00 33.

1.2 SYSTEM DESCRIPTION

1.2.1 Recycled Content and Regional Materials (LEED NC)

Submit documentation indicating the percentage of post-industrial (same as pre-consumer) recycled content per unit of product. Submit documentation indicating the percentage of post-consumer recycled content per unit of product. Provide the cost of any products with reported recycled content included in project. For products that are harvested, extracted and manufactured within 800 km of the project site, submit documentation indicating distance between manufacturing facility and the project site.

Indicate distance of raw material origin (either harvest/extraction location, or location of the source of recycled content) from the project site. For products that are harvested, extracted and manufactured within 800 km of the project site, the cost of the products must be reported.

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

SD-03 Product Data

Preformed Expansion Joint Filler Sealant

Recycled Content and Regional Materials (LEED NC)

SD-04 Samples

Lubricant for Preformed Compression Seals Field-Molded Type

SD-07 Certificates

Preformed Expansion Joint Filler Sealant

1.4 DELIVERY, STORAGE, AND HANDLING

Protect material delivered and placed in storage off the ground from moisture, dirt, and other contaminants. Deliver sealants in the manufacturer's original unopened containers. Remove sealants from the site whose shelf life has expired.

SECTION 03 15 00.00 10 Page 3

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 D1751 or ASTM D1752, Type I, or resin impregnated fiberboard conforming to the physical requirements of ASTM D1752. Submit certified manufacturer's test reports for premolded expansion joint filler strips, compression seals and lubricant, and metallic waterstops to verify compliance with applicable specification . 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 D5249.

2.3 SEALANT

Joint sealant shall conform to the following:

2.3.1 Preformed Polychloroprene Elastomeric Type

ASTM D2628.

2.3.2 Lubricant for Preformed Compression Seals

ASTM D2835. Submit 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. Provide one L of lubricant.

2.3.3 Field-Molded Type

ASTM C920. Sealant shall be Type M, Grade P or NS, Class 25, Use T 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. Submit 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.

2.4 TESTS, INSPECTIONS, AND VERIFICATIONS

2.4.1 Materials Tests

2.4.1.1 Field-Molded Sealants

Samples of sealant and primer, when use of primer is recommended by the manufacturer, as required in paragraph FIELD-MOLDED TYPE, shall be tested by and at the expense of the Government for compliance with paragraph

FIELD-MOLDED TYPE.

SECTION 03 15 00.00 10 Page 4

PART 3 EXECUTION

3.1 INSTALLATION

Joint locations and details, including materials and methods of installation of joint fillers, shall be as specified and indicated. In no case shall any fixed metal be continuous through an expansion or contraction joint.

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. Make joints 3 mm to 5 mm wide and extend into the slab one-fourth the slab thickness, minimum, but not less than 25 mm.

3.1.1.1 Joint Strips

Provide strips of the required dimensions and as long as practicable.

After the first floating, groove the concrete with a tool at the joint locations. Insert the strips in the groove and depress them until the top edge of the vertical surface is flush with the surface of the slab. Float and finish the slab as specified. Working of the concrete adjacent to the joint shall be the minimum necessary to fill voids and consolidate the concrete. Where indicated, saw out the top portion of the strip after the curing period to form a recess for sealer. Discard the removable section of PVC or HIPS strips and leave the insert in place. Maintain true alignment of the strips during insertion.

3.1.1.2 Sawed Joints

Saw joints early enough to prevent uncontrolled cracking in the slab, but late enough that this can be accomplished without appreciable spalling.

Cutting shall be started as soon as the concrete has hardened sufficiently to prevent raveling of the edges of the saw cut. Cutting shall be completed before shrinkage stresses become sufficient to produce cracking.

Use concrete sawing machines that are adequate in number and power, and with sufficient replacement blades to complete the sawing at the required rate. Cut joints to true alignment and in sequence of concrete placement. Remove sludge and cutting debris. Form reservoir for joint sealant.

3.1.1.3 Bond Breaker

Coat joints requiring a bond breaker with curing compound or with bituminous paint.

3.1.2 Expansion Joints

Use preformed expansion joint filler in expansion and isolation joints in slabs around columns and between slabs on grade and vertical surfaces where indicated. Extend the filler to the full slab depth, unless otherwise indicated. neatly finish the edges of the joint 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. Remove the wood strip

SECTION 03 15 00.00 10 Page 5 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. Thoroughly clean the groove of laitance, curing compound, foreign materials, protrusions of hardened concrete, and any dust. If blowing out the groove use oil-free compressed air.

3.1.3 Joint Sealant

Fill sawed contraction joints and expansion joints in slabs 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. Apply joint sealant as recommended by the manufacturer of the sealant.

3.1.3.1 Joints With Preformed Compression Seals

Install compression seals 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. Cover the sides of the joint and, if necessary, the sides of the compression seal with a coating of lubricant.

Coat butt joints with liberal applications of lubricant.

3.1.3.2 Joints With Field-Molded Sealant

Do not seal joints 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 C919 shall be followed. Coat joints requiring a bond breaker with curing compound or with bituminous paint. Install bond breaker and back-up material where required. Joints shall be primed and filled flush with joint sealant in accordance with the manufacturer's recommendations.

3.2 CONSTRUCTION JOINTS

Treat construction joints coinciding with expansion and contraction joints as expansion or contraction joints as applicable.

SECTION 03 15 00.00 10 Page 6

SECTION TABLE OF CONTENTS

DIVISION 03 - CONCRETE

SECTION 03 20 00.00 10

CONCRETE REINFORCING

PART 1 GENERAL

1.1 REFERENCES

1.1.1 ACCEPTABLE ALTERNATIVES FOR JAPANESE STANDARDS

1.2 SYSTEM DECSCRIPTION

1.2.1 Recycled Content and Regional Materials

1.3 SUBMITTALS

1.4 QUALITY ASSURANCE

1.4.1 Welding Qualifications

1.4.2 Qualification of Steel Bar Butt-Splicers

1.4.3 Qualification of Butt-Splicing Procedure

1.5 DELIVERY, STORAGE, AND HANDLING

PART 2 PRODUCTS

2.1 DOWELS

2.2 FABRICATED BAR MATS

2.3 REINFORCING STEEL

2.4 WELDED WIRE FABRIC

2.5 WIRE TIES

2.6 SUPPORTS

2.7 TESTS, INSPECTIONS, AND VERIFICATIONS

2.7.1 Reinforcement Steel Tests

2.7.2 Radiographic Examination of Welds

PART 3 EXECUTION

3.1 REINFORCEMENT

3.1.1 Placement

3.1.2 Splicing

3.1.3 Placing Tolerances

3.1.3.1 Spacing

3.1.3.2 Concrete Cover

3.1.4 Splicing

3.1.4.1 Lap Splices

3.1.4.2 Butt-Splices

3.2 WELDED-WIRE FABRIC PLACEMENT

3.3 DOWEL INSTALLATION

3.4 SPECIAL INSPECTION AND TESTING FOR SEISMIC-RESISTING SYSTEMS

3.5 FIELD TESTS AND INSPECTIONS

3.5.1 Identification of Splices

3.5.2 Examining, Testing, and Correcting

SECTION 03 20 00.00 10 Page 1

SECTION 03 20 00.00 10

CONCRETE REINFORCING

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. Contractor may substitute compatible JIS / JASS standards for non-Japanese standards, as approved by the Contracting Officer's representative.

AMERICAN CONCRETE INSTITUTE INTERNATIONAL (ACI)

ACI 318M (2011) Building Code Requirements for Structural Concrete & Commentary

ACI SP-66 (2004) ACI Detailing Manual

AMERICAN WELDING SOCIETY (AWS)

AWS D1.4/D1.4M (2011) Structural Welding Code - Reinforcing Steel

ASTM INTERNATIONAL (ASTM)

ASTM A370 (2011a) Standard Test Methods and Definitions for Mechanical Testing of Steel Products

ASTM E94 (2004; R 2010) Radiographic Examination

CONCRETE REINFORCING STEEL INSTITUTE (CRSI)

CRSI 10MSP (2009; 28th Ed) Manual of Standard Practice

JAPAN STANDARDS ASSOCATION (JSA)

JIS G 3112 (2010) Steel Bars for Concrete Reinforcement

JIS G 3551 (2005) Welded Steel Wire and Bar Fabrics

U.S. DEPARTMENT OF DEFENSE (DOD)

UFC 3-310-04 (2007; Change 1) Seismic Design for Buildings

1.1.1 ACCEPTABLE ALTERNATIVES FOR JAPANESE STANDARDS

In addition to the American Standards and criteria referenced in this specification section, certain Japanese Standards have been determined by the Contracting Officer to be acceptable alternatives to the listed US

SECTION 03 20 00.00 10 Page 2

Standards. See Section 01 42 00.00 33 ACCEPTABLE ALTERNATIVES FOR JAPANESE STANDARDS for a listing of these acceptable Japanese Standards and information on the use of Japanese Standards not explicitly listed in Section 01 42 00.00 33.

1.2 SYSTEM DECSCRIPTION

1.2.1 Recycled Content and Regional Materials

Submit documentation indicating the percentage of post-industrial (same as pre-consumer) recycled content per unit of product. Submit documentation indicating the percentage of post-consumer recycled content per unit of product. Provide the cost of any products with reported recycled content included in project. For products that are harvested, extracted and manufactured within 800 km of the project site, submit documentation indicating distance between manufacturing facility and the project site.

Indicate distance of raw material origin (either harvest/extraction location, or location of the source of recycled content) from the project site. For products that are harvested, extracted and manufactured within 800 km of the project site, the cost of the products must be reported.

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

SD-02 Shop Drawings

Reinforcement; G

SD-03 Product Data

Welding Butt-Splices; G Material; G Recycled Content and Regional Materials

SD-06 Test Reports

Material; G Tests, Inspections, and Verifications; G

SD-07 Certificates

Reinforcing Steel Qualification of Steel Bar Butt-Splicers

1.4 QUALITY ASSURANCE

1.4.1 Welding Qualifications

Welders shall be qualified in accordance with AWS D1.4/D1.4M .

Qualification test shall be performed at the worksite and notify the Contracting Officer 24 hours prior to conducting tests. Special welding

SECTION 03 20 00.00 10 Page 3 procedures and welders qualified by others may be accepted as permitted by AWS D1.4/D1.4M . Submit a list of qualified welders names.

1.4.2 Qualification of Steel Bar Butt-Splicers

Qualification of steel bar butt-splicers shall be certified to have satisfactorily completed a course of instruction in the proposed method of butt-splicing or have satisfactorily performed such work within the preceding year. Submit certificates on the Qualifications of Steel Bar Butt-Splicers prior to commencing butt-splicing.

1.4.3 Qualification of Butt-Splicing Procedure

As a condition of approval of the butt-splicing procedure, make three test butt-splices of steel bars of each size to be spliced using the proposed butt-splicing method, in the presence of the Contracting Officer. These test butt-splices and unspliced bars of the same size shall be tension tested to destruction with stress-strain curves plotted for each test.

Test results shall show that the butt-splices meet the specified strength and deformation requirements in order for the splicing procedure to be approved.

1.5 DELIVERY, STORAGE, AND HANDLING

Reinforcement and accessories shall be stored off the ground on platforms, skids, or other supports.

PART 2 PRODUCTS

2.1 DOWELS

Dowels shall conform to JIS G 3112 .

2.2 FABRICATED BAR MATS

Fabricated bar mats shall conform to JIS G 3551 .

2.3 REINFORCING STEEL

Reinforcing steel shall be deformed bars conforming to JIS G 3112 grades and sizes as indicated.

Submit certified copies of mill reports attesting that the reinforcing steel furnished contains no less than 25 percent recycled scrap steel and meets the requirements specified herein, prior to the installation of reinforcing steel.

2.4 WELDED WIRE FABRIC

Welded wire and bar fabric shall conform to JIS G 3551 .

2.5 WIRE TIES

Wire ties shall be 16 gauge or heavier black annealed steel wire.

2.6 SUPPORTS

Bar supports for formed surfaces shall be designed and fabricated in accordance with CRSI 10MSP and shall be steel or precast concrete blocks.

SECTION 03 20 00.00 10 Page 4

Precast concrete blocks shall have wire ties and shall be not less than 100 by 100 mm when supporting reinforcement on ground. Precast concrete block shall have compressive strength equal to that of the surrounding concrete. Where concrete formed surfaces will be exposed to weather or where surfaces are to be painted, steel supports within 13 mm of concrete surface shall be galvanized, plastic protected or of stainless steel.

Concrete supports used in concrete exposed to view shall have the same color and texture as the finish surface. For slabs on grade, supports shall be precast concrete blocks, plastic coated steel fabricated with bearing plates, or specifically designed wire-fabric supports fabricated of plastic.

Bar supports shall comply with the requirements of ACI SP-66 . Supports for bars in concrete with formed surfaces exposed to view or to be painted shall be plastic-coated wire, stainless steel or precast concrete supports. Precast concrete supports shall be wedged-shaped, not larger than 90 by 90 mm, of thickness equal to that indicated for concrete cover and have an embedded hooked tie-wire for anchorage. Bar supports used in precast concrete with formed surfaces exposed to view shall be the same quality, texture and color as the finish surfaces.

2.7 TESTS, INSPECTIONS, AND VERIFICATIONS

Perform material tests, specified and required by applicable standards, by an approved laboratory and certified to demonstrate that the materials are in conformance with the specifications. Tests, inspections, and verifications shall be performed and certified at the Contractor's expense. Submit certified tests reports of reinforcement steel showing that the steel complies with the applicable specifications for each steel shipment and identified with specific lots prior to placement. Submit three copies of the heat analyses for each lot of steel furnished certifying that the steel conforms to the heat analyses.

2.7.1 Reinforcement Steel Tests

Mechanical testing of steel shall be in accordance with ASTM A370 or equivalent JIS standard except as otherwise specified or required by the material specifications. Tension tests shall be performed on full cross-section specimens using a gage length that spans the extremities of specimens with welds or sleeves included. Chemical analyses of steel heats shall show the percentages of carbon, phosphorous, manganese, sulphur and silicon present in the steel.

2.7.2 Radiographic Examination of Welds

Radiographic examination of welds shall be in accordance with ASTM E94 or equivalent JIS standard and shall be performed and evaluated by an approved testing agency adequately equipped to perform such services.

Radiographs of welds and evaluations of the radiographs submitted for approval shall become the property of the Government.

PART 3 EXECUTION

3.1 REINFORCEMENT

Reinforcement steel and accessories shall be fabricated and placed as specified and shown and approved shop drawings. Fabrication and placement details of steel and accessories not specified or shown shall be in

SECTION 03 20 00.00 10 Page 5 accordance with ACI SP-66 and ACI 318M . Reinforcement shall be cold bent unless otherwise authorized. Bending may be accomplished in the field or at the mill. Bars shall not be bent after embedment in concrete. Safety caps shall be placed on all exposed ends of vertical concrete reinforcement bars that pose a danger to life safety. Wire tie ends shall face away from the forms. Submit detail drawings showing reinforcing steel placement, schedules, sizes, grades, and splicing and bending details. Drawings shall show support details including types, sizes and spacing.

3.1.1 Placement

Reinforcement shall be free from loose rust and scale, dirt, oil, or other deleterious coating that could reduce bond with the concrete.

Reinforcement shall be placed in accordance with ACI 318M at locations shown plus or minus one bar diameter. Reinforcement shall not be continuous through expansion joints and shall be as indicated through construction or contraction joints. Concrete coverage shall be as indicated or as required by ACI 318M . If bars are moved more than one bar diameter to avoid interference with other reinforcement, conduits or embedded items, the resulting arrangement of bars, including additional bars required to meet structural requirements, shall be approved before concrete is placed.

3.1.2 Splicing

Splices of reinforcement shall conform to ACI 318M and shall be made only as required or indicated. Splicing shall be by lapping or by mechanical or welded butt connection; except that lap splices shall not be used for bars larger than D38 unless otherwise indicated. Welding shall conform to AWS D1.4/D1.4M . Welded butt splices shall be full penetration butt welds. Lapped bars shall be placed in contact and securely tied or spaced transversely apart to permit the embedment of the entire surface of each bar in concrete. Lapped bars shall not be spaced farther apart than one-fifth the required length of lap or 150 mm. Mechanical butt splices shall be in accordance with the recommendation of the manufacturer of the mechanical splicing device. Butt splices shall develop 125 percent of the specified minimum yield tensile strength of the spliced bars or of the smaller bar in transition splices. Bars shall be flame dried before butt splicing. Adequate jigs and clamps or other devices shall be provided to support, align, and hold the longitudinal centerline of the bars to be butt spliced in a straight line.

3.1.3 Placing Tolerances

3.1.3.1 Spacing

The spacing between adjacent bars and the distance between layers of bars may not vary from the indicated position by more than one bar diameter nor more than 25 mm.

3.1.3.2 Concrete Cover

The minimum concrete cover of main reinforcement steel bars shall be as shown. The allowable variation for minimum cover shall be as follows:

SECTION 03 20 00.00 10 Page 6

MINIMUM COVER (mm) VARIATION (mm)

150 plus 13

100 plus 10

75 plus 10

50 plus 6

38 plus 6

25 plus 3

19 plus 3

3.1.4 Splicing

Splices in steel bars shall be made only as required. Bars may be spliced at alternate or additional locations at no additional cost to the Government subject to approval.

3.1.4.1 Lap Splices

Lap splices shall be used only for bars smaller than size D38 and welded wire fabric . Lapped bars may be placed in contact and securely tied or spaced transversely apart to permit the embedment of the entire surface of each bar in concrete. Lapped bars shall not be spaced farther apart than 1/5 the required length of lap or 150 mm.

3.1.4.2 Butt-Splices

Use butt-splices only for splicing size D41 and D51 bars and for splicing D38 bars to larger bars except where otherwise shown or authorized. Make butt-splices by a method which develops splices suitable for tension, compression and stress reversal applications. Welded butt-splices shall be full penetration butt welds. Butt-splices shall develop 90 percent of the specified minimum ultimate tensile strength of the smallest bar of each splice. Bars shall be cleaned of all oil, grease, dirt, rust, scale and other foreign substances and shall be flame dried before splicing.

Adequate jigs and clamps or other devices shall be provided to support, align and hold the longitudinal centerline of the bars to be butt-spliced in a straight line. Submit proposed procedure for butt-splicing steel bars prior to making the test butt-splices for qualification of the procedure. Properties and analyses of steel bars and splicing materials shall be included in the submitted procedure. Physical properties of splicing sleeves shall include length, inside and outside diameters, and inside surface details.. Butt-splices shall be as follows:

a. Thermit Welded Butt Splices - Bars to be thermit welded shall be restricted to steel shown by heat analysis to have a sulfur content not exceeding 0.05 percent. The ends of bars to be thermit welded shall be cut square and smooth. Flame cutting will be permitted provided grinding is employed to remove the resulting scale and to square and smooth the cut ends to a condition equivalent to a saw cut. No shearing will be permitted. Bars shall be cleaned and flame

SECTION 03 20 00.00 10 Page 7 dried before splicing. The joint shall be properly aligned in the mold with a gap opening in accordance with the manufacturer's recommendations. Charging and firing shall conform to the manufacturer's recommendations. The end of bars and the welded mold shall be preheated before welding to a temperature of not less than 40 degrees C and the mold shall be left in place for at least 15 minutes after ignition. Risers shall be broken or burned off after removing the mold. Tension splices shall be staggered longitudinally a minimum of 1500 mm so that no more than half of the bars are spliced at any one section or as otherwise indicated.

b. Mechanical Butt-Splices - Mechanical butt-splices shall be an approved exothermic, threaded coupling, swaged sleeve or other positive connecting type. Bars to be spliced by a mechanical butt-splicing process may be sawed, sheared or flame cut provided the ends of sheared bars are reshaped after shearing and all slag is removed from the ends of flame cut bars by chipping and wire brushing prior to splicing. Surfaces to be enclosed within a splice sleeve or coupling shall be cleaned by wire brushing or other approved method prior to splicing. Splices shall be made using manufacturer's standard jigs, clamps, ignition devices and other required accessories. In addition to the strength requirements specified paragraph BUTT-SPLICES the additional deformation of number D41 and smaller bars due to slippage or other movement within the splice sleeve shall not exceed 0.38 mm (unit strain 0.0015 mm/mm) beyond the elongation of an unspliced bar based upon a 250 mm gage length spanning the extremities of the sleeve at a stress of 200 MPa. The additional deformation of number D51 bars shall not exceed 0.75 mm (unit strain 0.003 mm/mm) beyond the elongation of an unspliced bar based upon a 250 mm gage length spanning the extremities of the sleeve at a stress of 200 MPa. The amount of the additional deformation shall be determined from the stress-strain curves of the unspliced and spliced bars tested as required paragraph QUALIFICATION OF BUTT-SPLICING PROCEDURE for qualification of the butt-splicing procedure.