PTFL182103_Repair_Loading_Dock_Specs.pdf

Construction Documents

SPECIFICATIONS

Repair Loading Dock Plates Building 3369

NJANG Project No. PTFL 182103

NEW JERSEY AIR NATIONAL GUARD

108th Wing

Joint Base McGuire-Dix-Lakehurst, New Jersey

February 21, 2018

02050 DEMOLITION

INDEX

PAGE

SECTION 02050 – DEMOLITION 02050 – 1-3

SECTION 02520 – PORTLAND CEMEMT CONCRETE PAVING 02520 – 1-11

SECTION 02521 - CONCRETE CURBS, SIDEWALKS AND PAVEMENTS 02521 – 1-5

SECTION 03300 – CAST-IN-PLACE CONCRETE 03300 – 1-19

SECTION 03301 - REINFORCED CONCRETE 03301 – 1-8

SECTION 03600 – GROUT 03600 - 1-5

SECTION 05500 – METAL FABRICATIONS 05500 – 1-12

SECTION 05810 – EXPANSION JOINT COVER ASSEMBLIES 05810 – 1-3

SECTION 07270 – FIRESTOPPING 07270 – 1-8

SECTION 07901 – JOINT SEALANTS 07901 – 1-8

SECTION 16050 - BASIC METHODS AND REQUIREMENTS

(ELECTRICAL) 16050 - 1-19

SECTION 16110 - RACEWAY SYSTEMS 16110 - 1-15

SECTION 16120 - WIRES AND CABLES, LOW VOLTAGE (600 Volts and Below) 16120 - 1-7 SECTION 16124 - CABLES, MEDIUM VOLTAGE (Above 600 Volts) 16124 - 1-11

SECTION 16140 - WIRING DEVICES 16140 - 1-4

SECTION 16400 - DISCONNECTS (MOTORS AND CIRCUIT) 16400 - 1-3

SECTION 16410 - POWER FACTOR CORRECTION 16410 - 1-2

SECTION 16450 - GROUNDING 16450 - 1-5

SECTION 16460 - TRANSFORMERS (GENERAL PURPOSE) 16460 - 1-5

SECTION 16462 - DISTRIBUTION SWITCHBOARDS 16462 - 1-6

SECTION 16470 - PANELBOARDS 16470 - 1-6

SECTION 16480 - MOTORS 16480 - 1-3

SECTION 16481 - MOTOR CONTROLLERS 16481 - 1-3

SECTION 16482 - MOTOR CONTROL CENTERS 16482 - 1-5

SECTION 111319 – LOADING DOCK LEVELERS ( UFGS Specifications ) 11 13 19.13 i

SECTION 02050 - DEMOLITION

PART 1 GENERAL

1.1 SECTION INCLUDES

A. Utility lines, and other items to be demolished and/or abandoned are as shown.

1.2 SUBMITTALS

A. Quality Control Submittals:

1. Schedule of demolition, as part of and consistent with the progress schedule specified in Section 01310, PROGRESS/CRITICAL PATH SCHEDULES.

2. Copies of any authorizations and permits required to perform Work.

PART 2 PRODUCTS (NOT USED)

PART 3 EXECUTION

3.1 PREPARATION

A. Utilities:

1. Notify CONTRACTING OFFICER or appropriate utilities to turn off affected services before starting demolition or alterations.

2. Remove utility lines exposed by demolition excavation.

3. Remove electric, sanitary, water, and storm drainage adjacent to buildings to be demolished.

4. Excavate utility lines serving buildings to be demolished and provide a permanent leak-proof closure for water and gas lines.

3.2 DEMOLITION

A. Drawings define minimum required demolition. Unless otherwise shown, rough cuts or breaks may be made exceeding limits of demolition shown.

B. Core drill floor slabs, catch basins, and other concrete improvements to remain in place below ground, or break holes at structure's lowest point to allow water to freely migrate through.

C. Remove piping as shown and from any other areas that interfere with CONTRACTOR’s work. Pipe, valves, and fittings adjacent to those to be removed may also be removed as salvage.

D. Cut off concealed or embedded conduit, boxes, or other materials a minimum of 6 inches below final finished surface.

E. Perform site cleanup daily before leaving the work site. Store equipment in a neat and orderly arrangement.

F. Abandonment of Buried Utility Piping Systems:

1. Plug pipelines at exposed excavations and at manholes or other utility structures with minimum 5-foot long concrete plug.

2. Manholes/wet wells/drainage structures:

a. Remove frames and covers/grates for salvage.

b. Remove structures shown on Drawings.

c. Backfill as described herein.

G. Demolition of utility poles, street signs and similar items:

1. Remove entire structure, including portions below ground.

2. Remove and separate items for salvage.

3. Backfill as described herein.

3.3 DISPOSAL

A. Dispose of debris and other nonsalvaged materials off base at location selected by

CONTRACTOR.

3.4 BACKFILLING

A. Demolished Areas: Backfill to existing ground level or foundation level of new construction.

B. Backfill Material and Compaction:

1. Conform to Section 02220, FILL AND BACKFILL.

3.5 SALVAGE

1. Do not use demolition debris as backfill material.

A. Equipment and materials, including piping within the limits of demolition, unless otherwise specified, will become the property of the CONTRACTOR.

END OF SECTION

PORTLAND CEMENT CONCRETE PAVING 02520 - 1

SECTION 02520 - PORTLAND CEMENT CONCRETE PAVING

PART 1 - GENERAL

RELATED DOCUMENTS

Drawings and general provisions of the Contract, including General and Division 1 Specification Sections, apply to this Section.

SUMMARY

This Section includes exterior portland cement concrete paving for the following:

Roadways and drives.

Parking areas.

Curbs and gutters.

Walkways.

Related Sections: The following Sections contain requirements that relate to this Section:

Division 2 Section "Earthwork" for subgrade preparation, grading and stabilization.

Division 3 Section "Cast-in-Place Concrete" for general building applications of concrete.

Division 2 Section “Portland Cement Concrete Pavement for Airfield Construction”, for exterior apron and tow-way paving.

Division 7 Section "Joint Sealants" for joint fillers and sealants within concrete paving and at joints with adjacent construction.

SUBMITTALS

General: Submit the following according to the Conditions of the Contract and Division 1 Specification Sections.

Product data for proprietary materials and items, including reinforcement and forming accessories, admixtures, joint systems, curing compounds, and others if requested by Contracting Officer.

Design mixes for each class of concrete. Include revised mix proportions when characteristics of materials, project conditions, weather, test results, or other circumstances warrant adjustments.

Laboratory test reports for evaluation of concrete materials and mix design tests.

Material certificates in lieu of material laboratory test reports when permitted by Contracting Officer.

02520 - 2 PORTLAND CEMENT CONCRETE PAVING

Material certificates shall be signed by manufacturer and Contractor certifying that each material item complies with or exceeds requirements.

QUALITY ASSURANCE

Concrete Standards: Comply with provisions of the following standards, except where more stringent requirements are indicated.

American Concrete Institute (ACI) 301, "Specifications for Structural Concrete for Buildings."

ACI 318, "Building Code Requirements for Reinforced Concrete."

Concrete Reinforcing Steel Institute (CRSI) "Manual of Standard Practice."

Concrete Testing Service: Employ at Contractor's expense a qualified independent testing agency to perform materials evaluation tests and to design concrete mixes.

PROJECT CONDITIONS

Traffic Control: Maintain access for vehicular and pedestrian traffic as required for other construction activities.

PART 2 - PRODUCTS

FORMS

Form Materials: Plywood, metal, metal-framed plywood, or other acceptable panel-type materials to provide full-depth, continuous, straight, smooth exposed surfaces.

Use flexible or curved forms for curves of a 100-foot or less radius.

Form Release Agent: Provide commercial formulation form-release agent with a maximum of 350 g/L volatile organic compounds (VOCs) that will not bond with, stain, or adversely affect concrete surfaces and will not impair subsequent treatments of concrete surfaces. Product shall be equal to “React S”, Conspec Marketing & Mfg. Co.

REINFORCING MATERIALS

Reinforcing Bars and Tie Bars: ASTM A 615, Grade 60, deformed.

Welded Steel Wire Fabric: ASTM A 185.

Furnish in flat sheets, not rolls.

Joint Dowel Bars: Plain steel bars, ASTM A 615, Grade 60. Cut bars true to length with ends square and free of burrs.

Supports for Reinforcement: Chairs, spacers, dowel bar supports and other devices for spacing, supporting, and fastening reinforcing bars, welded wire fabric, and dowels in place. Use wire bar-type supports complying with CRSI specifications.

02520 - 3 PORTLAND CEMENT CONCRETE PAVING

Use supports with sand plates or horizontal runners where base material will not support chair legs.

CONCRETE MATERIALS

Portland Cement: ASTM C 150, Type I.

Use one brand of cement throughout Project.

Fly Ash: Fly ash will not be permitted in concrete.

Normal-Weight Aggregates: ASTM C 33, as Specified in Section 03300. Provide aggregates from a single source. Coarse aggregates shall meet the requirements for deleterious substances contained in ASTM C 33, Class 45.

Water: Potable.

ADMIXTURES

Provide concrete admixtures that contain not more than 0.1 percent chloride ions.

Air-Entraining Admixture: ASTM C 260, certified by manufacturer to be compatible with other required admixtures.

Water-Reducing Admixture: ASTM C 494, Type A.

High-Range Water-Reducing Admixture: ASTM C 494, Type F or Type G.

Water-Reducing and Accelerating Admixture: ASTM C 494, Type E.

Water-Reducing and Retarding Admixture: ASTM C 494, Type D.

Products: Subject to compliance with requirements, provide products specified in Section 03300.

CURING MATERIALS

Absorptive Cover: Burlap cloth made from jute or kenaf, weighing approximately 9 oz. per sq. yd., complying with AASHTO M 182, Class 2.

Moisture-Retaining Cover: One of the following, complying with ASTM C 171.

Waterproof paper.

Polyethylene film.

White burlap-polyethylene sheet.

Water-based Resin Liquid Membrane-Forming Curing Compound: ASTM C 309, Type II, Class A or B, wax free.

Evaporation Control: Monomolecular film-forming compound applied to exposed concrete slab surfaces for temporary protection from rapid moisture loss.

02520 - 4 PORTLAND CEMENT CONCRETE PAVING

Products: Subject to compliance with requirements, provide one of the following:

White Pigment Water-Based Resin Liquid Membrane-Forming Curing Compound:

D.O.T. Resin Cure; Type II Conspec Marketing & Mfg. Co.

Kurez Vox, Type II; Euclid Chemical Co.

Evaporation Control:

Aquafilm; Conspec Marketing and Mfg. Co.

Eucobar; Euclid Chemical Co.

E-Con; L&M Construction Chemicals, Inc.

Confilm; Master Builders, Inc.

RELATED MATERIALS

Traffic Paint: Alkyd-resin ready-mixed, complying with AASHTO M 248 and Federal Specification TT- P-001952.

Color: As indicated on drawings.

Bonding Agent: Acrylic or styrene butadiene. Product shall be equal to “Strongbond”, Conspec Marketing & Mfg. Co.

Epoxy Adhesive: ASTM C 881, two-component material suitable for dry or damp surfaces. Provide material type, grade, and class to suit requirements. Product shall be equal to “Specbond Epoxies”, Conspec Marketing & Mfg. Co.

CONCRETE MIX

Prepare design mixes for each type and strength of normal-weight concrete by either laboratory trial batch or field experience methods as specified in ACI 301. For the trial batch method, use a qualified independent testing agency for preparing and reporting proposed mix designs.

Use of fly ash will not be permitted.

Submit written reports to Contracting Officer’s Representative of each proposed mix for each class of concrete at least 15 days prior to start of Work. Do not begin concrete production until proposed mix designs have been reviewed by Contracting Officer’s Representative.

Proportion mixes according to ACI 211.1 and ACI 301 to provide normal-weight concrete with the following properties:

Compressive Strength (28-Day): 4000 psi, minimum.

Flexural Strength (28-Day): 650 psi, minimum.

02520 - 5 PORTLAND CEMENT CONCRETE PAVING

Maximum Water-Cement Ratio at Point of Placement: 0.45.

Cement Content: Not less than six bags per cubic yard.

Slump Limit at Point of Placement: Not more than 3 inches.

Slump limit for concrete containing high-range water-reducing admixture (superplasticizer): Not more than 8 inches after adding admixture to site-verified 2-to-3-inch slump concrete.

Add air-entraining admixture at manufacturer's prescribed rate to result in concrete at point of placement having an air content as follows:

Air Content: 5.5 percent to 7.0 percent.

Adjustment to Concrete Mixes: Mix design adjustments may be requested by Contractor when characteristics of materials, project conditions, weather, test results, or other circumstances warrant.

CONCRETE MIXING

Ready-Mixed Concrete: Comply with requirements of Specification Section 03300.

PART 3 - EXECUTION

SURFACE PREPARATION

Proof-roll prepared subbase surface to check for unstable areas and verify need for additional compaction.

Do not begin paving work until such conditions have been corrected and are ready to receive paving.

Refer to Specification Section 02200.

Remove loose material from compacted subbase surface immediately before placing concrete.

EDGE FORMS AND SCREED CONSTRUCTION

Set, brace, and secure edge forms, bulkheads, and intermediate screed guides for paving to required lines, grades, and elevations. Install forms to allow continuous progress of work and so that forms can remain in place at least 24 hours after concrete placement.

Check completed formwork and screeds for grade and alignment to following tolerances:

Top of Forms: Not more than 1/8 inch in 10 feet.

Vertical Face on Longitudinal Axis: Not more than 1/4 inch in 10 feet.

Clean forms after each use and coat with form release agent as required to ensure separation from concrete without damage.

02520 - 6 PORTLAND CEMENT CONCRETE PAVING

PLACING REINFORCEMENT

General: Comply with Concrete Reinforcing Steel Institute's recommended practice for "Placing Reinforcing Bars" for placing and supporting reinforcement.

Clean reinforcement of loose rust and mill scale, earth, ice, or other bond-reducing materials.

Arrange, space, and securely tie bars and bar supports to hold reinforcement in position during concrete placement. Maintain minimum cover to reinforcement.

Install welded wire fabric in lengths as long as practicable. Lap adjoining pieces at least one full mesh and lace splices with wire. Offset laps of adjoining widths to prevent continuous laps in either direction.

JOINTS

General: Construct contraction, construction, and isolation joints true to line with faces perpendicular to surface plane of concrete. Construct transverse joints at right angles to the centerline, unless indicated otherwise.

Contraction Joints: Provide weakened-plane contraction joints, sectioning concrete into areas as shown on Drawings. Construct contraction joints for a depth equal to at least 1/4 of the concrete thickness, as follows:

Tooled Joints: Form contraction joints in fresh concrete by grooving and finishing each edge of joint with a radiused jointer tool. Permitted for use on walkways only.

Sawed Joints: Form contraction joints with power saws equipped with shatterproof abrasive or diamond-rimmed blades. Cut joints into hardened concrete as shown on drawings when cutting action will not tear, abrade, or otherwise damage surface and before development of random contraction cracks. Cutting shall be completed not more than 12 hours after placement of concrete.

Construction Joints: Set construction joints at side and end terminations of paving and at locations where paving operations are stopped for more than 1/2 hour, unless paving terminates at isolation joints.

Continue reinforcement across construction joints unless indicated otherwise.

Use bonding agent on existing concrete surfaces that will be joined with fresh concrete.

Isolation Joints: Form isolation joints of preformed joint filler strips abutting concrete curbs, catch basins, manholes, inlets, structures, walks, other fixed objects, and where indicated.

Locate expansion joints as indicated on Drawings, or, if not indicated, at maximum intervals of 50 feet as acceptable by Contracting Officer’s Representative.

Extend joint fillers full width and depth of joint, not less than 1/2 inch or more than 1 inch below finished surface where joint sealant is indicated.

All isolation and expansion joints shall be filled with joint sealant.

02520 - 7 PORTLAND CEMENT CONCRETE PAVING

Furnish joint fillers in one-piece lengths for full width being placed wherever possible. Where more than one length is required, lace or clip joint filler sections together.

Protect top edge of joint filler during concrete placement with a metal, plastic, or other temporary preformed cap. Remove protective cap after concrete has been placed on both sides of joint.

In combined curb and gutter and valley gutter sections, locate expansion joints at the tangent point of all curves, each side of inlets, and at intervals of not more than 250 feet in straight runs. Expansion joints shall be cut to full size and shape of the cross section of the curb and gutter less one-half inch from the finished surface thereof. The edges of the blocks against the joint shall be finished with an edging tool and the joint raked clean of concrete.

Installation of joint fillers and sealants is specified in Division 7 Section "Joint Sealants."

Install dowel bars and support assemblies at joints where indicated. Lubricate or asphalt-coat one half of dowel length to prevent concrete bonding to one side of joint.

CONCRETE PLACEMENT

Inspection: Before placing concrete, inspect and complete formwork installation, reinforcing steel, and items to be embedded or cast in. Notify other trades to permit installation of their work.

Remove snow, ice, or frost from subbase surface and reinforcing before placing concrete. Do not place concrete on surfaces that are frozen.

Moisten subbase to provide a uniform dampened condition at the time concrete is placed. Do not place concrete around manholes or other structures until they are at the required finish elevation and alignment.

Comply with requirements and with ACI 304R for measuring, mixing, transporting, and placing concrete.

Deposit and spread concrete in a continuous operation between transverse joints. Do not push or drag concrete into place or use vibrators to move concrete into place.

When concrete placing is interrupted for more than 1/2 hour, place a construction joint.

Use a bonding agent at locations where fresh concrete is placed against hardened or partially hardened concrete surfaces.

Consolidate concrete by mechanical vibrating equipment supplemented by hand-spading, rodding, or tamping. Use equipment and procedures to consolidate concrete complying with ACI 309R.

Consolidate concrete along face of forms and adjacent to transverse joints with an internal vibrator.

Keep vibrator away from joint assemblies, reinforcement, or side forms. Use only square-faced shovels for hand-spreading and consolidation. Consolidate with care to prevent dislocating reinforcing, dowels, and joint devices.

Screed paved surfaces with a straightedge and strike off. Use bull floats or darbies to form a smooth

02520 - 8 PORTLAND CEMENT CONCRETE PAVING

surface plane before excess moisture or bleed water appears on the surface. Do not further disturb concrete surfaces prior to beginning finishing operations.

Curbs and Gutters: When automatic machine placement is used for curb and gutter placement, submit revised mix design and laboratory test results that meet or exceed requirements. Produce curbs and gutters to required cross section, lines, grades, finish, and jointing as specified for formed concrete. If results are not acceptable, remove and replace with formed concrete.

Cold-Weather Placement: Comply with provisions of ACI 306R and as follows. Protect concrete work from physical damage or reduced strength that could be caused by frost, freezing actions, or low temperatures.

When air temperature has fallen to or is expected to fall below 40 deg F (4 deg C), uniformly heat water and aggregates before mixing to obtain a concrete mixture temperature of not less than 50 deg F (10 deg C) and not more than 80 deg F (27 deg C) at point of placement.

Do not use frozen materials or materials containing ice or snow.

Do not use calcium chloride, salt, or other materials containing antifreeze agents or chemical accelerators unless otherwise accepted in mix designs.

Hot-Weather Placement: Place concrete complying with ACI 305R and as specified when hot weather conditions exist.

Cool ingredients before mixing to maintain concrete temperature at time of placement to below 90 deg F (32 deg C). Mixing water may be chilled or chopped ice may be used to control temperature, provided water equivalent of ice is calculated to total amount of mixing water. Using liquid nitrogen to cool concrete is Contractor's option.

Cover reinforcing steel with water-soaked burlap if it becomes too hot, so that steel temperature will not exceed the ambient air temperature immediately before embedding in concrete.

Fog spray forms, reinforcing steel, and subgrade just before placing concrete. Keep subgrade moisture uniform without standing water, soft spots, or dry areas.

CONCRETE FINISHING

Float Finish: Begin floating when bleed water sheen has disappeared and the concrete surface has stiffened sufficiently to permit operations. Float surface with power-driven floats, or by hand-floating if area is small or inaccessible to power units. Finish surfaces to true planes within a tolerance of 1/4 inch in 10 feet as determined by a 10-foot-long straightedge placed anywhere on the surface in any direction. Cut down high spots and fill low spots. Refloat surface immediately to a uniform granular texture.

Medium Textured Broom Finish: Draw a bristle broom across concrete surface perpendicular to line of traffic to provide a uniform fine line texture finish. Repeat operation if required to provide a texture acceptable to Architect.

02520 - 9 PORTLAND CEMENT CONCRETE PAVING

Final Tooling: Tool edges of paving, gutters, curbs, and joints formed in fresh concrete with a jointing tool.

Repeat tooling of edges and joints after applying surface finishes. Eliminate tool marks on concrete surfaces.

CONCRETE PROTECTION AND CURING

General: Protect freshly placed concrete from premature drying and excessive cold or hot temperatures.

Comply with the recommendations of ACI 306R for cold weather protection and ACI 305R for hot weather protection during curing.

Evaporation Control: In hot, dry, and windy weather, protect concrete from rapid moisture loss before and during finishing operations with an evaporation-control material. Apply according to manufacturer's instructions after screeding and bull floating, but before floating.

Begin curing after finishing concrete but not before free water has disappeared from concrete surface.

Curing Methods: Cure concrete by moisture curing, moisture-retaining-cover curing, curing compound, or a combination of these as follows:

Moisture Curing: Keep surfaces continuously moist for not less than 7 days with the following materials:

Water.

Continuous water-fog spray.

Absorptive cover, water saturated, and kept continuously wet. Cover concrete surfaces and edges with a 12-inch lap over adjacent absorptive covers.

Moisture-Retaining-Cover Curing: Cover concrete surfaces with moisture-retaining cover for curing concrete, placed in widest practicable width, with sides and ends lapped at least 12 inches, and sealed by waterproof tape or adhesive. Immediately repair any holes or tears during curing period using cover material and waterproof tape.

Curing Compound: Apply uniformly in continuous operation by power spray or roller according to manufacturer's directions. Recoat areas subjected to heavy rainfall within 3 hours after initial application. Maintain continuity of coating and repair damage during curing period.

TRAFFIC PAINT

Traffic Paint: Apply traffic paint for striping and other markings with mechanical equipment to produce uniform straight edges. Apply at manufacturer's recommended rates to provide a 15-mil minimum wet film thickness.

FIELD QUALITY CONTROL TESTING

Employ a qualified independent testing and inspection agency to sample materials, perform tests, and

02520 - 10 PORTLAND CEMENT CONCRETE PAVING

submit test reports during concrete placement as specified in Section 03300.

REPAIRS AND PROTECTION

Remove and replace concrete paving that is broken, damaged, or defective, or does not meet the requirements of this Section.

Drill test cores where directed by Contracting Officer when necessary to determine magnitude of cracks or defective areas. Fill drilled core holes in satisfactory pavement areas with portland cement concrete bonded to paving with epoxy adhesive.

Protect concrete from damage. Exclude traffic from paving for at least 14 days after placement. When construction traffic is permitted, maintain paving as clean as possible by removing surface stains and spillage of materials as they occur.

Maintain concrete paving free of stains, discoloration, dirt, and other foreign material. Sweep concrete paving prior to date scheduled for Substantial Completion.

END OF SECTION 02520

02521 - 1 CONCRETE CURBS, SIDEWALKS, AND PAVEMENTS

SECTION 02521 - CONCRETE CURBS, SIDEWALKS AND PAVEMENTS

1.1 DEFINITIONS

A. Standard Specifications: 1996 Standard Specifications for Construction, Michigan

Department of Transportation.

A. Shop Drawings:

1. Form Material: Information on metal forms, if used, including type, condition, surface finish, and intended function.

2. Complete data on concrete mix, including aggregate gradations and admixtures in accordance with requirements of ASTM C94.

3. Jointing plan for concrete pavements.

B. Quality Control Submittals:

1. Curing Compound: Manufacturer's Certificate of Compliance and application instructions.

2. Ready-mix delivery ticket for each truck in accordance with ASTM C94.

1.3 QUALITY ASSURANCE

A. Conform to Standard Specifications.

PART 2 PRODUCTS

2.1 CONCRETE

A. As specified in Section 03301, REINFORCED CONCRETE.

2.2 EXPANSION JOINT FILLER

A. As specified in Section 03301, REINFORCED CONCRETE.

2.3 JOINT SEALANT

02521 - 2 CONCRETE CURBS, SIDEWALKS, AND PAVEMENTS

A. Preformed Joint Seals for Concrete Construction as specified in Section 914.04D of the Standard Specifications.

2.4 CURING COMPOUND

A. Liquid membrane-forming, clear or translucent, suitable for spray application and meeting ASTM C309, Type 1.

3.1 FORMWORK

A. Lumber Materials:

1. 2-inch dressed dimension lumber, or metal of equal strength, straight, free from defects that would impair appearance or structural quality of completed curb and sidewalk.

2. 1-inch dressed lumber or plywood may be used where short-radius forms are required.

B. Metals: Steel in new undamaged condition.

C. Setting Forms:

1. Construct forms to shape, lines, grades, and dimensions.

2. Stake securely in place.

D. Bracing:

1. Brace forms to prevent change of shape or movement resulting from placement.

2. Construct short-radius curved forms to exact radius.

E. Tolerances:

1. Do not vary tops of forms from gradeline more than 1/8-inch when checked with 10-foot straightedge.

02521 - 3 CONCRETE CURBS, SIDEWALKS, AND PAVEMENTS

2. Do not vary alignment of straight sections more than 1/8-inch in 10 feet.

3.2 PLACING CONCRETE

A. Prior to placing concrete, remove water from excavation and debris and foreign material from forms.

B. Place concrete as soon as possible, and within 1-1/2 hours after adding cement to mix without segregation or loss of ingredients, and without splashing.

C. Place concrete as specified in Section 03301, REINFORCED CONCRETE.

D. To compact, vibrate until concrete becomes uniformly plastic.

3.2 CURB CONSTRUCTION

A. Comply with Section 802 of the Standard Specifications and details as shown. If requirements differ from those specified herein, the more stringent shall govern.

B. Construct ramps at locations as shown on the Plans.

C. Expansion Joints: Place at maximum 45-foot intervals and at the beginning and end of curved portions of curb, and at connections to existing curbs. Install expansion joint filler at each joint.

D. Curb Facing: Do not allow horizontal joints within 7 inches from top of curb.

E. Contraction Joints:

1. Maximum 15-foot intervals in curb.

2. Provide open joint type by inserting thin, oiled steel sheet vertically in fresh concrete to force coarse aggregate away from joint.

3. Insert steel sheet to full depth of curb.

4. Remove steel sheet with sawing motion after initial set has occurred in concrete and prior to removing front curb form.

02521 - 4 CONCRETE CURBS, SIDEWALKS, AND PAVEMENTS

5. Finish top of curb with steel trowel and finish edges with steel edging tool.

F. Front Face:

1. Remove front form and finish exposed surfaces when concrete has set sufficiently to support its own weight.

3. Finish formed face by rubbing with burlap sack or similar device to produce uniformly textured surface, free of form marks, honeycomb, and other defects.

4. Remove and replace defective concrete.

5. Apply curing compound to exposed surfaces of curb upon completion of finishing.

6. Continue curing for minimum of 5 days.

F. Backfill curb with earth upon completion of curing period, but not before 7 days has elapsed since placing concrete.

1. Backfill shall be free from rocks 2 inches and larger and other foreign material.

2. Compact backfill firmly.

3.4 SIDEWALK CONSTRUCTION

A. Comply with Section 803 of the Standard Specifications and details as shown. If

B. Thickness:

1. 4 inches in walk areas.

2. 6 inches in driveway areas.

C. Expansion Joints: Place in adjacent curb, where sidewalk ends at curb, and around posts, poles, or other objects penetrating sidewalk. Install expansion joint filler at each joint.

D. Contraction Joints:

1. Maximum 7-1/2 feet.

02521 - 5 CONCRETE CURBS, SIDEWALKS, AND PAVEMENTS

2. Provide transversely to walks at locations opposite contraction joints in curb.

3. Dimensions: 3/16-inch by 1-inch weakened plane joints.

4. Construct straight and at right angles to surface of walk.

E. Finish:

1. Broom surface with fine-hair broom at right angles to length of walk and tool at edges, joints, and markings.

2. Mark walks transversely at 5-foot intervals with jointing tool; finish edges with rounded steel edging tool.

3. Apply curing compound to exposed surfaces upon completion of finishing.

4. Protect sidewalk from damage and allow to cure for at least 7 days.

3.5 CONCRETE PAVEMENT CONSTRUCTION

A. Comply with Section 602 of the Standard Specifications and details as shown. If

B. Expansion Joints: Place at locations where pavement slabs abut building construction. Install expansion joint filler at each joint.

C. Contraction Joints:

1. Provide jointing plan for review.

2. Dimensions: 3/16-inch by 1-inch weakened plane joints.

3. Construct straight and at right angles to adjacent features.

D. Construction Joints: As specified in Section 03301, REINFORCED

CONCRETE.

E. Finish: As specified in Section 03301, REINFORCED CONCRETE.

END OF SECTION 0521

CAST-IN-PLACE CONCRETE 03300 - 1

SECTION 03300 - CAST-IN-PLACE CONCRETE

PART 1 - GENERAL

RELATED DOCUMENTS

Drawings and general provisions of the Contract, including General and Division 1 Specification Sections, apply to this Section.

This Section specifies cast-in place concrete, including formwork, reinforcing, mix design, placement procedures, and finishes.

Related Sections: The following Sections contain requirements that relate to this Section:

Division 2 Section "Exterior Portland Cement Concrete" for concrete paving and walks.

Division 2 Section “Exterior Portland Cement Concrete Pavement for Airfield Construction” for exterior apron and tow-way paving.

Division 2 Section "Auger Cast Piles” for auger cast piles.

Division 4 Section “Unit Masonry” for grout.

Division 9 Section “Reflective Chemically Resistant Urethane Floor Coating” for coating on Hangar Bay slab.

General: Submit the following according to Conditions of the Contract and Division 1 Specification Sections.

Product data for proprietary materials and items, including reinforcement and forming accessories, admixtures, patching compounds, waterstops, joint systems, curing compounds, and others if requested by Architect.

Shop drawings for reinforcement detailing fabricating, bending, and placing concrete reinforcement.

Comply with ACI 315 "Manual of Standard Practice for Detailing Reinforced Concrete Structures" showing bar schedules, stirrup spacing, bent bar diagrams, and arrangement of concrete reinforcement.

Include special reinforcing required for openings through concrete structures.

Samples of materials as requested by Contracting Officer, including names, sources, and descriptions.

Laboratory test reports for concrete materials and mix design test.

Material certificates in lieu of material laboratory test reports when permitted by Contracting Officer.

03300 - 2 CAST-IN-PLACE CONCRETE

Material certificates shall be signed by manufacturer and Contractor, certifying that each material item complies with or exceeds specified requirements.

Codes and Standards: Comply with provisions of the following codes, specifications, and standards, except where more stringent requirements are shown or specified:

American Concrete Institute (ACI) 301, "Specifications for Structural Concrete for Buildings."

ACI 318, "Building Code Requirements for Reinforced Concrete."

Concrete Reinforcing Steel Institute (CRSI) "Manual of Standard Practice."

Concrete Testing Service: Employ at Contractor's expense a testing agency acceptable to Contracting Officer to perform material evaluation tests and to design concrete mixes.

Materials and installed work may require testing and retesting at any time during progress of Work. Tests, including retesting of rejected materials for installed Work, shall be done at Contractor's expense.

PROJECT CONDITIONS

Protection of Footings Against Freezing: Cover completed work at footing level with sufficient temporary or permanent cover as required to protect footings and adjacent subgrade against possibility of freezing, maintain cover for time period as necessary.

Protect adjacent finish materials against spatter during concrete placement.

FORM MATERIALS

Forms for Exposed Finish Concrete: Plywood, metal, metal-framed plywood faced, or other acceptable panel-type materials to provide continuous, straight, smooth, exposed surfaces. Furnish in largest practicable sizes to minimize number of joints.

Forms for Unexposed Finish Concrete: Plywood, lumber, metal, or another acceptable material. Provide lumber dressed on at least two edges and one side for tight fit.

Forms for Exposed Columns and Supports: Metal or glass-fiber-reinforced plastic that will produce smooth surfaces without joint indications. Provide units with sufficient wall thickness to resist wet concrete loads without deformation.

Form Release Agent: Provide commercial formulation form release agent with a maximum of 350 g/l volatile organic compounds (VOCs) that will not bond with, stain, or adversely affect concrete surfaces and will not impair subsequent treatments of concrete surfaces.

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Form Ties: Factory-fabricated, adjustable-length, removable or snap-off metal form ties designed to prevent form deflection and to prevent spalling of concrete upon removal. Provide units that will leave no metal closer than 1-1/2 inches to the plane of the exposed concrete surface.

Provide ties that, when removed, will leave holes not larger than 1 inch in diameter in the concrete surface.

REINFORCING MATERIALS

Reinforcing Bars: ASTM A 615, Grade 60, deformed, including supplementary requirements S1. Refer to Structural Drawings.

Welded Wire Fabric: ASTM A 185, welded steel wire fabric.

Supports for Reinforcement: Bolsters, chairs, spacers, and other devices for spacing, supporting, and fastening reinforcing bars and welded wire fabric in place. Use wire bar-type supports complying with CRSI specifications.

For slabs-on-grade, use supports with sand plates or horizontal runners where base material will not support chair legs.

CONCRETE MATERIALS

Portland Cement: ASTM C 150, Type I or II.

Use one brand of cement throughout Project.

Fly Ash: Fly ash will not be permitted in concrete.

Normal-Weight Aggregates: ASTM C 33 and as specified. Provide aggregates from a single source for exposed concrete.

For exposed exterior surfaces, do not use fine or coarse aggregates that contain substances that cause spalling.

Aggregates shall be proportioned such that mix design shall contain a minimum of 50% coarse aggregates by gradation requirements set forth in ASTM C 33. Coarse aggregate shall meet No. 67 grading requirements.

Coarse aggregates shall pass the five-cycle magnesium sulphate accelerated soundness test with less than 18% loss.

Coarse aggregates shall have an absorption limit of 4% or less as determined by ASTM C127.

Local aggregates not complying with ASTM C 33 but which have shown by special test or actual

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service to produce concrete of adequate strength and durability may be used when acceptable to Architect.

Water: Potable.

Admixtures, General: Provide concrete admixtures that contain not more than 0.1 percent chloride ions.

Concrete supplier shall certify that all admixtures, release agents, sealers and curing compounds are compatible with each other.

Air-Entraining Admixture: ASTM C 260, certified by manufacturer to be compatible with other required admixtures.

Products: Subject to compliance with requirements, provide one of the following:

Darex AEA or Daravair, W.R. Grace & Co.

MB-VR, Master Builders, Inc.

Sika AER, Sika Corp.

Water-Reducing Admixture: ASTM C 494, Type A.

WRDA Hycol, W.R. Grace & Co.

Pozzolith 344, Master Builders, Inc.

Plastocrete 161, Sika Corp.

High-Range Water-Reducing Admixture: ASTM C 494, Type F or Type G.

WRDA 19 or Daracem, W.R. Grace & Co.

Pozzolith 400, Master Builders, Inc.

Sikament 300 or Sikament 86, Sika Corp.

Water-Reducing, Accelerating Admixture: ASTM C 494, Type E.

Pozzolith 500, Master Builders, Inc.

Water-Reducing, Retarding Admixture: ASTM C 494, Type D.

Daratard-17, W.R. Grace & Co.

Pozzolith 300, Master Builders, Inc.

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Plastocrete 161 MR, Sika Corp.

RELATED MATERIALS

Reglets: Where sheet flashing or bituminous membranes are terminated in reglets, provide reglets of not less than 0.0217-inch-thick (26-gage) galvanized sheet steel. Fill reglet or cover face opening to prevent intrusion of concrete or debris.

Waterstops: Provide flat, dumbbell-type or centerbulb-type waterstops at construction joints and other joints as indicated. Size to suit joints.

Vapor Retarder: Provide vapor retarder that is resistant to deterioration when tested according to ASTM E 154, as follows:

Polyethylene sheet not less than 8 mils thick.

Absorptive Cover: Burlap cloth made from jute or kenaf, weighing approximately 9 oz. per sq. yd., complying with AASHTO M 182, Class 2.

Moisture-Retaining Cover: One of the following, complying with ASTM C 171.

Waterproof paper.

Polyethylene film.

Polyethylene-coated burlap.

Liquid Membrane-Forming Curing Compound: Liquid-type membrane-forming curing compound complying with ASTM C 309, Type I, Class A or B. Moisture loss not more than 0.55 kg/sq. meter when applied at 200 sq. ft./gal.

Products: Subject to compliance with requirements, provide one of the following:

RX Cure, Conspec Marketing & Mfg. Co.

Kurez Dre, Euclid Chemical Co.

L&M Cure R, L&M Construction Chemicals, Inc.

Underlayment Compound: Free-flowing, self-leveling, pumpable, cement-based compound for applications from 1 inch thick to feathered edges.

Products: Subject to compliance with requirements, provide one of the following:

Conflow, Conspec Marketing & Mfg. Co.

Level-Cure LCB, C-Cure Chemical Co., Inc.

Level-Cure SLU, C-Cure Chemical Co., Inc.

Thoro Underlayment Self-Leveling, Thoro System Products.

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Bonding Agent: Polyvinyl acetate or acrylic base.

Epoxy Adhesive: ASTM C 881, two-component material suitable for use on dry or damp surfaces.

Provide material type, grade, and class to suit Project requirements.

Products: Subject to compliance with requirements, provide one of the following:

Spec-Bond 100, Conspec Marketing & Mfg. Co.

Euco Epoxy System #452 or #620, Euclid Chemical Co.

Sikadur 32 Hi-Mod, Sika Corp.

Tyiopoxy, W.R. Grace.

Wear-Resistant Finish: Packaged dry combination of materials consisting of portland cement, silica quartz aggregate, and plasticizing admixture.

Products: Subject to compliance with requirements, provide one of the following.

Conshake 500, Conspec Marketing & Mfg. Co.

Expansion Joint Filler: Refer to Specification Section 07900.

Chemical Hardener: Colorless aqueous solution containing a blend of magnesium fluosilicate and zinc fluosilicate combined with a wetting agent, containing not less than 2 lbs. of fluosilicates per gal.

Products: Subject to compliance with requirements, provide one of the following:

Intraseal, Conspec Marketing & Mfg. Co.

Diamond Hard, Euclid Chemical Co.

PROPORTIONING AND DESIGNING MIXES

Prepare design mixes for each type and strength of concrete by either laboratory trial batch or field experience methods as specified in ACI 301. For the trial batch method, use an independent testing agency acceptable to Contracting Officer for preparing and reporting proposed mix designs.

Use of fly ash will not be permitted.

Submit written reports to Contracting Officer of each proposed mix for each class of concrete at least 15 days prior to start of Work. Do not begin concrete production until proposed mix designs have been reviewed by Contracting Officer.

Design mixes to provide normal weight concrete with the following properties and as indicated on drawings and schedules:

Exterior Concrete: 4000-psi. Refer to Section 02520.

Interior Concrete: Refer to Structural Drawings and General Structural Notes.

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Slump Limits: Proportion and design mixes to result in concrete slump at point of placement as follows:

Ramps, slabs, and sloping surfaces: Not more than 4 inches.

Reinforced foundation systems: Not less than 3 inches and not more than 5 inches.

Concrete containing high-range water-reducing admixture (superplasticizer): Not more than 8 inches after adding admixture to site-verified 2-to-3-inch slump concrete.

Other concrete: Not less than 1 inch nor more than 4 inches.

Adjustment to Concrete Mixes: Mix design adjustments may be requested by Contractor when characteristics of materials, job conditions, weather, test results, or other circumstances warrant, as accepted by Architect. Laboratory test data for revised mix design and strength results must be submitted to and accepted by Architect before using in Work.

ADMIXTURES

Use water-reducing admixture or high-range water-reducing admixture (superplasticizer) in concrete, as required, for placement and workability.

Use air-entraining admixture in exterior exposed concrete unless otherwise indicated. Add air-entraining admixture at manufacturer's prescribed rate to result in concrete at point of placement having total air content with a tolerance of plus or minus 1-1/2 percent within the following limits:

Concrete structures and slabs exposed to freezing and thawing, deicer chemicals, or hydraulic pressure:

Minimum 4.0 percent, maximum 7.0 percent for 3/4-inch maximum aggregate.

Other concrete not exposed to freezing, thawing, or hydraulic pressure, or to receive a surface hardener: 2 to 4 percent air.

Use admixtures in strict compliance with manufacturer's directions.

CONCRETE MIXING

Ready-Mixed Concrete: Comply with requirements of ASTM C 94, and as specified.

When air temperature is between 85 deg F (30 deg C) and 90 deg F (32 deg C), reduce mixing and delivery time from 1-1/2 hours to 75 minutes, and when air temperature is above 90 deg F (32 deg C), reduce mixing and delivery time to 60 minutes.

PART 3 - EXECUTION

GENERAL

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Coordinate the installation of joint materials, vapor retarder, and other related materials with placement of forms and reinforcing steel.

Reinforcement shall be bundled and tagged with weatherproof tags, indicating location, size and length.

FORMS

General: Design, erect, support, brace, and maintain formwork to support vertical, lateral, static, and dynamic loads that might be applied until concrete structure can support such loads. Construct formwork so concrete members and structures are of correct size, shape, alignment, elevation, and position. Maintain formwork construction tolerances and surface irregularities complying with the following ACI 347 limits:

Provide Class A tolerances for concrete surfaces exposed to view.

Provide Class C tolerances for other concrete surfaces.

Construct forms to sizes, shapes, lines, and dimensions shown and to obtain accurate alignment, location, grades, level, and plumb work in finished structures. Provide for openings, offsets, sinkages, keyways, recesses, moldings, rustications, reglets, chamfers, blocking, screeds, bulkheads, anchorages and inserts, and other features required in the Work. Use selected materials to obtain required finishes. Solidly butt joints and provide backup at joints to prevent cement paste from leaking.

Fabricate forms for easy removal without hammering or prying against concrete surfaces. Provide crush plates or wrecking plates where stripping may damage cast concrete surfaces. Provide top forms for inclined surfaces where slope is too steep to place concrete with bottom forms only. Kerf wood inserts for forming keyways, reglets, recesses, and the like for easy removal.

Provide temporary openings for clean-outs and inspections where interior area of formwork is inaccessible before and during concrete placement. Securely brace temporary openings and set tightly to forms to prevent losing concrete mortar. Locate temporary openings in forms at inconspicuous locations.

Chamfer exposed corners and edges as indicated, using wood, metal, PVC, or rubber chamfer strips fabricated to produce uniform smooth lines and tight edge joints.

Provisions for Other Trades: Provide openings in concrete formwork to accommodate work of other trades. Determine size and location of openings, recesses, and chases from trades providing such items.

Accurately place and securely support items built into forms.

Cleaning and Tightening: Thoroughly clean forms and adjacent surfaces to receive concrete. Remove chips, wood, sawdust, dirt, or other debris just before placing concrete. Retighten forms and bracing before placing concrete, as required, to prevent mortar leaks and maintain proper alignment.

VAPOR RETARDER INSTALLATION

General: Place vapor retarder sheeting in position with longest dimension parallel with direction of pour.

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Lap joints 6 inches and seal with manufacturer's recommended pressure-sensitive tape.

PLACING REINFORCEMENT

General: Comply with Concrete Reinforcing Steel Institute's recommended practice for "Placing Reinforcing Bars," for details and methods of reinforcement placement and supports and as specified.

Avoiding cutting or puncturing vapor retarder during reinforcement placement and concreting operations. Repair damages before placing concrete.

Clean reinforcement of loose rust and mill scale, earth, ice, and other materials that reduce or destroy bond with concrete.

Accurately position, support, and secure reinforcement against displacement. Locate and support reinforcing by metal chairs, runners, bolsters, spacers, and hangers, as required.

Place reinforcement to maintain minimum coverages as indicated for concrete protection. Arrange, space, and securely tie bars and bar supports to hold reinforcement in position during concrete placement operations. Set wire ties so ends are directed into concrete, not toward exposed concrete surfaces.

Install welded wire fabric in lengths as long as practicable. Overlap adjoining pieces a minimum of 2 wires plus 2” and lace splices with wire. Offset laps of adjoining widths to prevent continuous laps in either direction.

Heating of reinforcement for bending or placement shall not be permitted. Welding or tack-welding of reinforcement shall not be permitted, unless specifically indicated.

JOINTS

Construction Joints: Locate and install construction joints so they do not impair strength or appearance of the structure, as acceptable to Architect.

Provide keyways at least 1-1/2 inches deep in construction joints in walls and slabs and between walls and footings. Bulkheads designed and accepted for this purpose may be used for slabs.

Place construction joints perpendicular to main reinforcement. Continue reinforcement across construction joints except as indicated otherwise.

Use bonding agent on existing concrete surfaces that will be joined with fresh concrete.

Waterstops: Provide waterstops in construction joints as indicated. Install waterstops to form continuous diaphragm in each joint. Support and protect exposed waterstops during progress of Work.

Field-fabricate joints in waterstops according to manufacturer's printed instructions.

Isolation Joints in Slabs-on-Grade: Construct isolation joints in slabs-on-grade at points of contact between slabs-on-grade and vertical surfaces, such as column pedestals, foundation walls, grade beams, and other locations, as indicated.

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Joint fillers and sealants are specified in Division 7 Section "Joint Sealants."

Contraction (Control) Joints in Interior Slabs-on-Grade: Construct contraction joints in slabs-on-grade to form panels of patterns as shown and as directed. Use saw cuts 1/8 inch wide by one-fourth of slab depth or inserts 1/4 inch wide by one-fourth of slab depth, unless otherwise indicated.

Contraction joints in unexposed floor slabs may be formed by saw cuts as soon as possible after slab finishing as may be safely done without dislodging aggregate. Cutting shall be completed within 12 hours of placing concrete.

Location of control joints shall be reviewed and approved by Contracting Officer.

Joint fillers and sealants are specified in Division 7 Section "Joint Sealants."

Refer to Section 02520 for exterior joints in exterior pavement and walks.

INSTALLING EMBEDDED ITEMS

General: Set and build into formwork anchorage devices and other embedded items required for other work that is attached to or supported by cast-in-place concrete. Use setting drawings, diagrams, instructions, and directions provided by suppliers of items to be attached.

Install reglets to receive top edge of foundation sheet waterproofing and to receive through-wall flashings in outer face of concrete frame at exterior walls, where flashing is shown at lintels, relieving angles, and other conditions.

Forms for Slabs: Set edge forms, bulkheads, and intermediate screed strips for slabs to achieve required elevations and contours in finished surfaces.