W91QVN19R0242_TECHNICAL_REFERENCE.pdf

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CY19 WNHQ 19-1201, Repair Airfield Concrete Pavement at Suwon AB

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STRUCTURAL CAST-IN-PLACE CONCRETE FORMING

PART 1 GENERAL

REFERENCES

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

AMERICAN CONCRETE INSTITUTE 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 (2014) Standard Practice for Laboratories

Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Laboratory Evaluation

ASTM C31/C31M (2012) Standard Practice for Making and

Curing Concrete Test Specimens in the Field

ASTM C39/C39M (2014a) Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

ASTM C578 (2011be1) Standard Specification for

Rigid, Cellular Polystyrene Thermal Insulation

KOREAN INDUSTRIAL STANDARDS (KS)

KS F 3110 (2007) Plywood for Concrete Form

KS F 8006 (2009) Steel Framed Plywood Form

SYSTEM DESCRIPTION

The design, engineering, and construction of the formwork are the 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 Section 03 30 00 CAST-IN-PLACE CONCRETE 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.

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

SD-03 Product Data

Design Form Materials

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 (6 feet long and 4 feet 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 directed.

DELIVERY, STORAGE, AND HANDLING

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

PART 2 PRODUCTS

FORM MATERIALS

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

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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, or KS F 3110 or KS F 8006. 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.

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, KS F 3110, or KS F 8006. 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.

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, KS F 3110, or KS F 8006; 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.

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.

Retain-In-Place Metal Forms

Retain-in-place metal forms for concrete slabs and roofs shall be as specified in Section 05 30 00 STEEL DECKS.

Pan-Form Units

Pan-form units for one-way or two-way concrete joist and slab construction shall be factory-fabricated units of the approximate section indicated.

Units shall consist of steel or molded fiberglass concrete form pans.

Closure units shall be furnished as required.

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. Except where removable tie rods are used, ties shall not leave holes in the concrete surface less than 6 mm (1/4 inch) or more than 25 mm (1 inch) deep and not more than 25 mm (1 inch) in diameter. Terminate the embedded portion of metal ties not less that 50 mm (2 inches) from any concrete surface exposed to water. Removable tie rods shall be not more than 38 mm (1-1/2 inches) in

SECTION 03 11 13.00 10 Page 4 diameter. Plastic snap ties may be used in locations where the surface will not be exposed to view.

Form Releasing Agents

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

Fiber Voids

Fiber voids shall be the product of a reputable manufacturer regularly engaged in the commercial production of fiber voids. The voids shall be constructed of double faced, corrugated fiberboard. The corrugated fiberboard shall be fabricated of wet strength, or standard kraft paper liners, impregnated with paraffin, and laminated with moisture resistant adhesive, and shall have a board strength of 20 kg/square centimeter (275 psi). Voids which are impregnated with paraffin after construction, in lieu of being constructed with paraffin impregnated fiberboard, are acceptable. Voids shall be designed to support not less than 4900 kg/square meter (1000 psf). To prevent separation during concrete placement fiber voids shall be assembled with steel or plastic banding at

1.22 m (4 feet) on center maximum, or by adequate stapling or gluing as recommended by the manufacturer. Fiber voids placed under concrete slabs and that are 200 mm (8 inches) in depth may be heavy duty "waffle box" type, constructed of paraffin impregnated corrugated fiberboard. Submit one sample unit of fiber voids prior to installation of the voids and certificates attesting that fiber voids conform to the specified requirements.

FIBER VOID RETAINERS

Polystyrene Rigid Insulation

Polystyrene rigid insulation shall conform to ASTM C578, Type V, VI, or VII, square edged. Size shall be 38 mm (1-1/2 inches) thick by 400 mm (16 inches) in height by 1 m (3 feet) in length, unless otherwise indicated.

Precast Concrete

Precast concrete units shall have a compressive strength of not less than 17 MPa (2500 psi), reinforced with 150 mm by 150 mm by W1.4 WWF (6 inch by 6 inch by W1.4 WWF) wire mesh, and 300 mm (height) by 1 m (length) by 40 mm (thickness) (12 inches (height) by 3 feet (length) by 1-5/8 inches (thickness)) in size unless indicated.

LOCAL PRODUCTS

Local materials manufactured in the Republic of Korea authorized by USA EDFE Local Material Committee may be used in lieu of standard products as required under the contractor's quality control approval. These materials should be certified and listed in the Korean Industrial Standards (KS) at a minimum and may be subject to Contracting Officer's approval.

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PART 3 EXECUTION

INSTALLATION

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 CAST-IN-PLACE CONCRETE and 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 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, including dimensions of fiber voids, joints, supports, studding and shoring, and sequence of form and shoring removal.

Fiber Voids

Voids shall be placed on a smooth firm dry bed of suitable material, to avoid being displaced vertically, and shall be set tight, with no buckled cartons, in order that horizontal displacement cannot take place. Each section of void shall have its ends sealed by dipping in paraffin, with any additional cutting of voids at the jobsite to be field dipped in the same type of sealer, unless liners and flutes are completely impregnated with paraffin. Prior to placing reinforcement, the entire formed area for slabs shall be covered with a 1.22 x 2.44 m (4 x 8 feet) minimum flat sheets of fiber void corrugated fiberboard. Joints shall be sealed with a moisture resistant tape having a minimum width of 75 mm (3 inches). If voids are destroyed or damaged and are not capable of supporting the design load, they shall be replaced prior to placing of concrete.

Fiber Void Retainers

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

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 (twelve inches) outside the limit of the earth or rockfill so that the end of the chamfers will be clearly visible.

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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.

FORM REMOVAL

Forms shall not be removed without approval. The minimal time required for concrete to reach a strength adequate for removal of formwork without risking the safety of workers or the quality of the concrete depends on a number of factors including, but not limited to, ambient temperature, concrete lift heights, type and amount of concrete admixture, and type and amount of cementitious material in the concrete. Contractor shall 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, minimum ambient temperature, and minimum compressive strength requirements below are met, except as otherwise directed or specifically authorized. When conditions are such as to justify the requirement, forms will be required to remain in place for a longer period. All removal shall be accomplished in a manner which will prevent damage to the concrete and ensure the complete safety of the structure.

Where forms support more than one element, the forms shall not be removed until the form removal criteria are met by all supported elements. Form removal shall be scheduled so that all necessary repairs can be performed. 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.

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, evaluation and results of the control cylinder tests shall be submitted and approved before the forms are removed.

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

SECTION 03 11 13.00 10 Page 7 evidence the concrete has attained at least 70 percent of the compressive strength required for the structure in accordance with the quality and location requirements.

Tunnel Forms

Tunnel lining bulkhead forms shall not be removed in less than 12 hours and tunnel lining forms in not less than 16 hours.

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.

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 (1/4 inch in any 10 feet) of length Maximum for entire length -- 25 mm (1 inch)

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

6 mm in any 6 m (1/4 inch in any 20 feet) of length Maximum for entire length -- 13 mm (1/2 inch)

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 (1/4 inch in any 10 feet) of length 10 mm (3/8 inch) in any bay or in any 6 m (20 feet) of length Maximum for entire length -- 20 mm (3/4 inch)

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

6 mm (1/4 inch) in any bay or in any 6 m (20 feet) of length Maximum for entire length -- 13 mm (1/2 inch)

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

13 mm in any 6 m (1/2 inch in any 10 feet) 25 mm (1 inch) maximum

4. Variation of distance between walls, columns, partitions

6 mm per 3 m (1/4 inch per 10 feet) of distance, but not more than 13 mm (1/2 inch) in any one bay, and not more than 25 mm (1 inch) total variation

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TABLE 1

TOLERANCES FOR FORMED SURFACES

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

Minus 6 mm (1/4 inch), Plus 13 mm (1/2 inch)

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

Minus 6 mm (1/4 inch), Plus 13 mm (1/2 inch)

7. Footings:

a. Variation of dimensions in plan Minus 13 mm (1/2 inch), plus 50 mm (2 inches) when formed or plus 75 mm (3 inches) 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 (2 inches)

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

8. Variation in steps:

a. In a flight of stairs Riser -- 3 mm (1/8 inch) Tread -- 6 mm (1/4 inch)

b. In consecutive steps Riser -- 2 mm (1/16 inch) Tread -- 3 mm (1/8 inch)

-- End of Section --

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CONCRETE ACCESSORIES

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS

(AASHTO)

AASHTO T 111 (2011) Standard Method of Test for Mineral

Matter or Ash in Asphalt Materials

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

ASTM A1011/A1011M (2014) Standard Specification for Steel, Sheet, and Strip, Hot-Rolled, Carbon, Structural, High-Strength Low-Alloy and High-Strength Low-Alloy with Improved Formability and Ultra-High Strength

ASTM A109/A109M (2008) Standard Specification for Steel, Strip, Carbon (0.25 Maximum Percent), Cold-Rolled

ASTM A167 (2011) Standard Specification for

Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip

ASTM A480/A480M (2012) Standard Specification for General

Requirements for Flat-Rolled Stainless and Heat-Resisting Steel Plate, Sheet, and Strip

ASTM B152/B152M (2013) Standard Specification for Copper

Sheet, Strip, Plate, and Rolled Bar

ASTM B370 (2012) Standard Specification for Copper Sheet and Strip for Building Construction

ASTM C919 (2008) Use of Sealants in Acoustical

Applications

ASTM C920 (2014a) Standard Specification for Elastomeric Joint Sealants

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ASTM D1751 (2004; E 2013; R 2013) Standard

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

ASTM D1752 (2004a; R 2013) 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 D4 (1986; R 2010) Bitumen Content

ASTM D412 (2006a; R 2013) Standard Test Methods for

Vulcanized Rubber and Thermoplastic Elastomers - Tension

ASTM D471 (2012) Standard Test Method for Rubber

Property - Effect of Liquids

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

ASTM D6/D6M (1995e1; R 2011) Loss on Heating of Oil and Asphaltic Compounds

ASTM D7116 (2005) Standard Specification for Joint Sealants, Hot Applied, Jet Fuel Resistant Types, for Portland Cement Concrete Pavement

U.S. ARMY CORPS OF ENGINEERS (USACE)

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

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

KS D 5201 (2009) Copper and Copper Alloy Sheets, Plates and Strips

KS F 2538 (2005) Preformed Expansion Joint Fillers for Concrete Paving and Structural Construction

SECTION 03 15 00.00 10 Page 3 used, a designation following the "G" designation identifies the office

Preformed Expansion Joint Filler Sealant Waterstops

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.

CONTRACTION JOINT STRIPS

Contraction joint strips shall be 3 mm (1/8 inch) 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.

PREFORMED EXPANSION JOINT FILLER

Expansion joint filler shall be preformed material conforming to ASTM D1751, ASTM D1752, or KS F 2538. Unless otherwise indicated, filler material shall be 10 mm (3/8 inch) thick and of a width applicable for the joint formed. Backer material, when required, shall conform to ASTM D5249.

SEALANT

Joint sealant shall conform to the following:

Preformed Polychloroprene Elastomeric Type ASTM

D2628.

Lubricant for Preformed Compression Seals ASTM

D2835.2.3.3 Field-Molded Type

ASTM C920. Sealant shall be Type M, Grade P or NS, Class 25, Use NT for horizontal joints. Type M, Grade NS, Class 25, Use NT for vertical joints.

Bond breaker material shall be polyethylene tape, coated paper, metal foil or similar type materials. The back-up material shall be compressible, non-shrink, nonreactive with sealant, and non-absorptive material type such as extruded butyl or polychloroprene rubber.

2.3.4 Hot-Applied Jet-Fuel Resistant Type

ASTM D7116, Type I, II, or III, as indicated.

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WATERSTOPS

Shop fabricate intersection and change of direction waterstops.

Flexible Metal

Copper waterstops shall conform to ASTM B152/B152M, ASTM B370, or KS D 5201, O60 soft anneal temper and 0.686 mm (20 oz mass per sq ft) sheet thickness. Stainless steel waterstops shall conform to ASTM A167 and ASTM A480/A480M, UNS S30453 (Type 304L), and 0.9525 mm (0.0375 inch) thick strip.

Rigid Metal

Flat steel waterstops shall conform to ASTM A109/A109M, No. 2 (half hard) temper, No. 2 edge, No. 1 (matte or dull) finish or ASTM A1011/A1011M, Grade 40.

Non-Metallic Materials

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

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

Polyvinylchloride waterstops shall conform to COE CRD-C 572.

Thermoplastic elastomeric rubber waterstops shall conform to ASTM D471.

Non-Metallic Hydrophilic

Swellable strip type compound of polymer modified chloroprene rubber that swells upon contact with water shall conform to ASTM D412 as follows:

Tensile strength 2.9 MPa (420 psi) minimum; ultimate elongation 600 percent minimum. Hardness shall be 50 minimum on the type A durometer and the volumetric expansion ratio in distilled water at 20 degrees C (70 degrees F) shall be 3 to 1 minimum.

Preformed Elastic Adhesive

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

Chemical Composition

Meet the chemical composition of the sealing compound requirements shown below:

PERCENT BY WEIGHT

COMPONENT MINIMUM MAXIMUM TEST

Bitumen (Hydrocarbon plastic) 50 70 ASTM D4

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PERCENT BY WEIGHT

COMPONENT MINIMUM MAXIMUM TEST

Inert Mineral Filler 30 50 AASHTO T 111

Volatile Matter 2 ASTM D6/D6M

Adhesion Under Hydrostatic Pressure

The sealing compound shall not leak at the joints for a period of 24 hours under a vertical 2 m (6 foot) head pressure. In a separate test, the sealing compound shall not leak under a horizontal pressure of 65 kPa (10 psi) which is reached by slowly applying increments of 13 kPa (2 psi) every minute.

Sag of Flow Resistance

Sagging shall not be detected when tested as follows: Fill a wooden form 25 mm (1 inch) wide and 150 mm (6 inches) long flush with sealing compound and place in an oven at 58 degrees C (135 degrees F) in a vertical position for 5 days.

Chemical Resistance

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

2.5 LOCAL PRODUCTS

Local materials manufactured in Republic of Korea authorized by USA EDFE Local Material Committee may be used in lieu of standard products as stated above paragraph under the contractor's quality control approval.

These materials should be certified and listed Korean Industrial Standards (KS) as a minimum and may subject to Contracting Officer's approval.

INSTALLATION

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

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 (1/8 inch to 3/16 inch) wide and extend into the slab one-fourth the slab thickness, minimum, but not less than 25 mm (1 inch).

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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.

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.

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 (1/8 inch) 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 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.

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.

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.

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Joints With Field-Molded Sealant

Do not seal joints when the sealant material, ambient air, or concrete temperature is less than 4 degrees C (40 degrees F). 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.

WATERSTOPS, INSTALLATION AND SPLICES

Install waterstops at the locations shown to form a continuous water-tight diaphragm. Make adequate provision to support and completely protect the waterstops during the progress of the work. Repair or replace any waterstop punctured or damaged. Protect exposed waterstops during application of form release agents to avoid being coated. Provide suitable guards to protect exposed projecting edges and ends of partially embedded waterstops from damage when concrete placement has been discontinued. Accomplish splices with certified trained personnel using approved equipment and procedures.

Copper And Stainless Steel

Splices in copper waterstops shall be lap joints made by brazing. Splices in stainless steel waterstops shall be welded using a TIG or MIG process utilizing a weld rod to match the stainless. All welds shall not be annealed to maintain physical properties. Do not use carbon flame in the annealing process. Damaged waterstops shall be repaired by removing damaged portions and patching. Patches shall overlap a minimum of 25 mm ( 1 inch) onto undamaged portion of the waterstop.

Flat Steel

Splices in flat steel waterstops shall be properly aligned, butt welded, and cleaned of excessive material.

Non-Metallic

Fittings shall be shop made using a machine specifically designed to mechanically weld the waterstop. A miter guide, proper fixturing (profile dependant), and portable power saw shall be used to miter cut the ends to be joined to ensure good alignment and contact between joined surfaces.

The splicing of straight lengths shall be done by squaring the ends to be joined. Maintain continuity of the characteristic features of the cross section of the waterstop (ribs, tabular center axis, protrusions, etc.)

across the splice.

Rubber Waterstop

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

Polyvinyl Chloride Waterstop

Make splices by heat sealing the adjacent waterstop edges together using a

SECTION 03 15 00.00 10 Page 8 thermoplastic splicing iron utilizing a non-stick surface specifically designed for waterstop welding. Use the correct temperature to sufficiently melt without charring the plastic. Reform waterstops at splices with a remolding iron with ribs or corrugations to match the pattern of the waterstop. The spliced area, when cooled, shall show no signs of separation, holes, or other imperfections when bent by hand in as sharp an angle as possible.

Quality Assurance

Edge welding will not be permitted. Compress or close centerbulbs when welding to non-centerbulb type. Waterstop splicing defects which are unacceptable include, but are not limited to the following: 1) Tensile strength less than 80 percent of parent section. 2) Free lap joints. 3) Misalignment of centerbulb, ribs, and end bulbs greater than 2 mm (1/16 inch). 4) Misalignment which reduces waterstop cross section more than 15 percent. 5) Bond failure at joint deeper than 2 mm (1/16 inch) or 15 percent of material thickness. 6) Misalignment of waterstop splice resulting in misalignment of waterstop in excess of 13 mm in 3 m (1/2 inch in 10 feet). 7) Visible porosity in the weld area, including pin holes.

8) Charred or burnt material. 9) Bubbles or inadequate bonding. 10) Visible signs of splice separation when cooled splice is bent by hand at a sharp angle.

Non-Metallic Hydrophilic Waterstop Installation

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

Preformed Plastic Adhesive Installation

The installation of preformed plastic adhesive waterstops shall be a prime, peel, place and pour procedure. Joint surfaces shall be clean and dry before priming and just prior to placing the sealing strips. The end of each strip shall be spliced to the next strip with a 25 mm (1 inch) overlap; the overlap shall be pressed firmly to release trapped air.

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

3.3 CONSTRUCTION JOINTS

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

SECTION 03 20 00.00 10 Page 1

SECTION 03 20 00.00 10

CONCRETE REINFORCING

08/10

ACI 318 (2011; Errata 2011) Building Code

Requirements for Structural Concrete and Commentary

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 A1035/A1035M (2011) Standard Specification for Deformed and Plain, Low-carbon, Chromium, Steel Bars for Concrete Reinforcement

ASTM A184/A184M (2006; E2011) Standard Specification for

Fabricated Deformed Steel Bar Mats for Concrete Reinforcement

ASTM A185/A185M (2007) Standard Specification for Steel

Welded Wire Reinforcement, Plain, for

ASTM A496/A496M (2007) Standard Specification for Steel

Wire, Deformed, for Concrete Reinforcement

ASTM A497/A497M (2007) Standard Specification for Steel Welded Wire Reinforcement, Deformed, for

ASTM A53/A53M (2012) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A615/A615M (2013) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

SECTION 03 20 00.00 10 Page 2

ASTM A675/A675M (2003; R 2009) Standard Specification for

Steel Bars, Carbon, Hot-Wrought, Special Quality, Mechanical Properties

ASTM A706/A706M (2009b) Standard Specification for

Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement

ASTM A767/A767M (2009) Standard Specification for

Zinc-Coated (Galvanized) Steel Bars for Concrete Reinforcement

ASTM A775/A775M (2007b) Standard Specification for

Epoxy-Coated Steel Reinforcing Bars

ASTM A82/A82M (2007) Standard Specification for Steel Wire, Plain, for Concrete Reinforcement

ASTM A884/A884M (2006) Standard Specification for

Epoxy-Coated Steel Wire and Welded Wire

ASTM A934/A934M (2007) Standard Specification for

Epoxy-Coated Prefabricated Steel Reinforcing Bars

ASTM C1116/C1116M (2010a) Standard Specification for

Fiber-Reinforced Concrete

CONCRETE REINFORCING STEEL INSTITUTE (CRSI)

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

U.S. DEPARTMENT OF DEFENSE (DOD)

UFC 3-310-04 (2013) Seismic Design for Buildings

KS D 3503 (2008) Rolled Steels for General Structure

KS D 3504 (2011) Steel Bars for Concrete

KS D 3629 (2005) Fusion Bonded Epoxy Coated

Reinforcing Steel Bars

KS D 7017 (2007) Welded Steel Wire Fabrics used, a designation following the "G" designation identifies the office

SECTION 03 20 00.00 10 Page 3

Epoxy-Coated Bars

SD-07 Certificates

Welding Qualifications

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 procedures and welders qualified by others may be accepted as permitted by AWS D1.4/D1.4M. Submit a list of qualified welders' names.

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.

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.

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

DOWELS

Dowels shall conform to ASTM A675/A675M, Grade 80, or KS D 3503, SS540 or SS490. Steel pipe conforming to ASTM A53/A53M, Schedule 80, may be used as dowels provided the ends are closed with metal or plastic inserts or with mortar.

FABRICATED BAR MATS

Fabricated bar mats shall conform to ASTM A184/A184M.

SECTION 03 20 00.00 10 Page 4

REINFORCING STEEL

Reinforcing steel shall be deformed bars conforming to ASTM A615/A615M, ASTM A706/A706M, ASTM A1035/A1035M, or KS D 3504 grades and sizes as indicated. Cold drawn wire used for spiral reinforcement shall conform to ASTM A82/A82M. In highly corrosive environments or when directed by the Contracting Officer, reinforcing steel shall conform to ASTM A767/A767M, ASTM A775/A775M, ASTM A1035/A1035M, ASTM A934/A934M, or KS D 3629, as appropriate.

Zinc-Coated (Galvanized) Bars

Zinc-coated (galvanized) bars shall comply with the requirements of ASTM A767/A767M, Coating Class as indicated , galvanized after fabrication.

Epoxy-Coated Bars

Epoxy-coated steel bars shall comply with the requirements of ASTM A775/A775M or ASTM A934/A934M as applicable, including written certifications for coating material and coated bars.

WELDED WIRE FABRIC

Welded wire fabric shall conform to ASTM A185/A185M, ASTM A496/A496M, ASTM A497/A497M, or KS D 7017. When directed by the Contracting Officer for special applications, welded wire fabric shall conform to

ASTM A884/A884M.

WIRE TIES

Wire ties shall be 16 gauge or heavier black annealed steel wire. Ties for epoxy-coated bars shall be vinyl-coated or epoxy-coated. Ties for zinc-coated bars shall be zinc-coated.

SUPPORTS

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

Precast concrete blocks shall have wire ties and shall be not less than 100 by 100 mm (4 inches square) 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 (1/2 inch) 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.

SYNTHETIC FIBER REINFORCEMENT

Synthetic fiber shall be polypropylene with a denier less than 100 and a nominal fiber length of 50 mm (2 inches).

SECTION 03 20 00.00 10 Page 5

REINFORCEMENT

Reinforcement steel and accessories shall be fabricated and placed as specified and as shown on approved shop drawings. Fabrication and placement details of steel and accessories not specified or shown shall be in accordance with ACI SP-66 and ACI 318M (ACI 318). Reinforcement shall be cold bent unless otherwise authorized. Bending may be accomplished in the field or at the mill. Zinc-Coated and epoxy-coated bars shall be mill-bent prior to coating. All steel shall be bent cold unless authorized by Contracting Officer Representative. 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.

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 (ACI 318) 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 (ACI 318). 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.

Splicing

Splices of reinforcement shall conform to ACI 318M (ACI 318) 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 No. 11 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 (6 inches). 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.

WELDED-WIRE FABRIC PLACEMENT

Welded-wire fabric shall be placed in slabs as indicated. Fabric placed in slabs on grade shall be continuous between expansion, construction, and contraction joints. Fabric placement at joints shall be as indicated.

Lap splices shall be made in such a way that the overlapped area equals

SECTION 03 20 00.00 10 Page 6 the distance between the outermost crosswires plus 50 mm (2 inches). Laps shall be staggered to avoid continuous laps in either direction. Fabric shall be wired or clipped together at laps at intervals not to exceed 1.2 m (4 feet). Fabric shall be positioned by the use of supports.

DOWEL INSTALLATION

Dowels shall be installed in slabs on grade at locations indicated and at right angles to joint being doweled. Dowels shall be accurately positioned and aligned parallel to the finished concrete surface before concrete placement. Dowels shall be rigidly supported during concrete placement. One end of dowels shall be coated with a bond breaker.

SYNTHETIC FIBER REINFORCED CONCRETE

Fiber reinforcement shall be added to the concrete mix in accordance with the applicable sections of ASTM C1116/C1116M and the recommendations of the manufacturer, and in an amount of 0.1 percent by volume.

SPECIAL INSPECTION AND TESTING FOR SEISMIC-RESISTING SYSTEMS

Special inspections and testing for seismic-resisting systems and components shall be done in accordance with UFC 3-310-04.

SECTION 03 30 00 Page 1

SECTION 03 30 00

CAST-IN-PLACE CONCRETE

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS

(AASHTO)

AASHTO M 182 (2005; R 2009) Standard Specification for

Burlap Cloth Made from Jute or Kenaf and Cotton Mats

AASHTO M 322M/M 322 (2010) Standard Specification for

Rail-Steel and Axle-Steel Deformed Bars for Concrete Reinforcement

ACI/MCP-1 (2012) Manual of Concrete Practice Part 1

ACI/MCP-2 (2012) Manual of Concrete Practice Part 2

ACI/MCP-3 (2012) Manual of Concrete Practice Part 3

ACI/MCP-4 (2012) Manual of Concrete Practice Part 4

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

AMERICAN WELDING SOCIETY (AWS)

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

ASTM A123/A123M (2013) Standard Specification for Zinc

(Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A185/A185M (2007) Standard Specification for Steel

Welded Wire Reinforcement, Plain, for

ASTM A496/A496M (2007) Standard Specification for Steel

Wire, Deformed, for Concrete Reinforcement

ASTM A497/A497M (2007) Standard Specification for Steel Welded Wire Reinforcement, Deformed, for

SECTION 03 30 00 Page 2

ASTM A53/A53M (2012) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A615/A615M (2013) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

ASTM A706/A706M (2009b) Standard Specification for Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement

ASTM A767/A767M (2009) Standard Specification for Zinc-Coated (Galvanized) Steel Bars for Concrete Reinforcement

ASTM A775/A775M (2007b) Standard Specification for Epoxy-Coated Steel Reinforcing Bars

ASTM A780/A780M (2009) Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings

ASTM A82/A82M (2007) Standard Specification for Steel Wire, Plain, for Concrete Reinforcement

ASTM A934/A934M (2007) Standard Specification for Epoxy-Coated Prefabricated Steel Reinforcing Bars

ASTM A996/A996M (2009b) Standard Specification for Rail-Steel and Axle-Steel Deformed Bars for Concrete Reinforcement

ASTM C1017/C1017M (2007) Standard Specification for Chemical Admixtures for Use in Producing Flowing Concrete

ASTM C1107/C1107M (2011) Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Nonshrink)

ASTM C1116/C1116M (2010a) Standard Specification for Fiber-Reinforced Concrete

ASTM C143/C143M (2012) Standard Test Method for Slump of Hydraulic-Cement Concrete

ASTM C150/C150M (2012) Standard Specification for Portland Cement

ASTM C156 (2011) Standard Test Method for Water Retention by Concrete Curing Materials

ASTM C171 (2007) Standard Specification for Sheet Materials for Curing Concrete

ASTM C172/C172M (2010) Standard Practice for Sampling

SECTION 03 30 00 Page 3

Freshly Mixed Concrete

ASTM C173/C173M (2014) Standard Test Method for Air

Content of Freshly Mixed Concrete by the Volumetric Method

ASTM C192/C192M (2014) Standard Practice for Making and

Curing Concrete Test Specimens in the Laboratory

ASTM C231/C231M (2010) Standard Test Method for Air

Content of Freshly Mixed Concrete by the Pressure Method

ASTM C233/C233M (2011) Standard Test Method for

Air-Entraining Admixtures for Concrete

ASTM C260/C260M (2010a) Standard Specification for Air-Entraining Admixtures for Concrete

ASTM C309 (2011) Standard Specification for Liquid

Membrane-Forming Compounds for…