GENERAL 1.01 DESCRIPTION the WORK of This Section Includes Providing Concrete Formwork, Bracing

SECTION 03100

FORMWORK

PART 1 -- GENERAL

1.01 DESCRIPTION

The WORK of this Section includes providing concrete formwork, bracing, shoring, supports and formwork requirements for concrete construction.

1.02 RELATED SECTIONS

The WORK of the following Sections applies to the WORK of this Section. Other Sections of the Specifications, not referenced below, shall also apply to the extent required for proper performance of the WORK.

1. Section 03200 Concrete Reinforcement

2. Section 03290 Joints in Concrete Structure

3. Section 03300 Cast-in-Place Concrete

4. Section 03600 Grout

1.03 STANDARD SPECIFICATIONS

Except as otherwise indicated in this Section of the Specifications, the CONTRACTOR shall comply with the Standard Specifications for Public Works Construction (SSPWC), as specified in Section 01071 Standard References.

1.04 QUALITY ASSURANCE

A. REFERENCES:

This section contains references to the documents listed below. They are a part of this section as specified and modified. Where a referenced document cites other standards, such standards are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail.

FORMWORK DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03100-1 issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, has been discontinued, or has been replaced.

Reference Title PS 1 U.S. Product Standard for Concrete Forms, Class I. ACI 116R Cement and Concrete Terminology ACI 117 Standard Tolerances for Concrete Construction and Materials ACI 347 Recommended Practice for Concrete Formwork ACI 347R Guide to Formwork for Concrete

B. TOLERANCES:

The variation from established grade or lines shall not exceed 1/4 inch in 10 feet and there shall be no offsets or visible waviness in the finished surface. All other tolerances shall be within the tolerances of ACI 117.

C. DESIGN:

Formwork design requirements shall conform to the following:

1. Formwork, shoring, and reshoring shall be designed by a civil or structural engineer currently registered in the State of California having a minimum of 3 years experience in this type of design work.

2. Design and engineering of formwork, shoring and reshoring, as well as its construction, is the responsibility of the Contractor.

3. A procedure and schedule shall be developed for removal of shores (and installation of reshores) and for calculating the loads transferred to the structure during this process.

4. Structural calculations shall be made as required to prove that all portions of the structure in combination with remaining forming and shoring system has sufficient strength to safely support its own weight plus the loads placed thereon.

5. When developing procedure, schedule, and structural calculations, consideration shall be made regarding the structural system that exists, effects of all loads during construction and strength of concrete at each state of construction.

FORMWORK 03100-2 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 D. DESIGN CRITERIA:

Design of formwork shall conform to the following criteria:

1. Formwork shall be designed for loads, lateral pressures and allowable stresses outlined in ACI 347R and for design considerations, wind loads, allowable stresses and other applicable requirements of the controlling local building code. Where conflicts occur between the above two standards, the more stringent requirements shall govern.

2. Formwork shall be made to limit maximum deflection of form facing materials reflected in concrete surfaces exposed to view to 1/240 of span between structural members.

1.05 SUBMITTALS

Submittals shall be provided in accordance with Section 01300 and shall include the following information:

1. A copy of this specification section, with addendum updates included, with each paragraph check-marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. A check mark shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated, and therefore requested by the Contractor, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph referenced to a detailed written explanation of the reasons for requesting the deviation. The Construction Manager shall be the final authority for determining acceptability of requested deviations. The remaining portions of the paragraph not underlined will signify compliance on the part of the Contractor with the specifications. Failure to include a copy of the marked-up specification sections, along with justification(s) for any requested deviations to the specification requirement, with the submittal shall be sufficient cause for rejection of the entire submittal with no further consideration.

2. Manufacturer's installation instructions and acknowledgement that products submitted meet requirements of standards referenced.

3. Manufacturer and type of proposed form materials, form ties and form coating materials.

4. Formwork designer qualifications.

5. If requested, structural analysis and concrete strength data used in planning and implementing form removal and shoring.

FORMWORK DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03100-3

1.06 SHOP DRAWINGS AND SAMPLES

The following shall be submitted in compliance with Section 01300.

A. FALSEWORK CALCULATIONS AND DRAWINGS:

The CONTRACTOR's attention is directed to the provisions of Section 1717 of the Division of Industrial Safety, Construction Safety Orders, as revised November 1973, which requires that all falsework or vertical shoring installations where the height of the falsework or vertical shoring, as measured from the top of the sills to the soffit of the superstructure, exceeds 14 feet, or where individual horizontal span lengths exceed 16 feet, or provision for vehicular or railroad traffic through falsework or vertical shoring is made, shall be approved and signed by a civil engineer, registered in the State of California; provided further, that a copy of the falsework plan or shoring layout shall be available on the job site at all times.

B. DETAILED PLANS OF THE FALSEWORK PROPOSED TO BE USED:

Such plans shall be in sufficient detail to indicate the general layout, sizes of members, anticipated stresses, grade of materials to be used in the falsework, means of protecting existing construction which supports falsework, and typical soil conditions.

C. CATALOG INFORMATION ON:

1. Form ties and all related accessories, including taper tie plugs, if taper ties are used.

2. Form gaskets.

1.07 QUALITY ASSURANCE

A. TOLERANCES:

PART 2 -- PRODUCTS

2.01 GENERAL

Materials for concrete forms and falsework shall conform to SSPWC Subsection 303-1.3 and the requirements herein.

FORMWORK 03100-4 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 Except as otherwise expressly accepted, all lumber brought on the job site for use as forms, shoring, or bracing shall be new material. All forms shall be smooth surface forms and shall be of the following materials:

Walls - Steel or plywood panel Columns - Steel, plywood, or fiber glass Roof and floor - Plywood All other work - Steel panels, plywood or tongue and groove lumber

Form materials which may remain or leave residues on or in the concrete shall be classified as acceptable for potable water use by the Environmental Protection Agency within 30 days of application or use.

2.01 FORMS AND FALSEWORK MATERIALS

Materials for concrete forms, formwork, and falsework shall conform to the following requirements:

1. Lumber shall be Douglas Fir or Southern Pine, construction grade or better, in conformance with U.S. Product Standard PS20.

2. Plywood for concrete formwork shall be new, waterproof, synthetic resin bonded, exterior type Douglas Fir or Southern Pine plywood manufactured especially for concrete formwork and shall conform to the requirements of PS 1 for Concrete Forms, Class I, and shall be edge sealed.

3. Form materials shall be metal, wood, plywood, or other approved material that will not adversely affect the concrete and will facilitate placement of concrete to the shape, form, line, and grade shown. Metal forms shall be an approved type that will accomplish such results. Wood forms for surfaces to be painted shall be Medium Density Overlaid plywood, MDO Ext. Grade.

Unless otherwise indicated, exterior corners in concrete members shall be provided with 3/4-inch chamfers. Re-entrant corners in concrete members shall not have fillets unless otherwise indicated.

Forms and falsework to support the roof and floor slabs shall be designed for the total dead load, plus a live load of 30 psf (minimum).

A. WOOD FORMS:

Wood forms shall be new 5/8-inch or 3/4-inch, 5-ply structural plywood of concrete form grade. Forms shall be built-in-place type or pre-fabricated panel. Built in place type forms shall

FORMWORK DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03100-5 be 4 by 8 foot sheets except where smaller pieces will cover entire area. When approved by the Construction Manager, plywood may be reused.

B. METAL FORMS:

Metal forms excluding aluminum may be used. Forms shall be tight to prevent leakage, free of rust and straight without dents to provide members of uniform thickness.

2.02 FORM TIES

Form ties shall be commercially fabricated for use in form construction and shall be constructed so that ends or end fasteners can be removed without causing spilling at surfaces of the concrete. Diameter on ends shall be 3/4 inch minimum to 1 inch maximum. Embedded portion of ties shall be not less than 1 1/2 inch from face of concrete after ends have been removed. Ties with built-in waterstops shall be provided in all walls that will be in contact with process liquid during plant operation and/or high ground water.

Form ties with integral waterstops shall be provided with a plastic cone or other suitable means for forming a conical hole to insure that the form tie may be broken off back of the face of the concrete. The maximum diameter of removable cones for rod ties, or of other removable form-tie fasteners having a circular cross-section, shall not exceed 1-1/2 inches; and all such fasteners shall be such as to leave holes of regular shape for reaming.

Form ties for water-retaining structures shall have integral waterstops. Removable taper ties may be used when approved. A preformed neoprene or polyurethane tapered plug sized to seat at the center of the wall shall be inserted in the hole left by the removal of the taper tie.

2.03 MANUFACTURERS

Products of the type indicated shall be manufactured by one of the following (or equal):

1. Form Ties:

a. Burke Penta - Tie System by the Burke Company b. Richmond Snap Tys by the Richmond Screw Anchor Company

2. Form ties with Integral Waterstops

a. Burke Taper - Tie System by the Burke Company b. Taper Ty by the Richmond Screw Anchor Company

FORMWORK 03100-6 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 PART 3 -- EXECUTION

3.01 GENERAL

Forms and falsework shall be designed and constructed in accordance with ACI 347 and SSPWC Subsections 303-1.3, 303-1.6, and 303-5.2, and the requirements herein, except that the submittal of detailed falsework will not be required.

1. TOLERANCES: The variation from established grade or lines shall not exceed 1/4-inch in 10 feet and there shall be no offsets or visible waviness in the finished surface. All other tolerances shall be within the tolerances of ACI 117.

Forms to confine the concrete and shape it to the required lines shall be used wherever necessary. The CONTRACTOR shall assume full responsibility for the adequate design of all forms, and any forms which are unsafe or inadequate in any respect shall promptly be removed from the WORK and replaced at the CONTRACTOR's expense. A sufficient number of forms of each kind shall be provided to permit the required rate of progress to be maintained. The design and inspection of concrete forms, falsework, and shoring shall comply with applicable local, state and Federal regulations. Plumb and string lines shall be installed before concrete placement and shall be maintained during placement. Such lines shall be used by CONTRACTOR's personnel and by the ENGINEER and shall be in sufficient number and properly installed. During concrete placement, the CONTRACTOR shall continually monitor plumb and string line form positions and immediately correct deficiencies.

Concrete forms shall conform to the shape, lines, and dimensions of members as called for on the Drawings, and shall be substantial, free from surface defects, and sufficiently tight to prevent leakage. Forms shall be properly braced or tied together to maintain their position and shape under a load of freshly-placed concrete. If adequate foundation for shores cannot be secured, trussed supports shall be provided.

3.02 PREPARATION

Preparation shall conform to the following:

1. Before placing of either reinforcing steel or concrete, surfaces of forms shall be covered with an approved coating material that will effectively prevent absorption of moisture and prevent bond with concrete, will not stain concrete or prevent bonding of future finishes. A field applied form release agent or sealer of approved type or a factory applied non absorptive liner may be used.

2. Excess form coating material shall not be permitted to stand in puddles in forms nor in contact with hardened concrete against which fresh concrete is to be placed.

FORMWORK DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03100-7 3. Temporary openings shall be provided at base of column and wall forms and at other points where necessary to facilitate cleaning and observation immediately before concrete is placed, and to limit height of free fall of concrete to prevent aggregate segregation.

4. Temporary openings, also called form “windows”, shall be used to limit height of free fall of concrete and to limit the lateral movement of concrete during placement. Openings are required in walls placements greater than 20 feet in height and shall be spaced so that no more than 8 feet of solid form exists between openings measured horizontally and vertically.

5. Surfaces of forms, reinforcing steel and other embedded materials shall be cleaned of any accumulated mortar or grout from previous concreting and of all other foreign material before concrete is placed.

3.03 FORM DESIGN

All forms shall be true in every respect to the required shape and size, shall conform to the established alignment and grade, and shall be of sufficient strength and rigidity to maintain their position and shape under the loads and operations incident to placing and vibrating the concrete. Suitable and effective means shall be provided on all forms for holding adjacent edges and ends of panels and sections tightly together and in accurate alignment so as to prevent the formation of ridges, fins, offsets, or similar surface defects in the finished concrete. Plywood, 5/8-inch and greater in thickness, may be fastened directly to studding if the studs are spaced close enough to prevent visible deflection marks in the concrete. The forms shall be tight so as to prevent the loss of water, cement and fines during placing and vibrating of the concrete. Specifically, the bottom of wall forms that rest on concrete footings or slabs shall be provided with a gasket to prevent loss of fines and paste during placement and vibration of concrete. Such gasket may be a 1- to 1-1/2-inch diameter polyethylene rod held in position to the underside of the wall form. Adequate clean-out holes shall be provided at the bottom of each lift of forms. The size, number, and location of such clean-outs shall be as acceptable to the CONSTRUCTION MANAGER. Whenever concrete cannot be placed from the top of a wall form in a manner that meets the requirements of the Contract Documents, form windows shall be provided in the size and spacing needed to allow placement of concrete to the requirements of Section 03300. The size, number, and location of such form windows shall be acceptable to the CONSTRUCTION MANAGER.

3.04 ERECTION

Form erection shall conform to the following:

1. Products shall be installed in accordance with manufacturer’s written instructions.

2. Surfaces of columns, piers, walls, and in risers shall vary from plumb a maximum of 1/2 inch for entire height and 1/4 inch in 10 feet of height. Exposed corner columns, control-joint grooves, and other exposed to view

FORMWORK 03100-8 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 lines shall vary from plumb a maximum of 1/2 inch for entire length and 1/4 inch in 20 feet of length.

3. Maximum variation from level or from grade shall be 3/4 inch for entire length, 3/8 inch for any bay or 20 foot length and 1/4 inch in 10 feet of length for slab soffits, ceilings, beam soffits and in arises, measured before removal of supporting shores and shall be 1/2 inch for entire length and 1/4 inch in 20 feet of length for exposed lintels, sills, parapets, horizontal grooves, and other exposed to view lines.

4. Maximum variation of linear structure lines from established position in plan and related position of columns, walls, and partitions shall be 3/4 inch for entire length and 3/8 inch for any bay or 20 foot length.

5. Maximum variation in size and location of sleeves, floor openings, and wall openings and variation in horizontal plan location of beam, column, and wall centerlines shall be ± 1/2 inch

6. Maximum variation in cross sectional dimensions of columns and beams and in thickness of slabs and walls shall be ± 1/2 inch and in concrete plan dimensions for footings and foundations shall be - 1/2 inch + 2 inches.

7. Maximum misplacement or eccentricity of footings and foundations shall be 2 percent of footing width in direction of misplacement but not more than 2 inches.

8. Specified thickness of footings and foundations may be decreased by up to 5 percent with no maximum increase except that which may interfere with other construction.

9. Maximum step variance in the flight of stairs for Rise is ± 1/8 inch and for Tread is ± 1/4 inch and in consecutive steps for Rise is ± 1/16 inch and for Tread is ± 1/8 inch.

10. Sufficient control points and benchmarks to be used for reference purposes to check tolerances shall be established and maintained in an undisturbed condition until final completion and acceptance of the work.

11. Regardless of tolerances listed, no portion of a structure shall be allowed to extend beyond the legal boundary of work site.

12. To maintain specified tolerances, formwork shall be cambered to compensate for anticipated deflections in formwork prior to hardening of concrete. Forms shall be sufficiently tight to prevent loss of mortar from concrete.

13. A 3/4-inch chamfer strip shall be placed in exposed to view corner of form to produce a 3/4-inch wide beveled edge.

FORMWORK DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03100-9 14. At construction joints, contact surface of form sheathing for flush surfaces exposed to view over hardened concrete in previous placement shall be overlapped by at least 1 inch. Forms against hardened concrete shall be held to prevent offsets or loss of mortar at construction joint and to maintain a true surface. Where possible, juncture of built-in-place wood or metal forms shall be located at architectural lines, control joints or at construction joints.

15. Where circular walls are formed and forms made up of straight sections are proposed for use, straight lengths not exceeding 2 feet wide shall be provided for curved surfaces 25 feet or larger. Formwork shall be braced and tied to maintain correct position and shape of members.

16. Wood forms for wall openings shall be constructed to facilitate loosening, if necessary, to counteract swelling. Formwork shall be anchored to shores or other supporting surfaces of members so that movement of any part of formwork system is prevented during concrete placement.

17. Runways for moving equipment shall be provided with struts or legs, supported directly on formwork or structural member without resting on reinforcing steel.

18. A positive means of adjustment (wedges or jacks) of shores and struts and take up all settlement during concrete placing operation shall be provided. Forms shall be securely braced against lateral deflection. Wedges used for final adjustment of forms shall be fastened prior to concrete placement in position after final check.

3.05 CONSTRUCTION

A. VERTICAL SURFACES:

All vertical surfaces of concrete members shall be formed, except where placement of the concrete against the ground is shown. Not less than 1-inch of concrete shall be added to the thickness of the concrete member as shown where concrete is permitted to be placed against trimmed ground in lieu of forms. Such permission will be granted only for members of comparatively limited height and where the character of the ground is such that it can be trimmed to the required lines and will stand securely without caving or sloughing until the concrete has been placed.

FORMWORK 03100-10 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 B. CONSTRUCTION JOINTS:

Concrete construction joints will not be permitted at locations other than those shown or specified, except as may be acceptable to the CONSTRUCTION MANAGER. When a second lift is placed on hardened concrete, special precautions shall be taken in the way of the number, location, and tightening of ties at the top of the old lift and bottom of the new to prevent any unsatisfactory effect whatsoever on the concrete. Pipe stubs and anchor bolts shall be set in the forms where required.

C. FORM TIES:

1. EMBEDDED TIES: Holes left by the removal of form tie cones shall be reamed with suitable toothed reamers so as to leave the surface of the holes clean and rough before being filled with mortar as indicated in Section 03300. Wire ties for holding forms will not be permitted. No form-tying device or part thereof, other than metal, shall be left embedded in the concrete. Ties shall not be removed in such manner as to leave a hole extending through the interior of the concrete members. The use of snap-ties which cause spalling of the concrete upon form stripping or tie removal will not be permitted. If steel panel forms are used, rubber grommets shall be provided where the ties pass through the form in order to prevent loss of cement paste. Where metal rods extending through the concrete are used to support or to strengthen forms, the rods shall remain embedded and shall terminate not less than 1-inch back from the formed face or faces of the concrete.

2. REMOVABLE TIES: Where taper ties are approved for use, the larger end of the taper tie shall be on the wet side of walls in water retaining structures. After the taper tie is removed, the hole shall be thoroughly cleaned and roughened for bond. A precast neoprene or polyurethane tapered plug shall be located at the wall centerline. The hole shall be completely filled with non-shrink grout for water bearing and below-grade walls. The hole shall be completely filled with non-shrink or regular cement grout for above-grade walls which are dry on both sides. Exposed faces of walls shall have the outer 2 inches of the exposed face filled with a cement grout which shall match the color and texture of the surrounding wall surface.

3.06 REMOVAL OF FORMS

Careful procedures for the removal of forms shall be strictly followed, and this work shall be done with care so as to avoid injury to the concrete. Removal of forms shall conform to the following:

1. No construction loads shall be supported on, nor any shoring removed from, any part of the structure under construction except when that portion of the structure in combination with remaining forming and shoring system has sufficient strength to safely support its weight and loads placed thereon.

FORMWORK DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03100-11 2. When required for concrete curing in hot weather, required for repair of surface defects or when finishing is required at an early age, forms shall be removed as soon as concrete has hardened sufficiently to resist damage from removal operations or lack of support.

3. Top forms on sloping surfaces of concrete shall be removed as soon as concrete has attained sufficient stiffness to prevent sagging. Any needed repairs or treatment required on such sloping surfaces shall be performed at once, followed by curing specified in Section 03300.

4. Wood forms for wall openings shall be loosened as soon as this can be accomplished without damage to concrete.

5. Formwork for columns, walls, sides of beams, and other parts not supporting weight of concrete may be removed as soon as concrete has hardened sufficiently to resist damage from removal.

6. Where no reshoring is planned, forms and shoring used to support weight of concrete shall be left in place until concrete has attained its specified 28-day compressive strength. Where a reshoring procedure is planned, supporting formwork may be removed when concrete has reached the concrete strength required by the formwork designer’s structural calculations.

7. In the case of roof slabs and above-ground floor slabs, forms shall remain in place until test cylinders for the roof concrete attain a minimum compressive strength of 75 percent of the 28-day strength specified in Section 03300; provided, that no forms shall be disturbed or removed under an individual panel or unit before the concrete in the adjacent panel or unit has attained 75 percent of the specified 28-day strength and has been in place for a minimum of 7 days.

a. The time required to establish said strength shall be as determined by the CONSTRUCTION MANAGER who will make several test cylinders for this purpose from concrete used in the first group of roof panels placed. If the time so determined is more than the 7- day minimum, then that time shall be used as the minimum length of time.

8. Forms for all vertical walls and columns shall remain in place at least 2 days after the concrete has been placed. Forms for all parts of the WORK not specifically mentioned herein shall remain in place for periods of time as determined by the CONSTRUCTION MANAGER.

FORMWORK 03100-12 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 9. When shores and other vertical supports are so arranged that non-load- carrying form facing material may be removed without loosening or disturbing shores and supports, facing material may be removed when concrete has sufficiently hardened to resist damage from removal.

10. No heavy loading on green concrete will be permitted.

3.07 REUSE OF FORMS

Forms may be reused only if in good condition and only if acceptable to the CONSTRUCTION MANAGER. Light sanding between uses will be required wherever necessary to obtain uniform surface texture on all exposed concrete surfaces. Exposed concrete surfaces are defined as surfaces which are permanently exposed to view. In the case of forms for the inside wall surfaces of hydraulic/water retaining structures, unused tie rod holes in forms shall be covered with metal caps or shall be filled by other methods acceptable to the CONSTRUCTION MANAGER.

3.08 RESHORING

Reshoring shall conform to the following:

2. While reshoring is underway, no superimposed dead or live loads shall be permitted on the new construction.

3. During reshoring, concrete in structural members shall not be subjected to combined dead and construction loads in excess of loads that structural members can adequately support.

4. Reshores shall be placed as soon as practicable after stripping operations are complete but in no case later than the end of working day on which stripping occurs.

5. Reshores shall be placed to carry their required loads without overstressing.

6. Where no reshoring is planned, forms and shoring used to support weight of concrete shall be left in place until concrete has attained its specified 28 day compressive strength. Where a reshoring procedure is planned, supporting formwork may be removed when concrete has reached the concrete strength by the formwork designer’s structural calculations.

FORMWORK DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03100-13 3.09 MAINTENANCE OF FORMS

Forms shall be cleaned, treated with a releasing agent, and maintained in accordance with SSPWC Subsection 303-1.3 and the following. The form surfaces shall be treated with a nonstaining mineral oil or other lubricant [compatible with the waterproofing membrane material and] acceptable to the CONSTRUCTION MANAGER. Any excess lubricant shall be satisfactorily removed before placing the concrete. Where field oiling of forms is required, the CONTRACTOR shall perform the oiling at least two weeks in advance of their use. Care shall be exercised to keep oil off the surfaces of steel reinforcement and other metal items to be embedded in concrete.

3.10 FALSEWORK

Falsework, including staging, walkways, forms, ladders, and similar appurtenances, shall be designed, engineered, constructed, and maintained according to the applicable requirements of the provisions of the OSHA Safety and Health Standards for Construction, and the requirements of the Construction Safety Orders of the California Division of Industrial Safety.

** END OF SECTION **

FORMWORK 03100-14 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014

SECTION 03121

FORM LINERS FOR ARCHITECTURAL CONCRETE

PART 1 – GENERAL

1.01 SECTION INCLUDES

Elastomeric form liners for texturing architectural concrete.

Form liner accessories as scheduled or required.

1.02 RELATED SECTIONS

Section 03100 - Concrete Formwork.

1.03 SUBMITTALS

Submit under provisions of Section 01300.

A. PRODUCT DATA:

Installation instructions and product data verifying compliance with specifications.

1.04 DELIVERY, STORAGE, AND HANDLING

Inspect the materials upon delivery to assure that specified products have been received.

Cover form liners to protect from oil, dirt and UV exposure.

Do not use damaged products. Do not install products not bearing product trade name and manufacturer's name.

Store and dispose of solvent-based materials, and materials used with solvent-based materials, in accordance with requirements of local authorities having jurisdiction.

1.05 PROJECT CONDITIONS

Maintain environmental conditions (temperature, humidity, and ventilation) within limits recommended by manufacturer for optimum results. Do not install products under environmental conditions outside manufacturer's absolute limits.

FORM LINERS FOR ARCHITECTURAL CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03121-1 PART 2 – PRODUCTS

2.01 MANUFACTURERS

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

1. Nawkaw Corporation. 2. Or Equal.

Must also manufacture complete system accessory line of products, in addition to the elastomeric formliners, to include release agent formliner adhesive and repair kit.

Requests for substitutions will be considered in accordance with provisions of Section 01600.

2.02 MATERIALS

Elastomeric form liner for creating textures in poured-in-place or precast concrete.

1. PATTERN AND TEXTURE: 2/32 Inn (Nawkaw Corporation), or equal

2. PHYSICAL CHARACTERISTICS: The Photo-Engraving process is a computer- based method for transferring image data onto sheet materials by means of milling technology. First an image template is scanned and converted into 256 grey scales. In order to transfer the image onto the sheet material, a machining file is generated from the identified grey values, whereby the file includes milling commands for a special CNC milling machine. The milled model is used as a master for casting the elastic formliners.

2.03 ACCESSORIES

Proper Stripping Wax, Mould Wax and Adhesives for the complete form liner system.

PART 3 - EXECUTION

3.01 FORM LINER PREPARATION

Verify lines and levels of formwork and form liner patterns are within allowable tolerances.

On multiple use liners, clean liner before each use. Do not use damaged liner when continued use or repair would diminish the aesthetics of the Work.

The release agent to be used with the formliners should be solvent or water-based depending upon conditions. Please take care that all sections, angles of the pattern are covered with the release agent. The formliners should have 2 applications of the wax. The first coat of wax should be dry before applying the second coat. FORM LINERS FOR ARCHITECTURAL CONCRETE 03121-2 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014

Drying time for the release agents depends on ambient temperatures and air movement. Consumption is approx. 100 - 150 g/m2 depending on the type of pattern. The applied wax film must be protected against rain and other damaging weather conditions by covering with polyethylene sheets.

3.02 FORM LINER INSTALLATION

Store and use form liner panels at temperatures between 40 degrees F and 140 degrees F.

The size of the formliner is limited by the maximum dimensions of the available sheet material and the selected pattern. It is possible to put more plates together to one common picture or to several parts of one picture. But please note that junctions cross to the vertical running engraving grooves will unavoidably lead to visible joint lines.

For making larger shutters and moulds in the horizontal, the formliners can be butted together. The edges of the formliner being flexible can be pressed together tightly which will stop any “bleeding” between the formliners.

The formliner can be cut to size with hand or circular saw.

3.03 CONCRETE PLACEMENT The heat resistance of the formliner is approx. +60oC. If you expect concrete temperatures to exceed +60oC at the formliner face, for whatever reason, it will be necessary to reduce the temperature by suitable methods.

3.04 FORM LINER MAINTENANCE

Proper cleaning and storage of form liner is required to obtain acceptable results. Prevent matrix build-up on the liner surface. All excess release agent shall be blown or wiped off before the form and liner is put back into service.

Storage of form liner shall be out of direct sunlight and in temperatures below 140 degrees F (60 degrees C). Store formliner in rolled up position.

Formliners must be stored dry. If building storage is not available make sure they are raised from the ground and covered securely with black polythene or other non-transparent covers. The hardboard backing must be protected from rain and dampness.

**END OF SECTION**

FORM LINERS FOR ARCHITECTURAL CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03121-3 THIS PAGE INTENTIONALLY LEFT BLANK

FORM LINERS FOR ARCHITECTURAL CONCRETE 03121-4 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 SECTION 03200

CONCRETE REINFORCEMENT

PART 1 -- GENERAL

1.01 DESCRIPTION

This section specifies reinforcing steel for use in reinforced concrete.

1.02 WORK OF THIS SECTION

The WORK of this Section includes providing all concrete reinforcement steel, welded wire fabric, couplers, and concrete inserts for use in reinforced concrete and masonry construction, including all the wires, clips, supports, chairs, spacers, and other accessories.

1.03 RELATED SECTIONS

1. Section 03100 Formwork 2. Section 03300 Cast-in-Place Concrete 3. Section 04232 Reinforced Concrete Block Masonry

1.04 CODES

The WORK of this Section shall comply with the current editions of the following codes as adopted by the City of Carlsbad Municipal Code:

1. California Building Code (CBC)

1.05 QUALITY ASSURANCE

A. QUALITY CONTROL BY CONTRACTOR:

To demonstrate conformance with the specified requirements for cast-in-place concrete, the Contractor shall provide the services of an independent testing laboratory which complies with the requirements of ASTM E329. The testing laboratory shall sample and test concrete related materials as required in Section 03300. Costs of testing laboratory services shall be borne by the Contractor.

CONCRETE REINFORCEMENT DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03200-1 B. REFERENCES:

This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail.

Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued, or replaced.

Except as otherwise indicated, the current editions of the following apply to the WORK of this Section.

Reference Title ACI 315 Details and Detailing of Concrete Reinforcement ACI 318 Building Code Requirements for Structural Concrete ASTM A82 Steel Wire, Plain, for Concrete Reinforcement ASTM A185 Welded Steel Wire, Fabric, Plain for Concrete Reinforcement ASTM A615/A615M REV B Deformed and Plain Billet-Steel Bars for Concrete Reinforcement ASTM A616/A616M Rail-Steel Deformed and Plain Bars for Concrete Reinforcement ASTM A617/A617M Axle-Steel Deformed and Plain Bars for Concrete Reinforcement ASTM A706/A706M REV B Low-Alloy Steel Deformed Bars for Concrete Reinforcement ASTM A775/A775M Epoxy-Coated Reinforcing Steel Bars ASTM E329 Inspection and Testing Agencies for Concrete, Steel, and Bituminous Materials as Used in Construction AWS D1.4 Structural Welding Code--Reinforcing Steel CRSI-PRB Placing Reinforcing Bars

CONCRETE REINFORCEMENT 03200-2 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 Reference Title CRSI-MSP 1 Concrete Reinforcing Steel Institute Manual of Standard Practice FEDSPEC QQ-W-461H Wire, Steel, Carbon (Round, Bare, and Coated) WRI Manual of Standard Practice for Welded Wire Fabric

1.06 SUBMITTALS

The Contractor shall submit the following in compliance with SSPWC Subsection-2-5.3.

Certified mill test reports.

Welder qualification certificate in accordance with AWS D1.4.

Placing Drawings.

1.07 PLACING DRAWINGS

The Contractor shall prepare reinforcement placing drawings conforming to the requirements of ACI 315. Placing drawings shall include bar lists, schedules, bending details, placing details, and placing plans and elevations as required to fully delineate this portion of the work.

The placement drawings shall be stamped and signed by a Licensed Professional Engineer of the State of California.

1.08 DELIVERY, STORAGE AND HANDLING

Deliver reinforcing steel to the site bundled and tagged with identification. Store on skids to keep bars clean and free of mud and debris. If contaminated, all bars shall be cleaned by wire brushing, sand blasting, or other means prior to being set in forms.

1.09 SHOP DRAWINGS AND SAMPLES

The following shall be submitted in accordance with Section 01300:

1. Shop bending diagrams, placing lists, and drawings of all reinforcement steel prior to fabrication.

Details of the concrete reinforcement steel and concrete inserts shall be submitted by the CONTRACTOR at the earliest possible date after receipt by the CONTRACTOR of the Notice to Proceed. Details of reinforcement steel for fabrication and erection shall conform to ACI 315 and the requirements indicated. The shop bending diagrams shall show the actual lengths of bars, to the nearest inch measured to the intersection of the extensions (tangents for bars of

CONCRETE REINFORCEMENT DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03200-3 circular cross section) of the outside surface. The shop drawings shall include bar placement diagrams which clearly indicate the dimensions of each bar splice.

Where mechanical couplers are required or permitted to be used to splice reinforcement steel, manufacturer's literature shall be submitted which contains instructions and recommendations for installation for each type of coupler used; certified test reports which verify the load capacity of each type and size of coupler used; and shop drawings which show the location of each coupler with details of how they are to be installed in the formwork.

If reinforcement steel is spliced by welding at any location, the CONTRACTOR shall submit mill test reports which shall contain the information necessary for the determination of the carbon equivalent as specified in AWS D1.4. The CONTRACTOR shall submit a written welding procedure for each type of weld for each size of bar which is to be spliced by welding; merely a statement that AWS procedures will be followed is not acceptable.

Mill certificates shall be delivered with each shipment of reinforcing bars.

1.10 FACTORY TESTING

If requested by the CONSTRUCTION MANAGER, the CONTRACTOR shall provide samples from each heat of reinforcement steel delivered in a quantity adequate for testing. Costs of initial tests and sample materials will be paid by the OWNER. Costs of additional tests due to material failing initial tests shall be paid by the CONTRACTOR.

If reinforcement steel is spliced by welding at any location, the CONTRACTOR shall submit certifications of procedure qualifications for each welding procedure used and certification of welder qualifications, for each welding procedure, and for each welder performing the work. Such qualifications shall be as specified in AWS D1.4.

1.11 FIELD TESTING

Products shall be field tested for compliance with the indicated requirements. If requested by the CONSTRUCTION MANAGER, the CONTRACTOR shall provide samples of each type of welded splice used in the work in a quantity and of dimensions adequate for testing. At the discretion of the CONSTRUCTION MANAGER, radiographic testing of direct butt welded splices will be performed. The CONTRACTOR shall provide assistance necessary to facilitate testing. The CONTRACTOR shall repair any weld which fails to meet the requirements of AWS D1.4. The costs of testing will be paid by the OWNER; except, the costs of all tests which fail to meet specified requirements shall be paid by the CONTRACTOR at no additional cost to the OWNER.

CONCRETE REINFORCEMENT 03200-4 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 PART 2 – PRODUCTS

2.01 GENERAL

Materials specified in this Section which may remain or leave residues on or within the concrete shall be classified as acceptable for potable water use by the Environmental Protection Agency within 30 days of application or use.

2.02 BAR REINFORCEMENT

Reinforcing bars shall be deformed billet steel in conformance with ASTM A615, including supplementary requirements. Bars shall be Grade 60, except ties or field-bent bars where specified shall be Grade 40. Bars to be welded shall be Grade 40 or shall be deformed billet steel conforming to ASTM A706. ASTM A616 or ASTM A617 steel shall not be used. Bars provided as dowels for future construction and bars where specified shall be epoxy-coated in conformance with ASTM A775.

2.03 WELDED WIRE FABRIC

Welded wire fabric shall be welded steel mesh conforming to the requirements of ASTM A 185 and as indicated; provided, that welded wire fabric with longitudinal wire of W4 size wire and smaller shall be either furnished in flat sheets or in rolls with a core diameter of not less than 10 inches; and provided further, that welded wire fabric with longitudinal wires larger than W4 size shall be furnished in flat sheets only.

2.04 WIRE AND PLAIN BARS

Wire used as reinforcement and bars used as spiral reinforcement in structures shall be cold drawn steel conforming to ASTM A82.

2.05 TIE WIRE

The wire shall be minimum 16 gage annealed steel conforming to FEDSPEC QQ-W-461H.

2.06 BAR SUPPORTS

All bar supports shall meet the requirements of the CRSI Manual of Standard Practice including special requirements for supporting epoxy coated reinforcing bars. Bar supports coming into contact with forms shall be CRSI Class 1for maximum protection with a 1/8-inch minimum thickness of gray plastic coating which extends at least 1/2-inch from the concrete surface or Class 2 stainless steel protected and shall be located in accordance with CRSI MSP-1 and placed in accordance with CRSI PRB. Concrete block supports shall be provided for footing and slabs on grade. Stainless steel or plastic protected plain steel supports shall be provided for other work.

CONCRETE REINFORCEMENT DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03200-5 2.07 PRODUCT DATA

The following information shall be provided prior to installation in accordance with Section 01300:

1. Certified mill test reports 2. Welder qualification certificate in accordance with AWS D1.4. 3. Placing Drawings

2.08 MECHANICAL COUPLERS

Mechanical couplers shall be provided where shown and where approved by the CONSTRUCTION MANAGER. The couplers shall develop a tensile strength which exceeds 125 percent of the yield strength of the reinforcement bars being spliced at each splice.

Where the type of coupler used is composed of more than one component, all components required for a complete splice shall be supplied. This shall apply to all mechanical splices, including those splices intended for future connections.

The reinforcement steel and coupler used shall be compatible for obtaining the required strength of the connection. Straight threaded type couplers shall require the use of the next larger size reinforcing bar or shall be used with reinforcing bars with specially forged ends which provide upset threads which do not decrease the basic cross section of the bar.

2.09 WELDED SPLICES

Welded splices shall be provided where shown and where approved by the CONSTRUCTION MANAGER. All welded splices of reinforcement steel shall develop a tensile strength which exceeds 125 percent of the yield strength of the reinforcement bars which are connected.

All materials required to conform the welded splices to the requirements of AWS D1.4 shall be provided.

2.10 EPOXY GROUT

Epoxy for grouting reinforcing bars shall be specifically formulated for such application, for the moisture condition, application temperature, and orientation of the hole to be filled. Epoxy grout shall meet the requirements found in Section 03600.

CONCRETE REINFORCEMENT 03200-6 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 2.11 MANUFACTURERS

Products of the type indicated, shall be manufactured by one of the following (or equal):

1. Couplers:

a. Lenton Form Saver by Erico Products b. Dowel Bar Splicer System by Richmond Screw Anchor Company

2.12 SPIRAL REINFORCEMENT

Spiral reinforcement shall be cold-drawn steel wire conforming to the requirements of ASTM A 82.

2.13 EPOXY COATING

Epoxy coating for reinforcing and accessories, where specified or shown, shall conform to ASTM A 775, but its usage shall be subject to City approval.

2.14 CONCRETE BLOCKS (DOBIES)

Concrete blocks (dobies) used to support and position reinforcement steel, shall have the same or higher compressive strength as specified for the concrete in which it is located. Wire ties shall be embedded in concrete block bar supports.

2.15 OTHER ACCESSORIES

Other accessories shall include all necessary chairs, slab bolsters, dips, supports, spacers, and other devices to position reinforcement during concrete placement.

PART 3 -- EXECUTION

3.01 GENERAL

All reinforcement steel, welded wire fabric, couplers, and other appurtenances shall be fabricated, and placed in accordance with the requirements of the California Building Code and the supplementary requirements specified herein.

3.02 FABRICATION

A. GENERAL:

Reinforcement steel shall be accurately formed to the dimensions and shapes shown, and the fabricating details shall be prepared in accordance with ACI 315 and ACI 318, except as indicated. Stirrups and tie bars shall be bent around a pin having a diameter not less than 1-1/2-

CONCRETE REINFORCEMENT DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03200-7 inch for No. 3 bars, 2-inch for No. 4 bars, and 2-1/2-inch for No. 5 bars. Bends for other bars shall be made around a pin having a diameter not less than 6 times the bar diameter, except for bars larger than 1 inch, in which case the bends shall be made around a pin of 8 bar diameters. Bars shall be bent cold.

The CONTRACTOR shall fabricate reinforcement bars for structures in accordance with bending diagrams, placing lists, and placing drawings.

Reinforcing steel shall not be bent or straightened in a manner which will injure the material. Bars with kinks or with bends not shown shall not be used. Heating or welding bars shall be performed in accordance with AWS D1.4 and shall only be permitted where specified or approved by the Construction Manager. Bars shall not be welded at the bend.

B. FABRICATING TOLERANCES:

Bars used for concrete reinforcement shall meet the following requirements for fabricating tolerances:

1. Sheared length: + 1 inch

2. Depth of truss bars: + 0, - 1/2 inch

3. Stirrups, ties, and spirals: + 1/2 inch

4. All other bends: + 1 inch

3.03 PLACEMENT

Reinforcing steel shall be placed in accordance with CRSI PRB and CRSI MSP-1.

All reinforcing steel shall be of the required sizes and shapes and placed where shown on the placement drawings.

Reinforcing steel shall be positioned accurately and secured against displacement by using annealed iron wire ties or suitable clips at intersections. All reinforcing steel shall be supported by concrete or metal chairs, spacers, or metal hangers which are strong and rigid enough to prevent any displacement of the reinforcement steel. Tack welding of cross bars is not acceptable. Bars shown on the drawings shall not be repositioned (buried) to act as support bars. Additional bars shall be provided as required for supports. Steel rods and pegs may be used to support reinforcing steel on rock foundations. Reinforcing steel shall be placed in such a manner as to not damage waterproofing membrane or plastic lining which has been previously applied or constructed. Reinforcing steel shall be shop-bent or slightly relocated where necessary to clear water stop. Reinforcing steel shall not be placed on fresh concrete or forced into fresh concrete.

CONCRETE REINFORCEMENT 03200-8 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 Supports for embedded items shall not be welded to the reinforcement. Additional reinforcement may be provided for this purpose.

Where concrete is to be placed on the ground, supporting concrete blocks (or dobies) shall be used, in sufficient numbers to support the bars without settlement, but in no case shall such support be continuous. All concrete blocks used to support reinforcement steel shall be tied to the steel with wire ties which are embedded in the blocks. For concrete over formwork, the CONTRACTOR shall furnish concrete, metal, plastic, or other acceptable bar chairs and spacers.

Do not straighten or re-bend reinforcing steel in a manner that will damage the material. Do not use bars with bends not shown on the drawings. All steel shall be cold bent – do not use heat.

Place reinforcement a minimum of 2-inches clear of any metal pipe, fittings, or exposed surfaces.

The reinforcement shall be so secured in position that it will not be displaced during the placement of concrete.

All reinforcing steel, wire mesh, and tie wire shall be completely encased in concrete.

Reinforcing steel shall not be welded unless specifically required by the Approved Plans or otherwise directed by the Construction Manager.

Secure reinforcing dowels in place prior to placing concrete. Do not press dowels into the concrete after the concrete has been placed.

Minimum lap for all reinforcement shall be 40 bar diameters unless otherwise specified on the Approved Plans.

Wire mesh reinforcement is to be rolled flat before being placed in the form. Support and tie wire mesh to prevent movement during concrete placement.

Limitations on the use of bar support materials shall be as follows:

1. Concrete Dobies: permitted at all locations except where architectural finish is required.

2. Wire Bar Supports: permitted only at slabs over dry areas, interior dry wall surfaces, and exterior wall surfaces.

3. Plastic Bar Supports: permitted at all locations except on grade.

Tie wires shall be bent away from the forms in order to provide the specified concrete coverage.

CONCRETE REINFORCEMENT DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03200-9 Bars additional to those shown which may be found necessary or desirable by the CONTRACTOR for the purpose of securing reinforcement in position shall be provided by the CONTRACTOR at no additional cost to the OWNER.

Unless otherwise specified, reinforcement placing tolerances shall be within the limits specified in Section 7.5 of ACI 318 except where in conflict with the requirements of the CBC.

Bars may be moved as necessary to avoid interference with other reinforcement steel, conduits, or embedded items. If bars are moved more than one bar diameter, or enough to exceed the above tolerances, the resulting arrangement of bars shall be subject to the approval of the CONSTRUCTION MANAGER.

Welded wire fabric reinforcement placed over horizontal forms shall be supported on slab bolsters. Slab bolsters shall be spaced not more than 30 inches on centers, shall extend continuously across the entire width of the reinforcement mat, and shall support the reinforcement mat in the plane indicated.

Welded wire fabric placed over the ground shall be supported on wired concrete blocks (dobies) spaced not more than 3 feet on centers in any direction. The construction practice of placing welded wire fabric on the ground and hooking into place in the freshly placed concrete shall not be used.

Epoxy coated reinforcing bars shall be stored, transported, and placed in such a manner as to avoid chipping of the epoxy coating. Non-abrasive slings made of nylon and similar materials shall be used. Specially coated bar supports shall be used. All chips or cracks in the epoxy coating shall be repaired with a compatible epoxy repair material prior to placing concrete.

Accessories supporting reinforcing bars shall be spaced such that there is no deflection of the accessory from the weight of the supported bars. When used to space the reinforcing bars from wall forms, the forms and bars shall be located so that there is no deflection of the accessory when the forms are tightened into position.

3.04 SPACING OF BARS

The clear distance between parallel bars (except in columns and between multiple layers of bars in beams) shall be not less than the nominal diameter of the bars nor less than 1-1/3 times the maximum size of the coarse aggregate, nor less than one inch.

Where reinforcement in beams or girders is placed in 2 or more layers, the clear distance between layers shall be not less than one inch.

In columns, the clear distance between longitudinal bars shall be not less than 1-1/2 times the bar diameter, nor less than 1-1/2 times the maximum size of the coarse aggregate, nor less than 1-1/2 inches.

CONCRETE REINFORCEMENT 03200-10 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 The clear distance between bars shall also apply to the distance between a contact splice and adjacent splices or bars.

3.05 SPLICING

A. GENERAL:

Reinforcing steel shall be spliced as shown and only be used at locations indicated. Additional splices may be provided where approved by the Construction Manager.

In slabs, beams, girders, and walls, reinforcing steel shall not be spliced in areas of maximum stress. Splices of adjacent bars shall be staggered at least one splice length, unless otherwise specified. Splices in welded wire fabric shall be at least 1 1/2 meshes wide.

B. SPLICES OF REINFORCEMENT:

The length of lap for reinforcement bars, unless otherwise indicated, shall be in accordance with ACI 318.

Laps of welded wire fabric shall be in accordance with the ACI 318. Adjoining sheets shall be securely tied together with No. 14 tie wire, one tie for each 2 running feet. Wires shall be staggered and tied in such a manner that they cannot slip.

Splices in column spiral reinforcement, when necessary, shall be made by welding or by a lap of 1-1/2 turns.

C. BENDING OR STRAIGHTENING:

Reinforcement shall not be straightened or rebent in a manner which will injure the material. Bars with kinks or bends not shown shall not be used. All bars shall be bent cold, unless otherwise permitted by the CONSTRUCTION MANAGER. No bars partially embedded in concrete shall be field-bent except as shown or specifically permitted by the CONSTRUCTION MANAGER.

Couplers which are located at a joint face shall be a type which can be set either flush or recessed from the face as shown. The couplers shall be sealed during concrete placement to completely eliminate concrete or cement paste from entering. Couplers intended for future connections shall be recessed a minimum of 1/2 inch from the concrete surface. After the concrete is placed, the coupler shall be plugged with plastic plugs which have an O-ring seal and the recess filled with sealant to prevent any contact with water or other corrosive materials. Threaded couplers shall be plugged .

Unless indicated otherwise, mechanical coupler spacing and capacity shall match the spacing and capacity of the reinforcing shown for the adjacent section.

Tack welding of reinforcing bars is prohibited.

CONCRETE REINFORCEMENT DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03200-11 3.06 CLEANING

Reinforcing steel shall be free from rust, scale, oil, or any other coating that would reduce or destroy the bond between concrete and steel. Reinforcing steel shall be cleaned of mill rust scale, dried concrete, or other coatings that may reduce bond. Reinforcement reduced in section is not acceptable. When concrete placement is delayed, reinforcement shall be cleaned by sandblasting if directed by the Construction Manager.

3.07 REPAIR OF EPOXY COATING

Epoxy coating damage need not be repaired in cases where the damaged area is 0.1 square inch or smaller. All damaged areas larger than 0.1 square inch shall be repaired in conformance with ASTM A775.

3.08 CLEANING AND PROTECTION

Reinforcement steel shall at all times be protected from conditions conducive to corrosion until concrete is placed around it.

The surfaces of all reinforcement steel and other metalwork to be in contact with concrete shall be thoroughly cleaned of all dirt, grease, loose scale and rust, grout, mortar and other foreign substances immediately before the concrete is placed. Where there is delay in depositing concrete, reinforcement shall be reinspected and, if necessary recleaned.

3.09 EMBEDMENT OF DRILLED REINFORCING STEEL DOWELS

A. HOLE PREPARATION:

The hole diameter shall be as recommended by the epoxy manufacturer but shall be no larger than 0.25 inch greater than the diameter of the outer surface of the reinforcing bar deformations.

The depth of the hole shall be as recommended by the epoxy manufacturer to fully develop the bar but shall not be less than 12 bar diameters, unless noted otherwise.

The hole shall be drilled by methods which do not interfere with the proper bonding of epoxy.

Existing reinforcing steel in the vicinity of proposed holes shall be located prior to drilling. The location of holes to be drilled shall be adjusted to avoid drilling through or nicking any existing reinforcing bars.

The hole shall be blown clean with clean, dry compressed air to remove all dust and loose particles.

CONCRETE REINFORCEMENT 03200-12 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 Epoxy shall be injected into the hole through a tube placed to the bottom of the hole. The tube shall be withdrawn as epoxy is placed but kept immersed to prevent formation of air pockets. The hole shall be filled to a depth that insures that excess material will be expelled from the hole during dowel placement.

Dowels shall be twisted during insertion into the partially filled hole so as to guarantee full wetting of the bar surface with epoxy. The bar shall be inserted slowly enough to avoid developing air pockets.

** END OF SECTION **

CONCRETE REINFORCEMENT DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03200-13 THIS PAGE INTENTIONALLY LEFT BLANK

CONCRETE REINFORCEMENT 03200-14 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 SECTION 03290

JOINTS IN CONCRETE STRUCTURE

PART 1 -- GENERAL

1.01 WORK OF THIS SECTION

The WORK of this Section includes providing the construction joints, contraction joints, expansion joints, and control joints in structural concrete, including waterstops, joint fillers, and joint sealants.

1.02 RELATED SECTIONS

The WORK of the following Sections applies to the WORK of this Section. Other Sections of the specifications, not referenced below, shall also apply to the extent required for proper performance of this WORK.

1. Section 03100 Formwork 2. Section 03200 Concrete Reinforcement 3. Section 03300 Cast-in-Place Concrete 4. Section 07900 Sealants

1.03 SPECIFICATIONS AND STANDARDS

Except as otherwise indicated, the current editions of the following apply to the WORK of this Section.

Reference Title ASTM C 920 Specification for Elastomeric Joint Sealants. ASTM D 412 Test Methods for Rubber Properties in Tension. ASTM D 624 Test Method for Rubber Property -- Tear Resistance. ASTM D 638 Test Method for Tensile Properties of Plastics. ASTM D 746 Test Method for Brittleness Temperature of Plastics and Elastomers by Impact. ASTM D 747 Test Method for Apparent Bending Modulus of Plastics by Means of a Cantilever Beam. ASTM D 1056 Specification for Flexible Cellular Materials -- Sponge or Expanded Rubber. ASTM D 1752 Specification for Preformed Sponge Rubber and Cork Expansion Joint Fillers for Concrete Paving and Structural Construction.

JOINTS IN CONCRETE STRUCTURE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03290-1 Reference Title ASTM D 2240 Test Method for Rubber Property -- Durometer Hardness. CRD-C572 PVC Waterstop. TT-S-0227E(3) Sealing Compound, elastomeric type, Multi-component for Caulking, Sealing, and Glazing Buildings and Other Structures.

1.04 TYPES OF JOINTS

A. CONSTRUCTION JOINTS:

When fresh concrete is placed against a hardened concrete surface, the joint between the two pours is called a construction joint. Unless otherwise specified, all joints in water bearing members shall be provided with a waterstop and/or sealant groove of the shape specified and shown. The surface of the first pour may also be required to receive a coating of bond breaker as shown.

B. CONTRACTION JOINTS:

Contraction joints are similar to construction joints except that the fresh concrete shall not bond to the hardened surface of the first pour, which shall be coated with a bond breaker. The slab reinforcement shall be stopped 4-1/2 inches from the joint; which is provided with a sleeve-type dowel, to allow shrinkage of the concrete of the second pour. Waterstop and/or sealant groove shall also be provided when specified or shown.

C. EXPANSION JOINTS:

To allow the concrete to expand freely, a space is provided between the two pours, the joint shall be formed as shown. This space is obtained by placing a filler joint material against the first pour, which acts as a form for the second pour. Unless otherwise specified, all expansion joints in water bearing members shall be provided with a center-bulb type waterstop as shown.

Premolded expansion joint material shall be installed with the edge at the indicated distance below or back from finished concrete surface, and shall have a slightly tapered, dressed, and oiled wood strip secured to or placed at the edge thereof during concrete placement, which shall later be removed to form space for sealing material.

The space so formed shall be filled with a joint sealant material as indicated below. In order to keep the two wall or slab elements in line the joint shall also be provided with a sleeve- type dowel as shown.

JOINTS IN CONCRETE STRUCTURE 03290-2 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 D. CONTROL JOINTS:

The function of the control joint is to provide a weaker plane in the concrete, where shrinkage cracks will probably occur. A groove, of the shape and dimensions shown, is formed or saw-cut in the concrete. This groove is afterward filled with a joint sealant material.

1.05 SHOP DRAWINGS AND SAMPLES

The following shall be submitted in compliance with Section 01300:

1. WATERSTOPS: Prior to production of the material required under this contract, qualification samples shall be submitted. Such samples shall consist of extruded or molded sections of each size or shape to be used, and shall be accomplished so that the material and workmanship represents in all respects the material to be furnished under this contract. The balance of the material to be used under this contract shall not be produced until after the CONSTRUCTION MANAGER has reviewed the qualification samples.

2. WATERSTOP SAMPLES: Prior to use of the waterstop material in the field, a sample of a fabricated mitered cross and a tee constructed of each size or shape of material to be used shall be submitted. These samples shall be fabricated so that the material and workmanship represent in all respects the fittings to be furnished under this contract.

Field samples of fabricated fittings (crosses, tees, etc.) will be selected at random by the CONSTRUCTION MANAGER for testing by a laboratory at the OWNER's expense. When tested, they shall have a tensile strength across the joints equal to at least 600 psi.

3. JOINT SEALANT: Prior to ordering the sealant material, the CONTRACTOR shall submit sufficient data to show general compliance with the requirements of the Contract Documents.

4. JOINT LOCATION: The CONTRACTOR shall submit placement shop drawings showing the location and type of all joints for each structure.

Certified test reports from the sealant manufacturer on the actual batch of material being supplied indicating compliance with the above requirements shall be furnished before the sealant is used on the job.

1.06 OWNER'S MANUAL

A. SHIPPING CERTIFICATION:

The CONTRACTOR shall provide written certification from the manufacturer as an integral part of the shipping form, to show that all of the material shipped to this project meets or exceeds the physical property requirements of the Contract Documents. Supplier certificates are not acceptable.

JOINTS IN CONCRETE STRUCTURE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03290-3 1.07 SERVICES OF MANUFACTURER

Before work is commenced, the CONTRACTOR shall arrange for a representative of the sealant manufacturer to instruct the crew doing the WORK on the proper methods of mixing and applying the sealant.

When requested by the CONSTRUCTION MANAGER, the CONTRACTOR shall arrange for field technical assistance from the bentonite manufacturer.

1.08 INSPECTION AND TESTING

A. WATERSTOP INSPECTION:

It is required that all waterstop field joints shall be subject to rigid inspection, and no such work shall be scheduled or started without having made prior arrangements with the CONSTRUCTION MANAGER to provide for the required inspections. Not less than 24 hours' notice shall be provided to the CONSTRUCTION MANAGER for scheduling such inspections.

All field joints in waterstops shall be subject to rigid inspection for misalignment, bubbles, inadequate bond, porosity, cracks, offsets, and other defects which would reduce the potential resistance of the material to water pressure at any point. All defective joints shall be replaced with material which shall pass said inspection, and all faulty material shall be removed from the site and disposed of by the CONTRACTOR at its own expense.

The following waterstop defects represent a partial list of defects which shall be grounds for rejection:

1. Offsets at joints greater than 1/16-inch or 15 percent of material thickness, at any point, whichever is less.

2. Exterior crack at joint, due to incomplete bond, which is deeper than 1/16- inch or 15 percent of material thickness, at any point, whichever is less.

3. Any combination of offset or exterior crack which will result in a net reduction in the cross section of the waterstop in excess of 1/16-inch or 15 percent of material thickness at any point, whichever is less.

4. Misalignment of joint which result in misalignment of the waterstop in excess of 1/2-inch in 10 feet.

5. Porosity in the welded joint as evidenced by visual inspection.

6. Bubbles or inadequate bonding which can be detected with a penknife test. (If, while prodding the entire joint with the point of a pen knife, the knife breaks through the outer portion of the weld into a bubble, the joint shall be considered defective.)

JOINTS IN CONCRETE STRUCTURE 03290-4 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014

B. CONSTRUCTION JOINT SEALANT:

The CONTRACTOR shall prepare adhesion and cohesion test specimens as specified herein, at intervals of 5 working days while sealants are being installed.

The sealant material shall show no signs of adhesive or cohesive failure when tested in accordance with the following procedure in laboratory and field tests:

1. Sealant specimen shall be prepared between 2 concrete blocks (1-inch by 2-inch by 3-inch). Spacing between the blocks shall be 1-inch. Coated spacers (2-inch by 1-1/2-inch by 1/2-inch) shall be used to insure sealant cross-sections of 1/2-inch by 2-inches with a width of 1-inch.

2. Sealant shall be cast and cured according to manufacturer's recommendations except that curing period shall not exceed 24 hours.

3. Following curing period, the gap between blocks shall be widened to 1- 1/2-inch. Spacers shall be used to maintain this gap for 24 hours prior to inspection for failure.

1.09 GUARANTEE

The CONTRACTOR shall provide a 5-year written guarantee of the entire sealant installation against faulty and/or incompatible materials and workmanship, together with a statement that it agrees to repair or replace, to the satisfaction of the OWNER, at no additional cost to the OWNER, any such defective areas which become evident within said 5-year guarantee period.

PART 2 -- PRODUCTS

2.01 GENERAL

All joint materials specified herein shall be classified as acceptable for potable water use, by the Environmental Protection Agency, within 30 days of application.

JOINTS IN CONCRETE STRUCTURE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03290-5 2.02 PVC WATERSTOPS

A. GENERAL:

Waterstops shall be extruded from an elastomeric polyvinyl chloride compound containing the plasticizers, resins, stabilizers, and other materials necessary to meet the requirements of these Specifications. No reclaimed or scrap material shall be used. The CONTRACTOR shall obtain from the waterstop manufacturer and shall furnish to the CONSTRUCTION MANAGER for review, current test reports and a written certification of the manufacturer that the material to be shipped to the job meets the physical requirements as outlined in the U.S. Army Corps of Engineers Specification CRD-C572 and those listed herein.

B. FLATSTRIP AND CENTER-BULB WATERSTOPS:

Flatstrip and center-bulb waterstops shall be as indicated; provided, that at no place shall the thickness of flat strip waterstops, including the center bulb type, be less than 3/8-inch.

C. MULTI-RIB WATERSTOPS:

Multi-rib waterstops, where required, shall be as indicated. Prefabricated joint fittings shall be used at all intersections of the ribbed-type waterstops.

D. OTHER TYPES OF WATERSTOPS:

When other types of waterstops, not listed above, are required, they shall be subjected to the same requirements as those listed herein.

E. WATERSTOP TESTING REQUIREMENTS:

When tested in accordance with the specified test standards, the waterstop material shall meet or exceed the following requirements:

Physical Property, Sheet Material Value ASTM Std. Tensile Strength-min (psi) 1750 D 638, Type IV Ultimate Elongation-min (percent) 350 D 638, Type IV Low Temp Brittleness-max (degrees F) -35 D 746 Stiffness in Flexure-min (psi) 400 D 747

Accelerated Extraction (CRD-C572) Tensile Strength-min (psi) 1500 D 638, Type IV Ultimate Elongation-min (percent) 300 D 638, Type IV

Effect of Alkalies (CRD-C572) JOINTS IN CONCRETE STRUCTURE 03290-6 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 Physical Property, Sheet Material Value ASTM Std. Change in Weight (percent) +0.25 / -0.10 ------Change in Durometer, Shore A +5 D 2240

Finish Waterstop Tensile Strength-min (psi) 1400 D 638, Type IV Ultimate Elongation-min (percent) 280 D 638, Type IV

2.03 JOINT SEALANT

Joint sealant shall be polyurethane polymer designed for bonding to concrete which is continuously submerged in water. No material will be acceptable which has an unsatisfactory history as to bond or durability when used in the joints of water retaining structures.

Joint sealant material shall meet the following requirements (73 degrees F and 50 percent R.H.):

Work Life 45 - 180 minutes Time to Reach 20 Shore "A" Hardness 24 hours, maximum (at 77 degrees F, 200 gr quantity) Ultimate Hardness (ASTM D 2240) 20 - 45 Shore "A" Tensile Strength (ASTM D 412) 200 psi, minimum Ultimate Elongation (ASTM D 412) 400 percent, minimum Tear Resistance (Die C ASTM D 624) 75 pounds per inch of thickness, minimum Color Light Gray

All polyurethane sealants for waterstop joints in concrete shall conform to the following requirements:

1. Sealant shall be 2-part polyurethane with the physical properties of the cured sealant conforming to or exceeding the requirements of ANSI/ASTM C 920 Type M or Federal Specification TT-S-00227 E(3) for 2-part material, as applicable.

2. For vertical joints and overhead horizontal joints, only "non-sag" compounds shall be used; all such compounds shall conform to the requirements of ANSI/ASTM C 920 Class 25, Grade NS, or Federal Specification TT-S-0027 E(3), Type II, Class A.

3. For plane horizontal joints, the self-leveling compounds which meet the requirements of ANSI/ASTM C 920 Class 25, Grade P, or Federal JOINTS IN CONCRETE STRUCTURE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03290-7 Specification TT-S-0027 E(3), Type I shall be used. For joints subject to either pedestrian or vehicular traffic, a compound providing non-tracking characteristics, and having a Shore "A" hardness range of 35 to 45, shall be used.

4. Primer materials, if recommended by the sealant manufacturer, shall conform to the printed recommendations of the sealant manufacturer.

Sealants for non-waterstop joints in concrete shall conform to the requirements of Section 07900

2.04 JOINT MATERIALS

A. BEARING PAD:

Bearing pad to be neoprene conforming to ASTM D 1752 Type I, 40 durometer hardness unless otherwise noted.

B. NEOPRENE SPONGE:

Sponge to be neoprene, closed-cell, expanded, conforming to ASTM D 1056, type RE- 45-E1, with a compression deflection, 25 percent deflection (limits), 119 to 168 kPa (17 to 24 psi) minimum.

C. PREFORMED JOINT FILLER:

Preformed joint filler material for water retaining applications shall be of the preformed non-extruding type joint filler constructed of cellular neoprene sponge rubber or polyurethane of firm texture. Bituminous fiber type will not be permitted. All non-extruding and resilient-type preformed expansion joint fillers shall conform to the requirements and tests set forth in ASTM D 1752 for Type I, except as otherwise specified herein.

2.05 BACKING ROD

Backing rod shall be an extruded closed-cell, polyethylene foam rod. The material shall be compatible with the joint sealant material used and shall have a tensile strength of not less than 40 psi and a compression deflection of approximately 25 percent at 8 psi. The rod shall be 1/8-inch larger in diameter than the joint width except that a one-inch diameter rod shall be used for a 3/4-inch wide joint.

JOINTS IN CONCRETE STRUCTURE 03290-8 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 2.06 BOND BREAKER

Bond breaker shall contain a fugitive dye so that areas of application will be readily distinguishable.

2.07 BENTONITE WATERSTOP

Where called for, bentonite type waterstop, which shall expand in the presence of water to form a watertight joint seal without damaging the concrete in which it is cast, shall be provided.

The bentonite waterstop shall be composed of 75 percent bentonite. The balance of the material shall be butyl rubber-hydrocarbon with less than 1.0 percent volatile matter. The waterstop shall contain no asbestos fibers or asphaltics.

The manufacturer's rated application temperature range shall be from 5 to 125 degrees F. The service temperature range shall be from -40 to 212 degrees F.

The cross sectional dimensions of the unexpanded waterstop shall be one inch by 3/4- inch.

The waterstop shall be provided with an adhesive backing which will provide excellent adhesion to concrete surfaces.

2.08 SLIP DOWELS

Slip dowels in joints shall be A36 smooth epoxy-coated bars, conforming to ASTM A 775.

2.09 PVC TUBING

PVC tubing in joints shall be Sch. SDR 13.5, conforming to ASTM D 2241.

2.10 MANUFACTURERS

Products shall be manufactured by one of the following (or equal):

1. Flatstrip and Center-Bulb Waterstops:

a. Kirkhill Rubber Company b. Water Seals, Incorporated c. Progress Unlimited, Incorporated d. Greenstreak Plastic Products Company

JOINTS IN CONCRETE STRUCTURE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03290-9 2. Multi-Rib Waterstops:

a. Water Seals, Incorporated b. Progress Unlimited, Incorporated c. Greenstreak Plastic Products Company

3. Sealants:

a. Permapol RC-270 by Products Research b. Elastothane 227R by Pacific Polymers c. Sikaflex 2C by Sika Corporation

4. Bond Breaker:

a. Super Bond Breaker by Burke Company b. Select Cure CRB by Select Products Company

PART 3 -- EXECUTION

3.01 WATERSTOPS - GENERAL

Waterstops of the type specified herein shall be embedded in the concrete across joints as shown. All waterstops shall be fully continuous for the extent of the joint. Splices necessary to provide such continuity shall be accomplished in conformance to printed instructions of manufacturer of the waterstops. The CONTRACTOR shall take suitable precautions and means to support and protect the waterstops during the progress of the work and shall repair or replace at its own expense any waterstops damaged during the progress of the work. All waterstops shall be stored so as to permit free circulation of air around the waterstop material.

When any waterstop is installed in the concrete on one side of a joint, while the other half or portion of the waterstop remains exposed to the atmosphere for more than 2 days, suitable precautions shall be taken to shade and protect the exposed waterstop from direct rays of the sun during the entire exposure and until the exposed portion of the waterstop is embedded in concrete.

3.02 SPLICES IN WATERSTOPS

Splices in waterstops shall be performed by heat sealing the adjacent waterstop sections in accordance with the manufacturer's printed recommendations. It is essential that:

1. The material not be damaged by heat sealing.

2. The splices have a tensile strength of not less than 60 percent of the unspliced materials tensile strength.

JOINTS IN CONCRETE STRUCTURE 03290-10 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 3. The continuity of the waterstop ribs and of its tubular center axis be maintained.

Butt joints of the ends of 2 identical waterstop sections may be made while the material is in the forms.

All joints with waterstops involving more than 2 ends to be jointed together, and all joints which involve an angle cut, alignment change, or the joining of 2 dissimilar waterstop sections shall be prefabricated by the CONTRACTOR prior to placement in the forms, allowing not less than 24-inch long strips of waterstop material beyond the joint. Upon being inspected and approved, such prefabricated waterstop joint assemblies shall be installed in the forms and the ends of the 24-inch strips shall be butt welded to the straight run portions of waterstop in place in the forms.

Where a centerbulb waterstop intersects and is jointed with a non-centerbulb waterstop, care shall be taken to seal the end of the centerbulb, using additional PVC material if needed.

3.03 JOINT CONSTRUCTION

A. SETTING WATERSTOPS:

In order to eliminate faulty installation that may result in joint leakage, particular care shall be taken of the correct positioning of the waterstops during installation. Adequate provisions must be made to support and anchor the waterstops during the progress of the WORK and to insure the proper embedment in the concrete. The symmetrical halves of the waterstops shall be equally divided between the concrete pours at the joints. The center axis of the waterstops shall be coincident with the joint openings. Maximum density and imperviousness of the concrete shall be insured by thoroughly working it in the vicinity of all joints.

In placing flat-strip waterstops in the forms, means shall be provided to prevent them from being folded over by the concrete as it is placed. Unless otherwise shown, all waterstops shall be held in place with light wire ties on 12-inch centers which shall be passed through the edge of the waterstop and tied to the curtain of reinforcing steel. Horizontal waterstops, with their flat face in a vertical plane, shall be held in place with continuous supports to which the top edge of the waterstop shall be tacked. In placing concrete around horizontal waterstops, with their flat face in a horizontal plane, concrete shall be worked under the waterstops by hand so as to avoid the formation of air and rock pockets.

In placing centerbulb waterstops in expansion joints, the centerbulb shall be centered on the joint filler material.

Waterstop in vertical wall joints shall stop 6 inches from the top of the wall where such waterstop does not connect with any other waterstop and is not to be connected to for a future concrete placement.

JOINTS IN CONCRETE STRUCTURE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03290-11 B. JOINT LOCATION:

Construction joints, and other types of joints, shall be provided where shown. When not shown, construction joints shall be provided at 25-foot maximum spacing for all concrete construction, unless noted otherwise. The location of all joints, of any type, shall be submitted to the CONSTRUCTION MANAGER for acceptance.

C. JOINT PREPARATION:

Special care shall be used in preparing concrete surfaces at joints where bonding between 2 sections of concrete is required. Unless otherwise shown, such bonding will be required at all horizontal joints in walls. Surfaces shall be prepared in accordance with the requirements of Section 03300. Except on horizontal wall construction joints, wall to slab joints or where otherwise shown or specified, at all joints where waterstops are required, the joint face of the first pour shall be coated with a bond breaker as specified herein.

D. CONSTRUCTION JOINT SEALANT:

Construction joints in water-bearing floor slabs, and elsewhere as shown, shall be provided with tapered grooves which shall be filled with a construction joint sealant. The material used for forming the tapered grooves shall be left in the grooves until just before the grooves are cleaned and filled with joint sealant. After removing the forms from the grooves, all laitance and fins shall be removed, and the grooves shall be sand-blasted. The grooves shall be allowed to become thoroughly dry, after which they shall be blown out; immediately thereafter, they shall be primed, bond breaker tape placed in the bottom of the groove, and filled with the construction joint sealant. The primer used shall be supplied by the same manufacturer supplying the sealant. No sealant will be permitted to be used without a primer. Care shall be used to completely fill the sealant grooves. Areas designated to receive a sealant fillet shall be thoroughly cleaned, as outlined for the tapered grooves, prior to application of the sealant.

The primer and sealant shall be placed strictly in accordance with the printed recommendations of the manufacturer, taking special care to properly mix the sealant prior to application. The sides of the sealant groove shall not be coated with bond breaker, curing compound, or any other substance which would interfere with proper bonding of the sealant. All sealant shall achieve final cure at least 7 days before the structure is filled with water.

All sealant shall be installed by a competent waterproofing specialty contractor who has a successful record of performance in similar installations.

Thorough, uniform mixing of 2-part, catalyst-cured materials is essential; special care shall be taken to properly mix the sealer before its application.

Any joint sealant which, after the manufacturer's recommended curing time for the job conditions of the WORK hereunder, fails to fully and properly cure shall be completely removed; the groove shall be thoroughly sandblasted to remove all traces of the uncured or partially cured sealant and primer, and shall be re-sealed with the specified joint sealant. All

JOINTS IN CONCRETE STRUCTURE 03290-12 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 costs of such removal, joint treatment, re-sealing, and appurtenant work shall be at the expense of the CONTRACTOR.

E. BENTONITE WATERSTOP:

Where a bentonite waterstop is called for, it shall be installed with the manufacturer's instructions and recommendations; except, as modified herein.

Bentonite waterstop shall only be used where complete confinement by concrete is provided. Bentonite waterstop shall not be used in expansion or contraction joints nor in the first 6 inches of any intersecting joint.

The bentonite waterstop shall be located as near as possible to the center of the joint and it shall be continuous around the entire joint. The minimum distance from the edge of the waterstop to the face of the member shall be 5 inches.

Where the thickness of the concrete member to be placed on the bentonite waterstop is less than 12 inches, the waterstop shall be placed in grooves formed or ground into the concrete. The groove shall be at least 3/4 inch deep and 1-1/4 inches wide. When placed in the groove, the minimum distance from the edge of the waterstop to the face of the member shall be 2.5 inches.

** END OF SECTION **

JOINTS IN CONCRETE STRUCTURE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03290-13

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JOINTS IN CONCRETE STRUCTURE 03290-14 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 SECTION 03300

CAST-IN-PLACE CONCRETE

PART 1 -- GENERAL

1.01 DESCRIPTION

This section describes materials and methods for formwork, reinforcement, mixing, placement, curing and repairs of concrete, and the use of cementitious materials and other related products. This section includes concrete, mortar, grout, and reinforcement,

Non-structural cast-in-place concrete for thrust and anchor blocks, manhole bases, pipe encasement and trench supports shall be in accordance with Section 02223.

1.02 WORK OF THIS SECTION

The CONTRACTOR shall provide finished structural concrete, complete, in accordance with the Contract Documents.

The following types of concrete are covered in this Section:

1. STRUCTURAL CONCRETE: Concrete to be used in all cases except where noted otherwise in the Contract Documents.

2. LEAN CONCRETE: Concrete to be used for thrust blocks, anchor blocks, pipe trench cut-off blocks and cradles, where the preceding items are detailed on the Drawings as unreinforced. Concrete to be used as protective cover for dowels intended for future connection.

The term "hydraulic structure" used in these Specifications refers to environmental engineering concrete structures for the containment, treatment, or transmission of water, or other fluids.

1.03 RELATED SECTIONS

The Work of the following Sections applies to the Work of this Section. Other Sections, not referenced below, shall also apply to the extent required for proper performance of this Work.

1. Section 02200 Earthwork 2. Section 03100 Formwork 3. Section 03200 Concrete Reinforcement 4. Section 03290 Joints in Concrete Structure 5. Section 03600 Grout 6. Section 09881 Plastic Lining for Structures

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-1 1.04 RELATED WORK SPECIFIED ELSEWHERE

Standard Specifications 02223, 07100, 15050, 15073.

1.05 REFERENCE SPECIFICATIONS, CODES AND STANDARDS

Except as otherwise indicated in this Section, the CONTRACTOR shall comply with the latest adopted edition of the Standard Specifications for Public Works Construction (SSPWC).

The current edition of the California Building Code (CBC) as adopted by the City of Carlsbad Municipal Code.

Except as otherwise indicated, the current editions of the following standards apply to the work of this Section:

Reference Title Federal Specifications: UU-B-790A (1) (2) Building Paper, Vegetable Fiber (Kraft, Water-proofed, Water Repellant and Fire Resistant) Commercial Standards: ACI 117 Standard Tolerances for Concrete Construction and Materials ACI 214 Recommended Practice for Evaluation of Strength Test Results of Concrete ACI 301 Specifications for Structural Concrete for Buildings ACI 309 Consolidation of Concrete ACI 315 Details and Detailing of Concrete Reinforcement ACI 318 Building Code Requirements for Reinforced Concrete ACI 350R Environmental Engineering Concrete Structures 3. ASTM Standards in Building Codes: ASTM A 185 Specification for Steel Welded Wire Fabric, Plain, for Concrete Reinforcement ASTM A 615/A 615M Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcement ASTM C 31 Practice for Making and Curing Concrete Test Specimens in the Field ASTM C 33 Specification for Concrete Aggregates ASTM C 39 Test Method for Compressive Strength of Cylindrical

CAST-IN-PLACE CONCRETE 03300-2 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 Reference Title Concrete Specimens ASTM C 40 Test Method for Organic Impurities in Fine Aggregates for Concrete ASTM C 42 Test Method of Obtaining and Testing Drilled Cores and Sawed Beams of Concrete ASTM C 88 Test Method for Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate ASTM C 94 Specification for Ready-Mixed Concrete ASTM C 136 Test Method for Sieve Analysis of Fine and Coarse Aggregates ASTM C 138 Test Method for Unit Weight, Yield, and Air Content of Concrete ASTM C 143 Test Method for Slump of Hydraulic Cement Concrete ASTM C 150 Specification for Portland Cement ASTM C 156 Test Method for Water Retention by Concrete Curing Materials ASTM C 157 Test Method for Length Change of Hardened Hydraulic Cement Mortar and Concrete ASTM C 192 Practice for Making and Curing Concrete Test Specimens in the Laboratory ASTM C 231 Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method ASTM C 260 Specification for Air-Entraining Admixtures for Concrete ASTM C 289 Test Method for Potential Reactivity of Aggregates (Chemical Method) ASTM C 309 Specifications for Liquid Membrane-Forming Compounds for Curing Concrete ASTM C 494 Specification for Chemical Admixtures for Concrete ASTM C827 Test Method for Early Volume Change of Cementitious Mixtures. ASTM C 881 Specification for Epoxy-Resin-Base Bonding Systems for Concrete ASTM C 1077 Practice for Laboratories Testing Concrete and Concrete Aggregates for use in Construction & Criteria for Laboratory Evaluation ASTM D 1751 Specification for Preformed Expansion Joint Fillers for

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-3 Reference Title Concrete Paving and Structural Construction (Non- extruding and Resilient Bituminous Types) ASTM D 2419 Test Method for Sand Equivalent Value of Soils and Fine Aggregate ASTM E 119 Method for Fire Tests of Building Construction and Materials 4. CRSI Standards CRSI Recommended Practice for Placing Reinforcing Bars 5. SSPWC Standards SSPWC Standard Specifications for Public Works Construction "Greenbook"

1.06 APPLICATIONS

The following materials, referenced in other sections, shall be provided and installed in accordance with this specification for the applications noted below:

1. Concrete for thrust and anchor blocks for horizontal and vertical bends, ductile-iron or steel fittings, fire hydrant bury ells, and support blocks for valves 4-inches and larger, all in accordance with the Standard Drawings.

2. Concrete for collars, cradles, curbs, encasements, gutters, manhole bases, protection posts, sidewalks, splash pads, and other miscellaneous cast-in- place items.

3. Mortar for filling and finishing the joints between manhole and vault sections and setting manhole grade rings and cover frames. Mortar may also be used for repairs of minor surface defects of no more than ¼-inch in depth of ½-inch in width on non-structural, cast-in-place items such as splash pads or concrete rings around manholes. (Note that large voids, structural concrete and pipe penetrations into vaults shall be repaired with non-shrink grout; repairs to precast manholes and vaults and cast-in-place manhole bases shall be repaired with an epoxy bonding agent and repair mortar, as outlined below).

4. Epoxy bonding agent for bonding repair mortar to concrete on repairs to damaged surfaces to precast or cast-in-place concrete manholes and vaults.

5. Repair mortar for repair to damaged surfaces of precast or cast-in-place concrete manholes and vaults. An epoxy bonding agent shall be used in conjunction with repair mortar.

CAST-IN-PLACE CONCRETE 03300-4 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 6. Non-shrink grout for general purposes repair of large construction voids, pipe penetrations into vaults and grouting of base plates for equipment or structural members.

7. Epoxy adhesives for grouting of anchor bolts.

8. Protective epoxy coating for application to reinforcing steel with existing concrete structures exposed during construction.

9. Damp-proofing for application to the exterior surfaces of concrete manholes and vaults located at or below the water table or where showing evidence of moisture or seepage, and as directed by the Engineer.

1.07 CONTRACTOR SUBMITTALS

A. MIX DESIGNS:

Before starting the Work and within 14 days of the notice to proceed, the CONTRACTOR shall submit to the CONSTRUCTION MANAGER, for review, preliminary concrete mix designs which shall show the proportions and gradations of all materials proposed and 28-day compression test reports for each class and type of concrete specified herein in accordance with Section 01300 - Submittals. The mix designs shall be checked and certified to conform to these specifications by an independent testing laboratory acceptable to the CONSTRUCTION MANAGER to be in conformance with these Specifications. The mix design shall be stamped by California professional engineer. All costs related to such checking and testing shall be borne by the CONTRACTOR at no increased cost to the OWNER.

B. DELIVERY TICKETS:

Where ready-mix concrete is used, the CONTRACTOR shall furnish delivery tickets at the time of delivery of each load of concrete. Each ticket shall show the state certified equipment used for measuring and the total quantities, by weight, of cement, sand, each class of aggregate, admixtures, and the amounts of water in the aggregate added at the batching plant, and the amount allowed to be added at the site for the specific design mix. In addition, each ticket shall state the mix number, total yield in cubic yards, and the time of day, to the nearest minute, corresponding to the times when the batch was dispatched, when it left the plant, when it arrived at the site, when unloading began, and when unloading was finished.

The CONTRACTOR shall provide the following submittals in accordance with ACI 301:

1. Mill tests for cement. 2. Admixture certification. Chloride ion content must be included. 3. Aggregate gradation and certification. 4. Materials and methods for curing.

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-5 The CONTRACTOR shall provide catalog cuts and other manufacturer’s technical data demonstrating compliance with the requirements indicated and specified herein for all admixtures used in the concrete mix design.

1.08 CONCRETE CONFERENCE

A meeting shall be held to review the detailed requirements of the CONTRACTOR's proposed concrete design mixes and to determine the procedures for producing proper concrete construction no later than 14 days after the Notice to Proceed.

All parties involved in the concrete work shall attend the conference, including the following:

1. CONTRACTOR's representative 2. Testing laboratory representative 3. Concrete subcontractor 4. Reinforcing steel subcontractor and detailer 5. Concrete supplier 6. Admixture manufacturer's representative

The conference shall be held at a mutually agreed upon time and place. The CONSTRUCTION MANAGER shall be notified no less than 5 days before the date of the conference.

1.09 QUALITY ASSURANCE

A. GENERAL:

Tests on component materials and for compressive strength and shrinkage of concrete will be performed as specified herein. Test for determining slump will be in accordance with the requirements of ASTM C 143.

The cost of all laboratory tests requested by the CONSTRUCTION MANAGER on cement, aggregates, and concrete, will be borne by the OWNER. However, the CONTRACTOR will be charged for the cost of any additional tests and investigation on work performed which does not meet the Specifications. The laboratory must meet or exceed the requirements of ASTM C 1077.

Concrete for testing shall be supplied by the CONTRACTOR at no cost to the OWNER, and the CONTRACTOR shall provide assistance to the CONSTRUCTION MANAGER in obtaining samples, and disposal and cleanup of excess material. Where required to demonstrate conformance with the specified requirements for cast-in- place concrete, the Contractor shall provide the services of an independent testing laboratory.

CAST-IN-PLACE CONCRETE 03300-6 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 Tests and analyses of aggregates and of resulting concrete will be made by Contractor and mixes used shall be changed whenever, in opinion of Construction Manager, such change is necessary or desirable to secure required workability, density, impermeability, surface finish and strength. The Contractor shall be entitled to no additional compensation because of such changes.

B. FIELD COMPRESSION TESTS:

Compression test specimens will be taken during construction from the first placement of each class of concrete specified herein and at intervals thereafter as selected by the CONSTRUCTION MANAGER to ensure continued compliance with these Specifications. Each set of test specimens will be a minimum of five cylinders.

Compression test specimens for concrete shall be made in accordance with Section 9.2 of ASTM C 31. Specimens shall be 6-inch diameter by 12-inch high cylinders.

Compression tests shall be performed in accordance with ASTM C 39. One test cylinder will be tested at 7 days and two at 28 days. The remaining cylinders will be held to verify test results, if needed.

C. EVALUATION AND ACCEPTANCE OF CONCRETE:

Evaluation and acceptance of the compressive strength of concrete shall be according to the requirements of ACI 318, Chapter 5 "Concrete Quality," and as specified herein.

A statistical analysis of compression test results will be performed according to the requirements of ACI 214. The standard deviation of the test results shall not exceed 640 psi, when ordered at equivalent water content as estimated by slump.

If any concrete fails to meet these requirements, immediate corrective action shall be taken to increase the compressive strength for all subsequent batches of the type of concrete affected.

When the standard deviation of the test results exceeds 640 psi, the average strength for which the mix is designed shall be increased by an amount necessary to satisfy the statistical requirement that the probability of any test being more than 500 psi below or the average of any three consecutive tests being below the specified compressive strength is 1 in 100. The required average strength shall be calculated by Criterion No. 3 of ACI 214 using the actual standard of deviation.

All concrete which fails to meet the ACI requirements and these Specifications, is subject to removal and replacement at no increase in cost to the OWNER.

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-7 D. SHRINKAGE TESTS:

Drying shrinkage tests for concrete used in hydraulic structures will be made for the trial batch specified in Subsection 03300-2.5C, the first placement of each class of concrete, and during construction to insure continued compliance with these Specifications.

Drying shrinkage specimens shall be 4-inch by 4-inch by 11-inch prisms with an effective gauge length of 10 inches, fabricated, cured, dried and measured in accordance with ASTM C 157 modified as follows: specimens shall be removed from molds at an age of 23 +1 hour after trial batching, and shall be placed immediately in water at 70 degrees F + 3 degrees F for at least 30 minutes, and shall be measured within 30 minutes thereafter to determine original length, and then submerged in saturated lime water at 73 degrees F + 3 degrees F. Measurement to determine expansion expressed as a percentage of original length shall be made at age 7 days. This length at age 7 days shall be the base length for drying shrinkage calculations ("0" days drying age). Specimens shall then be stored immediately in a humidity controlled room maintained at 73 degrees F + 3 degrees F, and 50 percent at + 4 percent relative humidity for the remainder of the test. Measurements to determine shrinkage expressed as percentage of base length, shall be made and reported separately for 7, 14, 21 and 28 days of drying after 7 days of moist curing.

The drying shrinkage deformation of each specimen shall be computed as the difference between the base length (at "0" days drying age) and the length after drying at each test age. The average drying shrinkage deformation of the specimens shall be computed to the nearest 0.0001 inch at each test age. If the drying shrinkage of any specimen departs from the average of that test age by more than 0.0004 inch, the results obtained from that specimen shall be disregarded. Results of the shrinkage test shall be reported to the nearest 0.001 percent of shrinkage. Compression test specimens shall be taken in each case from the same concrete used for preparing drying shrinkage specimens. These tests shall be considered a part of the normal compression tests for the project. Allowable shrinkage limitations shall be as specified in Part 3, herein.

E. CONSTRUCTION TOLERANCES:

Set and maintain concrete forms and perform finishing operations so as to ensure that the completed Work is within the tolerances specified herein. Surface defects and irregularities are defined as finishes and are to be distinguished from tolerances. Tolerance is the specified permissible variation from lines, grades, or dimensions shown. Where tolerances are not stated in the Specifications, permissible deviations will be in accordance with ACI 117.

CAST-IN-PLACE CONCRETE 03300-8 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 The following construction tolerances are hereby established and apply to finished walls and slab unless otherwise shown:

Item Tolerance Variation of the constructed linear outline from the In 10 feet: 1/4-inch; established position in plan. In 20 feet or more: 1/2- inch Variation from the level or from the grades shown. In 10 feet: 1/4-inch; In 20 feet or more: 1/2- inch Variation from the plumb. In 10 feet: 1/4-inch; In 20 feet or more: 1/2- inch Variation in the thickness of slabs and walls. Minus 1/4-inch; Plus 1/2-inch Variation in the locations and sizes of slabs and Plus or minus 1/4-inch wall openings.

F. FLOOR SLAB SURFACE HARDENER:

6. JOB MOCKUP: In a location designated by the CONSTRUCTION MANAGER, place a minimum 100 square feet floor mockup using materials and procedures proposed for use in the Project. Revise materials and procedures as necessary to obtain acceptable finish surface. Maintain the same controls and procedures used in the acceptable mockup throughout the Project.

7. FIELD SERVICE: During job mock-up and initial period of installation, the manufacturer of the surface hardener shall furnish the service of a trained, full-time representative to advise on proper use of the product. Notify surface hardener manufacturer at least three days before initial use of the product.

8. INSTALLER QUALIFICATIONS: Installer shall have a minimum of 3 years’ experience and shall be specialized in the application of dry shake surface hardeners.

1.10 DELIVERY, STORAGE, AND HANDLING

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-9 PART 2 -- PRODUCTS

2.01 CONCRETE MATERIALS

A. GENERAL:

All materials specified herein shall be classified by the Environmental Protection Agency as acceptable for potable water use within 30 days of application.

Materials shall be delivered, stored, and handled so as to prevent damage by water or breakage. Only one brand of cement shall be used. Cement reclaimed from cleaning bags or leaking containers shall not be used. All cement shall be used in the sequence of receipt of shipments.

All materials furnished for the Work shall comply with the requirements of Sections 201, 203, and 204 of ACI 301, as applicable.

Storage of materials shall conform to the requirements of Section 2.5 of ACI 301 or the SSPWC.

Materials for concrete shall conform to the following requirements:

1. Cement shall be standard brand Portland cement conforming to ASTM C 150 for Type V, including Table 2 optional requirements, as well as to the provisions of Sections 201, 202, and 303 of the Standard Specifications for Public Works Construction (Greenbook).

A minimum of 85 percent of cement by weight shall pass a 325 screen. A single brand of cement shall be used throughout the Work, and before its use, the brand shall be acceptable to the CONSTRUCTION MANAGER. The cement shall be suitably protected from exposure to moisture until used. Cement that has become lumpy shall not be used. Sacked cement shall be stored in such a manner so as to permit access for inspection and sampling. Certified mill test reports, including fineness, for each shipment of cement to be used shall be submitted to the CONSTRUCTION MANAGER if requested regarding compliance with these Specifications.

2. Water for mixing and curing shall be potable, clean, and free from objectionable quantities of silty organic matter, alkali, salts and other impurities. The water shall be considered potable, for the purposes of this Section only, if it meets the requirements of the local governmental agencies. Agricultural water with high total dissolved solids concentration (over 1,000 mg/l) shall not be used.

CAST-IN-PLACE CONCRETE 03300-10 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 3. Aggregates shall be obtained from pits acceptable to the CONSTRUCTION MANAGER, shall be nonreactive, and shall conform to ASTM C 33. Maximum size of coarse aggregate shall be as specified herein. Lightweight sand for fine aggregate will not be permitted.

a. Coarse aggregates shall consist of clean, hard, durable gravel, crushed gravel, crushed rock or a combination thereof. The coarse aggregates shall be prepared and handled in two or more size groups for combined aggregates with a maximum size greater than 3/4 inch. When the aggregates are proportioned for each batch of concrete the two size groups shall be combined. See the Paragraph in Part 2 entitled "Trial Batch and Laboratory Tests" for the use of the size groups.

b. Fine aggregates shall be natural sand or a combination of natural and manufactured sand that are hard and durable. When tested in accordance with ASTM D 2419, the sand equivalency shall not be less than 75 percent for an average of three samples, nor less than 70 percent for an individual test. Gradation of fine aggregate shall conform to ASTM C 33, with 15 to 30 percent passing the number 50 screen and 5 to 10 percent passing the number 100 screen. The fineness modulus of sand used shall not be over 3.00.

c. Combined aggregates shall be well graded from coarse to fine sizes, and shall be uniformly graded between screen sizes to produce a concrete that has optimum workability and consolidation characteristics. Where a trial batch is required for a mix design, the final combined aggregate gradations will be established during the trial batch process.

d. When tested in accordance with ASTM C 33, the ratio of silica released to reduction in alkalinity shall not exceed 1.0.

e. When tested in accordance with ASTM C 33, the fine aggregate shall produce a color in the supernatant liquid no darker than the reference standard color solution.

f. When tested in accordance with ASTM C 33, the coarse aggregate shall show a loss not exceeding 42 percent after 500 revolutions, or 10.5 percent after 100 revolutions.

g. When tested in accordance with ASTM C 33, the loss resulting after five cycles shall not exceed 10 percent for fine or coarse aggregate when using sodium sulfate.

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-11 4. Ready-mix concrete shall conform to the requirements of ASTM C 94.

5. Admixtures: All admixtures shall be compatible and by a single manufacturer capable of providing qualified field service representation. Admixtures shall be used in accordance with manufacturer's recommendations. If the use of an admixture is producing an inferior end result, discontinue use of the admixture. Admixtures shall not contain thiocyanates nor more than 0.05 percent chloride ion, and shall be nontoxic after 30 days.

a. Air-entraining agent meeting the requirements of ASTM C 260 shall be used. Sufficient air-entraining agent shall be used to provide a total air content of 3 to 5 percent. The OWNER reserves the right, at any time, to sample and test the air-entraining agent received on the job. The air-entraining agent shall be added to the batch in a portion of the mixing water. The solution shall be batched by means of a mechanical batcher capable of accurate measurement. Air content shall be tested at the point of placement. Air entraining agent shall be Micro-Air by Master Builders; Daravair by W.R. Grace; Sika AEA-15 by Sika Corporation; or equal.

b. Set controlling and water reducing admixtures: Admixtures may be added at the CONTRACTOR's option to control the set, effect water reduction, and increase workability. The addition of an admixture shall be at no increase in cost to the OWNER. The use of an admixture shall be subject to acceptance by the CONSTRUCTION MANAGER. Concrete containing an admixture shall be first placed at a location determined by the CONSTRUCTION MANAGER. Admixtures specified herein shall conform to the requirements of ASTM C 494. The required quantity of cement shall be used in the mix regardless of whether or not an admixture is used.

(1) Concrete shall not contain more than one water reducing admixture. Concrete containing an admixture shall be first placed at a location determined by the CONSTRUCTION MANAGER.

(2) Set controlling admixture shall be either with or without water-reducing properties. Where the air temperature at the time of placement is expected to be consistently over 80 degrees F, a set retarding admixture such as Plastocrete by Sika Corporation; Pozzolith 300R by Master Builders; Daratard by W.R. Grace; or equal shall be used. Where the

CAST-IN-PLACE CONCRETE 03300-12 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 air temperature at the time of placement is expected to be consistently under 40 degrees F, a noncorrosive set accelerating admixture such as Plastocrete 161FL by Sika Corporation; Pozzutec 20 by Master Builders; Daraset by W.R. Grace; or equal shall be used.

(3) Normal range water reducer shall conform to ASTM C 494, Type A. WRDA 79 by W.R. Grace; Pozzolith 322-N by Master Builders; Plastocrete 161 by Sika Corporation; or equal. The quantity of admixture used and the method of mixing shall be in accordance with the Manufacturer's instructions and recommendations.

(4) In certain circumstances, rapid-setting concrete may be required. Accelerating admixtures shall conform to ASTM C-494 and may be used in the concrete mix as permitted by the City.

(5) High range water reducer shall conform to ASTM C 494, Type F or G. Daracem 100 or WDRA 19 by W.R. Grace; Sikament FF or Sikament 86 by Sika Corporation; Rheobuild 1000 or Rheobuild 716 by Master Builders; or equal. High range water reducer shall be added to the concrete after all other ingredients have been mixed and initial slump has been verified. No more than 14 ounces of water reducer per sack of cement shall be used. Water reducer shall be considered as part of the mixing water when calculating water cement ratio.

(6) If the high range water reducer is added to the concrete at the job site, it may be used in conjunction with the same water reducer added at the batch plant. Concrete shall have a slump of 3 inches + 2 inch before adding the high range water reducing admixture at the job site. The high range water reducing admixture shall be accurately measured and pressure injected into the mixer as a single dose by an experienced technician. A standby system shall be provided and tested before each day's operation of the job site system.

(7) Concrete shall be mixed at mixing speed for a minimum of 30 mixer revolutions after the addition of the high range water reducer.

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-13 (8) Flyash: Flyash shall not be used.

(9) Calcium chloride shall not be used in concrete.

Encasement concrete mix designs shall have the following minimum requirements unless otherwise shown or specified:

1. Minimum 28 day compressive strength - 5000 psi 2. Maximum water-cement ration (W/C) ratio – 0.40. 3. Maximum Slump – 4 inches 4. Minimum sack per cubic yard – 6.5.

2.02 CURING MATERIALS

Materials for curing concrete as specified herein shall conform to the following requirements and ASTM C 309:

1. All curing compounds shall be white pigmented and resin based. Sodium silicate compounds shall not be allowed. Concrete curing compound shall be Spartan Cote Cure-Seal Hardener by the Burke Company; Super Rez Seal by Euclid Chemical Company; MB-429 as manufactured by Master Builders; or equal. Water based resin curing compounds shall be used only where local air quality regulations prohibit the use of a solvent based compound. Water based curing compounds shall be Aqua Resincure by the Burke Company; Aqua-Cure by Euclid Chemical Company; Masterkure-W by Master Builders; or equal.

2. Polyethylene sheet for use as concrete curing blanket shall be white, and shall have a nominal thickness of 6 mils. The loss of moisture when determined in accordance with the requirements of ASTM C 156 shall not exceed 0.055 grams per square centimeter of surface.

3. Polyethylene-coated waterproof paper sheeting for use as concrete curing blanket shall consist of white polyethylene sheeting free of visible defects, uniform in appearance, having a nominal thickness of 2 mils and permanently bonded to waterproof paper conforming to the requirements of Federal Specification UU-B-790A (1) (2). The loss of moisture, when determined in accordance with the requirements of ASTM C 156, shall not exceed 0.055 gram per square centimeter of surface.

4. Polyethylene-coated burlap for use as concrete curing blanket shall be 4 mils thick, white opaque polyethylene film impregnated or extruded into one side of the burlap. Burlap shall weigh not less than 9 ounces per square yard. The loss of moisture, when determined in accordance with

CAST-IN-PLACE CONCRETE 03300-14 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 the requirements of ASTM C 156, shall not exceed 0.055 gram per square centimeter of surface.

5. Curing mats for use in Curing Method 6 as specified herein, shall be heavy shag rugs or carpets or cotton mats quilted at 4 inches on center. Curing mats shall weigh a minimum of 12 ounces per square yard when dry.

6. Evaporation retardant shall be a material such as Confilm as manufactured by Master Builders; Eucobar as manufactured by Euclid Chemical Company; or equal.

2.03 NONWATERSTOP JOINT MATERIALS

Materials for nonwaterstop joints in concrete shall conform to the following requirements:

1. Preformed joint filler shall be a nonextruding, resilient, bituminous type conforming to the requirements of ASTM D 1751.

2. Elastomeric joint sealer shall conform to the requirements of Section 07920 - Sealants and Caulking.

3. Mastic joint sealer shall be a material that does not contain evaporating solvents; that will tenaciously adhere to concrete surfaces; that will remain permanently resilient and pliable; that will not be affected by continuous presence of water and will not in any way contaminate potable water; and that will effectively seal the joints against moisture infiltration even when the joints are subject to movement due to expansion and contraction. The sealer shall be composed of special asphalts or similar materials blended with lubricating and plasticizing agents to form a tough, durable mastic substance containing no volatile oils or lubricants and shall be capable of meeting the test requirements set forth hereinafter, if testing is required by the CONSTRUCTION MANAGER.

2.04 MISCELLANEOUS MATERIALS

Dampproofing agent shall be an asphalt emulsion, such as Hydrocide 600 by Sonneborn; Damp-proofing Asphalt Coating by Euclid Chemical Company; Sealmastic by W. R. Meadows Inc., or equal. Damp-proofing material shall consist of two coats of a single-component self- priming, heavy-duty cold-applied coal tar selected from the Approved Materials List.

The epoxy bonding agent shall be an epoxy-resin-based product intended for bonding new mortar to hardened concrete and shall conform to ASTM C 881. The bonding agent shall be selected from the Approved Materials List.

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-15 2.05 EPOXY ADHESIVE

Epoxy adhesive shall be a high-modulus epoxy-resin-based product intended for structural grouting of anchor bolts and dowels to concrete. The epoxy adhesives shall conform to ASTM C 881. A pourable, medium-viscosity epoxy shall be used on horizontal surfaces, and a heavy-bodied, non-sag epoxy gel shall be used on vertical surfaces. The epoxy adhesives shall be selected from the Approved Materials List.

Bonding agents shall be epoxy adhesives conforming to the following products for the applications specified:

1. For bonding freshly-mixed, plastic concrete to hardened concrete, Sikadur 32 Hi-Mod Epoxy Adhesive, as manufactured by Sika Corporation; Concresive Liquid (LPL), as manufactured by Master Builders; BurkEpoxy MV as manufactured by The Burke Company; or equal.

2. For bonding hardened concrete or masonry to steel, Sikadur 31 Hi-Mod Gel as manufactured by Sika Corporation; BurkEpoxy NS as manufactured by The Burke Company; Concresive Paste (LPL) as manufactured by Master Builders; or equal.

2.06 REINFORCING STEEL

Reinforcing steel shall conform to ASTM A 615, Grade 60.

Fabricate reinforcing steel in accordance with the current edition of the Manual of Standard Practice, published by the Concrete Reinforcing Steel Institute.

Conform to requirements of Specification Section 032100 Concrete Reinforcement.

2.07 WELDED WIRE FABRIC

Welded wire fabric shall conform to ASTM A 185.

2.08 TIE WIRE

Tie wire shall be 16-gage minimum, black, soft annealed.

2.09 BAR SUPPORTS

Bar supports in beams and slabs exposed to view after removal of forms shall be stainless steel. Use concrete supports for reinforcing in concrete placed on grade.

CAST-IN-PLACE CONCRETE 03300-16 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 2.10 FORMS

Forms work and design shall conform to ACI 347. Plyform shall be at least 5/8 inch thick. Forms shall be accurately constructed of clean lumber. The surface of forms against which concrete is placed shall be smooth and free from irregularities, dents, sags, or holes.

Metal form systems may be used upon City approval. Include manufacturer's data for materials and installation with the request to use a metal form system.

2.11 MORTAR

Cement mortar shall consist of a mixture of Portland cement, sand, and water. One part cement and two parts sand shall first be combined, and then thoroughly mixed with the required amount of water.

2.12 REPAIR MORTAR

Repair mortar shall be a two-component, cement-based product specifically designed for structurally repairing damaged concrete surfaces. The repair mortar shall exhibit the properties of high compressive and bond strengths and low shrinkage. A medium-slump repair mortar shall be used on horizontal surfaces, and a non-sag, low-slump repair mortar shall be used on vertical or overhead surfaces. Repair mortar shall be selected from the Approved Materials List.

2.13 PROTECTIVE EPOXY COATING

The protective epoxy coating shall be an epoxy-resin-based product exhibiting high bond strength to steel and concrete surfaces, and shall conform to ASTM C 881. The protective epoxy coating shall be selected from the Approved Materials List.

2.14 CEMENT

Use ASTM C150, Type V cement for all concrete.

2.15 AGGREGATES

Fine and course aggregates shall conform to ASTM C 33.

Maximum size of course aggregate shall be determined by class of concrete used, except as otherwise specified herein.

Aggregates shall show an expansion of less than 0.1% when tested in accordance with ASTM C1260 or ASTM C1567 concrete mix test results shall be submitted verifying that the aggregates are not reactive per the criteria in this standard. ASTM C1260 and ASTM C1567 results shall be no older than 1 year.

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-17 2.16 ADMIXTURES

Admixtures shall be compatible with the concrete and with each other.

Calcium chloride or admixtures containing calcium chloride are not acceptable.

Admixtures shall be used in accordance with the manufacturer's recommendations and shall be added separately to the concrete mix.

Water reducing retarders and admixtures shall reduce the water required by at least 11 percent for a given concrete consistency and shall comply with the water/cement ratio standards of ACI 211.1.

When High Range Water Reducing admixture is used, the slump requirements shall apply to the concrete before the admixture is added and the slump of the concrete after the admixture is added shall not be less than 6 inches nor exceed 9 inches.

2.17 CURING AND SEALING COMPOUNDS

Curing compounds shall conform to ASTM C309.

Curing compound for exposed concrete shall contain a coloring agent so that areas of application will be readily distinguishable for 6 month period in sunlight.

2.18 CONCRETE DESIGN REQUIREMENTS

A. MIX DESIGN:

Each proposed mix design shall provide (1) the expected strength at 28 days, (2) corresponding slump before and after the introduction of high-range water-reducing admixtures, (3) water/cement ratios, (d) weights and test results of the ingredients, (4) aggregate gradation, (5) test results of mix design prepared by an independent testing laboratory, and (6) other physical properties necessary to review each mix design for conformance with these specifications.

1. GENERAL: Concrete shall be composed of cement, admixtures, aggregates and water. These materials shall be of the qualities specified. The exact proportions in which these materials are to be used for different parts of the Work will be determined during the trial batch. In general, the mix shall be designed to produce a concrete capable of being deposited so as to obtain maximum density and minimum shrinkage and, where deposited in forms, to have good consolidation properties and maximum smoothness of surface. In mix designs, the percentage of sand of the total weight of fine and coarse aggregate shall not exceed 41 for hydraulic structures or 50 for all other structures, unless noted otherwise. The aggregate gradations shall be formulated to provide fresh concrete that will not promote rock pockets around reinforcing steel or embedded items. The proportions shall be changed whenever

CAST-IN-PLACE CONCRETE 03300-18 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 necessary or desirable to meet the required results at no additional cost to the OWNER. All changes shall be subject to review by the CONSTRUCTION MANAGER.

2. WATER-CEMENT RATIO AND COMPRESSIVE STRENGTH: The minimum compressive strength and cement content of concrete shall be not less than that specified in the following tabulation.

Min 28-Day Max Minimum Compressive Size Cement Max W/C Strength Aggregate per cu yd Ratio Type of Work (psi) (in) (lb) (by weight) Structural Concrete:

Roof, floor slabs, columns, 5,000 3/4 564 0.40 walls and all other concrete items not specified elsewhere

12" and thicker walls, 5,000 1 564 0.40 slabs on grade and footings, with written approval of the CONSTRUCTION MANAGER

Bridge Abutment 5,000 1 ½” 515 0.40

Other Concretes: 3,000 1 470 0.50

Lean Concrete 2,500 1-1/2" 376 0.60

Note: The CONTRACTOR is cautioned that the limiting parameters specified above are not a mix design. Additional cement or water reducing agent may be required to achieve workability demanded by the CONTRACTOR's construction methods and aggregates. The CONTRACTOR is responsible for any costs associated with furnishing concrete with the required workability.

3. ADJUSTMENTS TO MIX DESIGN: The mixes used shall be changed whenever such change is necessary or desirable to secure the required strength, density, workability, and surface finish and the CONTRACTOR shall be entitled to no additional compensation because of such changes. Air-entrainment shall be used in each mix as defined 2.01A.5(a).

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-19 B. CONSISTENCY:

The quantity of water entering into a batch of concrete shall be just sufficient, with a normal mixing period, to produce a concrete which can be worked properly into place without segregation, and which can be compacted by the vibratory methods herein specified to give the desired density, impermeability and smoothness of surface. The quantity of water shall be changed as necessary, with variations in the nature or moisture content of the aggregates, to maintain uniform production of a desired consistency. The consistency of the concrete in successive batches shall be determined by slump tests in accordance with ASTM C 143. The slumps shall be as follows:

Part of Work Slump (in.) All concrete, unless noted otherwise 3 inches + 1 inch With high range water reducer added 7 inches + 2 inches Ductbanks 5 inches + 1 inch

C. TRIAL BATCH AND LABORATORY TESTS:

Before placing any concrete, a testing laboratory designated by the CONSTRUCTION MANAGER will prepare a trial batch of each class of structural concrete, based on the preliminary concrete mixes submitted by the CONTRACTOR. During the trial batch the aggregate proportions may be adjusted by the testing laboratory using the two coarse aggregate size ranges to obtain the required properties. If one size range produces an acceptable mix, a second size range need not be used. Such adjustments shall be considered refinements to the mix design and shall not be the basis for extra compensation to the CONTRACTOR. All concrete shall conform to the requirements of this Section, whether the aggregate proportions are from the CONTRACTOR's preliminary mix design, or whether the proportions have been adjusted during the trial batch process. The trial batch will be prepared using the aggregates, cement and admixture proposed for the project. The trial batch materials shall be of a quantity such that the testing laboratory can obtain 3 drying shrinkage, and six compression test specimens from each batch. The cost of not more than three laboratory trial batch tests for each specified concrete strength will be borne by the OWNER but the CONTRACTOR shall furnish and deliver the materials in steel drums at no cost. Any additional trial batch testing required shall be performed by the CONTRACTOR at no additional cost to the OWNER.

The determination of compressive strength will be made by testing 6-inch diameter by 12-inch high cylinders; made, cured and tested in accordance with ASTM C 192 and ASTM C 39. Three compression test cylinders will be tested at 7 days and 3 at 28 days. The average compressive strength for the three cylinders tested at 28 days for any given trial batch shall not be less than 125 percent of the specified compressive strength.

A sieve analysis of the combined aggregate for each trial batch shall be performed according to the requirements of ASTM C 136. Values shall be given for percent passing each sieve.

CAST-IN-PLACE CONCRETE 03300-20 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 In lieu of trial batch and laboratory tests specified in this Section, the CONTRACTOR may submit previously-designed, tested, and successfully-used concrete mixes, using materials similar to those intended for this project, together with a minimum of three certified test reports of the 28-day strength of the proposed concrete mix.

D. SHRINKAGE LIMITATION:

The maximum concrete shrinkage for specimens cast in the laboratory from the trial batch, as measured at 21-day drying age or at 28-day drying age shall be 0.036 percent or 0.042 percent, respectively. Use a mix design for construction that has first met the trial batch shrinkage requirements. Shrinkage limitations apply only to structural concrete.

The maximum concrete shrinkage for specimens cast in the field shall not exceed the trial batch maximum shrinkage requirement by more than 25 percent.

If the required shrinkage limitation is not met during construction, take any or all of the following actions, at no additional cost to the OWNER, for securing the specified shrinkage requirements. These actions may include changing the source or aggregates, cement and/or admixtures; reducing water content; washing of aggregate to reduce fines; increasing the number of construction joints; modifying the curing requirements; or other actions designed to minimize shrinkage or the effects of shrinkage.

E. MEASUREMENT OF CEMENT AND AGGREGATE:

1. The amount of cement and of each separate size of aggregate entering into each batch of concrete shall be determined by direct weighing equipment acceptable to the CONSTRUCTION MANAGER.

2. Weighing Tolerances:

Material Percent of Total Weight

Cement 1 Aggregates 3 Admixtures 3

F. MEASUREMENT OF WATER:

The quantity of water entering the mixer shall be measured by a suitable water meter or other measuring device of a type acceptable to the CONSTRUCTION MANAGER and capable of measuring the water in variable amounts within a tolerance of one percent. The water feed control mechanism shall be capable of being locked in position so as to deliver constantly any specified amount of water to each batch of concrete. A positive quick-acting valve shall be used for a cut-off in the water line to the mixer. The operating mechanism must be such that leakage will not occur when the valves are closed.

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-21 2.19 READY MIXED CONCRETE

At the CONTRACTOR's option, ready-mixed concrete may be used meeting the requirements as to materials, batching, mixing, transporting, and placing as specified herein and in accordance with ASTM C 94, including the following supplementary requirements.

Ready-mixed concrete shall be delivered to the site of the Work, and discharge shall be completed within one hour after the addition of the cement to the aggregates or before the drum has been revolved 250 revolutions, whichever is first.

Truck mixers shall be equipped with electrically-actuated counters by which the number of revolutions of the drum or blades may be readily verified. The counter shall be of the resettable, recording type, and shall be mounted in the driver's cab. The counters shall be actuated at the time of starting mixers at mixing speeds.

Each batch of concrete shall be mixed in a truck mixer for not less than 70 revolutions of the drum or blades at the rate of rotation designated by the manufacturer of equipment. Additional mixing, if any, shall be at the speed designated by the manufacturer of the equipment as agitating speed. All materials including mixing water shall be in the mixer drum before actuating the revolution counter for determining the number of revolution of mixing.

Truck mixers and their operation shall be such that the concrete throughout the mixed batch as discharged is within acceptable limits of uniformity with respect to consistency, mix, and grading. If slump tests taken at approximately the 1/4 and 3/4 points of the load during discharge give slumps differing by more than one inch when the specified slump is 3 inches or less, or if they differ by more than 2 inches when the specified slump is more than 3 inches, the mixer shall not be used on the Work unless the causing condition is corrected and satisfactory performance is verified by additional slump tests. All mechanical details of the mixer, such as water measuring and discharge apparatus, condition of the blades, speed of rotation, general mechanical condition of the unit, and clearance of the drum, shall be checked before a further attempt to use the unit will be permitted.

Each batch of ready-mixed concrete delivered at the job site shall be accompanied by a delivery ticket furnished to the CONSTRUCTION MANAGER in accordance with Subsection 03300-1.4B.

The use of nonagitating equipment for transporting ready-mixed concrete will not be permitted. Combination truck and trailer equipment for transporting ready-mixed concrete will not be permitted. The quality and quantity of materials used in ready-mixed concrete and in batch aggregates shall be subject to continuous inspection at the batching plant by the CONSTRUCTION MANAGER.

CAST-IN-PLACE CONCRETE 03300-22 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 2.20 FLOOR HARDENER (SURFACE APPLIED)

Surface hardener shall be a light reflective nonoxidizing metallic aggregate dry shake surface hardener.

1. Surface hardener shall be premeasured, premixed and packaged at the factory.

2. Apply surface hardener at the rate of 1.8 to 2.5 lb per square foot

3. Surface hardener shall be ALumiplate®, by Master Builders, Inc., or equal.

A CURING COMPOUND:

Curing compound shall meet the moisture retention requirements of ASTM C 309 and surface hardener manufacturer’s recommendations.

B. MONOMOLECULAR FILM:

Evaporation retarder shall be used to aid in maintaining concrete moisture during the early placement stages of plastic concrete. Evaporation retarder shall be as recommended by surface hardener manufacturer.

2.21 GROUT

Conform to requirements of Section 036000 Grout.

2.22 NON-SHRINK GROUT

Non-shrink grout shall be a non-metallic cement-based product intended for filling general construction voids or grouting base plates for equipment or structural members. The non-shrink grout shall exhibit the properties of high compressive and bond strengths and zero shrinkage, and shall be capable of mixing to a variable viscosity ranging from a dry pack to a fluid consistency as required for the application. The non-shrink grout shall be selected from the Approved Materials List.

PART 3 -- EXECUTION

3.01 FORMWORK

The Contractor shall notify the City a minimum of one working day in advance of intended placement of concrete to enable the City to check the form lines, grades, and other required items before placement of concrete.

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-23 The form surfaces shall be cleaned and coated with form oil prior to installation. The form surfaces shall leave uniform form marks conforming to the general lines of the structure.

The forms shall be braced to provide sufficient strength and rigidity to hold the concrete and to withstand the necessary fluid pressure and consolidation pressures without deflection from the prescribed lines.

Unless otherwise indicated on the plans, all exposed sharp concrete edges shall be 3/4- inch chamfered.

3.02 REINFORCEMENT

Place reinforcing steel in accordance with the current edition of Recommended Practice for Placing Reinforcing Bars, published by the Concrete Reinforcing Steel Institute.

All reinforcing steel shall be of the required sizes and shapes and placed where shown on the drawings or as directed by the City.

Do not straighten or re-bend reinforcing steel in a manner that will damage the material. Do not use bars with bends not shown on the drawings. All steel shall be cold bent – do not use heat.

All bars shall be free from rust, scale, oil, or any other coating that would reduce or destroy the bond between concrete and steel.

Position reinforcing steel in accordance with the Approved Plans and secure by using annealed wire ties or clips at intersections and support by concrete or metal supports, spacers, or metal hangers. Do not place metal clips or supports in contact with the forms. Bend tie wires away from the forms in order to provide the concrete coverage equal to that required of the bars. If required by the Engineer, the Contractor shall install bars additional to those shown on the drawings for the purpose of securing reinforcement in position.

Place reinforcement a minimum of 2-inches clear of any metal pipe, fittings, or exposed surfaces.

The reinforcement shall be so secured in position that it will not be displaced during the placement of concrete.

All reinforcing steel, wire mesh, and tie wire shall be completely encased in concrete.

Reinforcing steel shall not be welded unless specifically required by the Approved Plans or otherwise directed by the Engineer.

Secure reinforcing dowels in place prior to placing concrete. Do not press dowels into the concrete after the concrete has been placed.

CAST-IN-PLACE CONCRETE 03300-24 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 Minimum lap for all reinforcement shall be 40 bar diameters unless otherwise specified on the Approved Plans.

Place additional reinforcement around pipe penetrations or openings 6-inches diameter or larger. Replace cut bars with a minimum of 1/2 of the number of cut bars at each side of the opening, each face, each way, same size. Lap with the uncut bars a minimum of 40 bar diameters past the opening dimension. Place one same size diagonal bar at the four diagonals of the opening at 45° to the cut bars, each face. Extend each diagonal bar a minimum of 40 bar diameters past the opening dimension. Wire mesh reinforcement is to be rolled flat before being placed in the form. Support and tie wire mesh to prevent movement during concrete placement.

Extend welded wire fabric to within 2-inches of the edges of slabs. Lap splices at least 1- 1/2 courses of the fabric and a minimum of 6-inches. Tie laps and splices securely at ends and at least every 24-inches with 16-gage black annealed steel wire. Pull the fabric into position as the concrete is placed by means of hooks, and work concrete under the steel to ensure that it is at the proper distance above the bottom of the slab.

Reinforcement shall be provided per Section 03200.

3.03 EMBEDDED ITEMS

All embedded items, including bolts, dowels and anchors, shall be held correctly in place in the forms before concrete is placed.

3.04 MORTAR MIXING

The quantity of water to be used in the preparation of mortar shall be only that required to produce a mixture sufficiently workable for the purpose intended. Mortar shall be used as soon as possible after mixing and shall show no visible sign of setting prior to use. Re-mixing of mortar by the addition of water after signs of setting are evident shall not be permitted.

3.05 PROPORTIONING AND MIXING

A. PROPORTIONING:

Proportioning of the concrete mix shall conform to the requirements of Chapter 3 "Proportioning" of ACI 301.

B. MIXING:

Mixing of concrete shall conform to the requirements of Chapter 7 of said ACI 301 Specifications. Use of pumping shall not, however, because to change or relax specified mix design characteristics.

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-25 C. SLUMP:

Maximum slumps shall be as specified herein.

D. RETEMPERING:

Retempering of concrete or mortar which has partially hardened shall not be permitted.

3.06 PREPARATION OF SURFACES FOR CONCRETING

A. GENERAL:

Earth surfaces shall be thoroughly wetted by sprinkling, before the placing of any concrete, and these surfaces shall be kept moist by frequent sprinkling up to the time of placing concrete thereon. The surface shall be free from standing water, mud, and debris at the time of placing concrete.

B. JOINTS IN CONCRETE:

Concrete surfaces upon or against which concrete is to be placed, where the placement of the concrete has been stopped or interrupted so that, as determined by the CONSTRUCTION MANAGER, the new concrete cannot be incorporated integrally with that previously placed, are defined as construction joints. The surfaces of horizontal joints shall be given a compacted, roughened surface for good bond. The joint surfaces shall be cleaned of all laitance, loose or defective concrete, foreign material, and roughened to a minimum 1/4-inch amplitude. Such cleaning and roughening shall be accomplished by hydroblasting or sandblasting (exposing aggregate) followed by thorough washing. All pools of water shall be removed from the surface of construction joints, and the joint surface shall be coated with an epoxy-bonding agent, unless indicated otherwise, before the new concrete is placed.

After the surfaces have been prepared all approximately horizontal construction joints shall be covered with a 6-inch lift of a rich pea gravel mix, as specified hereinbefore. The mix shall be placed and spread uniformly. Wall concrete shall follow immediately and shall be placed upon the fresh pea gravel mix.

C. PLACING INTERRUPTIONS:

When placing of concrete is to be interrupted long enough for the concrete to take a set, the working face shall be given a shape by the use of forms or other means, that will secure proper union with subsequent Work; provided that construction joints shall be made only where acceptable to the CONSTRUCTION MANAGER.

CAST-IN-PLACE CONCRETE 03300-26 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 D. EMBEDDED ITEMS:

No concrete shall be placed until all formwork, installation of parts to be embedded, reinforcement steel, and preparation of surfaces involved in the placing have been completed and accepted by the CONSTRUCTION MANAGER at least 4 hours before placement of concrete. All surfaces of forms and embedded items that have become encrusted with dried grout from concrete previously placed shall be cleaned of all such grout before the surrounding or adjacent concrete is placed.

All inserts or other embedded items shall conform to the requirements herein.

All reinforcement, anchor bolts, sleeves, inserts, and similar items shall be set and secured in the forms where shown or by shop drawings and shall be acceptable to the CONSTRUCTION MANAGER before any concrete is placed. Accuracy of placement is the responsibility of the CONTRACTOR.

E. CASTING NEW CONCRETE AGAINST OLD:

Where concrete is to be cast against old concrete (any concrete which is greater than 60 days of age), the surface of the old concrete shall be thoroughly cleaned and roughened by hydroblasting or sandblasting (exposing aggregate). The joint surface shall be coated with an epoxy bonding agent unless indicated otherwise by the CONSTRUCTION MANAGER.

No concrete shall be placed in any structure until all water entering the space to be filled with concrete has been properly cut off or has been diverted by pipes, or other means, and carried out of the forms, clear of the Work. No concrete shall be deposited underwater nor shall the CONTRACTOR allow still water to rise on any concrete until the concrete has attained its initial set. Water shall not be permitted to flow over the surface of any concrete in such manner and at such velocity as will injure the surface finish of the concrete. Pumping or other necessary dewatering operations for removing ground water, if required, will be subject to the review of the CONSTRUCTION MANAGER.

F. CORROSION PROTECTION:

Pipe, conduit, dowels, and other ferrous items required to be embedded in concrete construction shall be so positioned and supported before placement of concrete that there will be a minimum of 2 inches clearance between said items and any part of the concrete reinforcement. Securing such items in position by wiring or welding them to the reinforcement will not be permitted.

Openings for pipes, inserts for pipe hangers and brackets, and the setting of anchors shall, where practicable, be provided for during the placing of concrete.

Anchor bolts shall be accurately set, and shall be maintained in position by templates while being embedded in concrete.

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-27 G. CLEANING:

The surfaces of all metalwork to be in contact with concrete shall be thoroughly cleaned of all dirt, grease, loose scale and rust, grout, mortar, and other foreign substances immediately before the concrete is placed.

3.07 HANDLING, TRANSPORTING, AND PLACING

A. GENERAL:

Placing of concrete shall conform to the applicable requirements of Chapter 8 of ACI 301 and the requirements of this Section. No aluminum materials shall be used in conveying any concrete. Concrete which has segregated in conveying shall be removed from the site of the work.

B. NONCONFORMING WORK OR MATERIALS:

Concrete which upon or before placing is found not to conform to the requirements specified herein shall be rejected and immediately removed from the Work. Concrete which is not placed in accordance with these Specifications, or which is of inferior quality, shall be removed and replaced at no additional expense to the OWNER.

C. UNAUTHORIZED PLACEMENT:

No concrete shall be placed except in the presence of duly authorized representative of the CONSTRUCTION MANAGER. The CONTRACTOR shall notify the CONSTRUCTION MANAGER in writing at least 24 hours in advance of placement of any concrete.

D. PLACEMENT IN WALL FORMS:

Concrete shall not be dropped through reinforcement steel or into any deep form, nor shall concrete be placed in any form in such a manner as to leave accumulation of mortar on the form surfaces above the placed concrete. In such cases, some means such as the use of hoppers and, if necessary, vertical ducts of canvas, rubber, or metal shall be used for placing concrete in the forms in a manner that it may reach the place of final deposit without separation. In no case shall the free fall of concrete exceed 4 feet below the ends of ducts, chutes, or buggies. Concrete shall be uniformly distributed during the process of depositing and in no case after depositing shall any portion be displaced in the forms more than 6 feet in horizontal direction. Concrete in forms shall be deposited in uniform horizontal layers not deeper than 2 feet; and care shall be taken to avoid inclined layers or inclined construction joints except where such are required for sloping members. Each layer shall be placed while the previous layer is still soft. The rate of placing concrete in forms shall not exceed 5 feet of vertical rise per hour. Sufficient illumination shall be provided in the interior of all forms so that the concrete at the places of deposit is visible from the deck or runway.

CAST-IN-PLACE CONCRETE 03300-28 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 E. CONVEYOR BELTS AND CHUTES:

All ends of chutes, hopper gates, and all other points of concrete discharge throughout the CONTRACTOR's conveying, hoisting and placing system shall be so designed and arranged that concrete passing from them will not fall separated into whatever receptacle immediately receives it. Conveyor belts, if used, shall be of a type acceptable to the CONSTRUCTION MANAGER. Chutes longer than 50 feet will not be permitted. Minimum slopes of chutes shall be such that concrete of the specified consistency will readily flow in them. If a conveyor belt is used, it shall be wiped clean by a device operated in such a manner that none of the mortar adhering to the belt will be wasted. All conveyor belts and chutes shall be covered.

F. PLACEMENT IN SLABS:

Concrete placed in sloping slabs shall proceed uniformly from the bottom of the slab to the top, for the full width of the placement. As the Work progresses, the concrete shall be vibrated and carefully worked around the slab reinforcement, and the surface of the slab shall be screeded in an up-slope direction.

G. TEMPERATURE OF CONCRETE:

The temperature of concrete when it is being placed shall be not more than 90 degrees F nor less than 55 degrees F for sections less than 12 inches thick nor less than 50 degrees for all other sections. Concrete ingredients shall not be heated to a temperature higher than that necessary to keep the temperature of the mixed concrete, as placed, from falling below the specified minimum temperature. When the temperature of the concrete is 85 degrees F or above, the time between the introduction of the cement to the aggregates and discharge shall not exceed 45 minutes. If concrete is placed when the weather is such that the temperature of the concrete would exceed 90 degrees F, the CONTRACTOR shall employ effective means, such as precooling of aggregates and mixing water using ice or placing at night, as necessary to maintain the temperature of the concrete, as it is placed, below 90 degrees F. The CONTRACTOR shall be entitled to no additional compensation on account of the foregoing requirements.

H. COLD WEATHER PLACEMENT:

Placement of concrete shall conform to ACI 306.1 - Standard Specification for Cold Weather Concreting, and the following.

Remove all snow, ice and frost from the surfaces, including reinforcement, against which concrete is to be placed. Before beginning concrete placement, thaw the subgrade to a minimum depth of 6 inches. All reinforcement and embedded items shall be warmed to above 32 degrees F before concrete placement.

Maintain the concrete temperature above 50 degrees F for at least 3 days after placement.

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-29 I. HOT WEATHER PLACEMENT:

Placement of concrete shall conform to ACI 305R - Hot Weather Concreting, and the following.

Only set retarding admixture shall be used in concrete when air temperature is expected to be consistently over 80 degrees F.

The maximum temperature of concrete shall not exceed 90 degrees F immediately before placement.

From the initial placement to the curing state, concrete shall be protected from the adverse effect of high temperature, low humidity, and wind.

At no time when placing concrete for cast-in-place manhole bases or other sanitary sewer structures shall the concrete be permitted to fall from a height greater than 6 feet (6') without the use of chutes, tremies or an elephant trunk. All structural concrete pours shall be performed in accordance with A.C.I. recommendations. All concrete shall be placed in forms before taking its initial set.

No concrete shall be placed in water except with permission of the City.

As the concrete is placed in forms, or in rough excavations (i.e., thrust or anchor blocks), it shall be thoroughly settled and compacted throughout the entire layer by internal vibration and tamping bars.

All existing concrete surfaces upon which or against which new concrete is to be placed shall be roughened, thoroughly cleaned, wetted, and grouted before the new concrete is deposited.

3.08 CONSOLIDATED CONCRETE

Immediately upon the removal of forms, voids shall be neatly filled with cement mortar, non-shrink grout, or epoxy bonding agent and repair mortar as required for the application.

The surfaces of concrete exposed to view shall be smooth and free from projections or depressions.

Exposed surfaces of concrete not poured against forms, such as horizontal or sloping surfaces, shall be screeded to a uniform surface, steel-trowelled to densify the surface, and finished to a light broom finish.

Dusting with dry cement or sand to absorb excess moisture will not be permitted.

CAST-IN-PLACE CONCRETE 03300-30 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 3.09 PUMPING OF CONCRETE

A. GENERAL:

If the pumped concrete does not produce satisfactory end results, discontinue the pumping operation and proceed with the placing of concrete using conventional methods.

B. PUMPING EQUIPMENT:

The pumping equipment must have two cylinders and be designed to operate with one cylinder only in case the other one is not functioning. In lieu of this requirement, the CONTRACTOR may have a standby pump on the site during pumping.

The minimum diameter of the hose (conduits) shall be in accordance with ACI 304.2R.

Pumping equipment and hoses (conduits) that are not functioning properly, shall be replaced.

Aluminum conduits for conveying the concrete shall not be permitted.

C. FIELD CONTROL:

Concrete samples for slump, air content, and test cylinders will be taken at the placement (discharge) end of the line.

Concrete may be placed by pumping at Contractor’s discretion. Use of pumping shall not, however, because to change or relax specified mix design characteristics. Concrete shall possess the specified characteristics at the point of placement.

Slump shall be measured at the hose discharge, except as follows. Initial slump testing in each pour shall occur at both the pumping unit inlet hopper and hose discharge. Slump loss in pumping, measured between the inlet hopper and the hose discharge, shall not exceed 1 inch. After these criteria have been satisfied, slump may be measured at the inlet hopper with allowable slump increased by the earlier measured difference, not to exceed 1 inch.

3.10 ORDER OF PLACING CONCRETE

The order of placing concrete in all parts of the Work shall be acceptable to the CONSTRUCTION MANAGER. In order to minimize the effects of shrinkage, the concrete shall be placed in units as bounded by construction joints shown. The placing of units shall be done by placing alternate units in a manner such that each unit placed shall have cured at least 7 days for hydraulic structures and 3 days for all other structures before the contiguous unit or units are placed, except that the corner sections of vertical walls shall not be placed until the two adjacent wall panels have cured at least 14 days for hydraulic structures and 7 days for all other structures.

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-31 The surface of the concrete shall be level whenever a run of concrete is stopped. To ensure a level, straight joint on the exposed surface of walls, a wood strip at least 3/4 inch thick shall be tacked to the forms on these surfaces. The concrete shall be carried about 1/2 inch above the underside of the strip. About one hour after the concrete is placed, the strip shall be removed and any irregularities in the edge formed by the strip shall be leveled with a trowel and all laitance shall be removed.

3.11 TAMPING AND VIBRATING

As concrete is placed in the forms or in excavations, it shall be thoroughly settled and compacted, throughout the entire depth of the layer which is being consolidated, into a dense, homogeneous mass, filling all corners and angles, thoroughly embedding the reinforcement, eliminating rock pockets, and bringing only a slight excess of water to the exposed surface of concrete during placement. Vibrators shall be Group 3 (per ACI 309) high speed power vibrators (8,000 to 12,000 rpm) of an immersion type in sufficient number and with (at least one) standby units as required. Group 2 vibrators may be used only at specific locations when accepted by the CONSTRUCTION MANAGER.

Care shall be used in placing concrete around waterstops. The concrete shall be carefully worked by rodding and vibrating to make sure that all air and rock pockets have been eliminated. Where flat-strip type waterstops are placed horizontally, the concrete shall be worked under the waterstops by hand, making sure that all air and rock pockets have been eliminated. Concrete surrounding the waterstops shall be given additional vibration, over and above that used for adjacent concrete placement to assure complete embedment of the waterstops in the concrete.

Concrete in walls shall be internally vibrated and at the same time rammed, stirred, or worked with suitable appliances, tamping bars, shovels, or forked tools until it completely fills the forms or excavations and closes snugly against all surfaces. Subsequent layers of concrete shall not be placed until the layers previously placed have been worked thoroughly as specified. Vibrators shall be provided in sufficient numbers, with standby units as required, to accomplish the results herein specified within 15 minutes after concrete of the prescribed consistency is placed in the forms. The vibrating head shall be kept from contact with the surfaces of the forms. Care shall be taken not to vibrate concrete excessively or to work it in any manner that causes segregation of its constituents.

3.12 FINISHING CONCRETE SURFACES

A. GENERAL:

Surfaces shall be free from fins, bulges, ridges, offsets, honeycombing, or roughness of any kind, and shall present a finished, smooth, continuous hard surface. Allowable deviations from plumb or level and from the alignment, profiles, and dimensions shown are defined as tolerances and are specified in Part 1, herein. These tolerances are to be distinguished from irregularities in finish as described herein. Aluminum finishing tools shall not be used.

CAST-IN-PLACE CONCRETE 03300-32 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 B. FORMED SURFACES:

No treatment is required after form removal except for curing, repair of defective concrete, and treatment of surface defects. Where architectural finish is required, it shall be as specified or as shown.

Surface holes larger than 1/2 inch in diameter or deeper than 1/4-inch are defined as surface defects in basins and exposed walls.

C. UNFORMED SURFACES:

After proper and adequate vibration and tamping, all unformed top surfaces of slabs, floors, walls, and curbs shall be brought to a uniform surface with suitable tools. Immediately after the concrete has been screeded, it shall be treated with a liquid evaporation retardant. The retardant shall be used again after each Work operation as necessary to prevent drying shrinkage cracks. The classes of finish specified for unformed concrete surfaces are designated and defined as follows:

1. FINISH U1: Sufficient leveling and screeding to produce an even, uniform surface with surface irregularities not to exceed 3/8-inch. No further special finish is required.

2. FINISH U2: After sufficient stiffening of the screeded concrete, surfaces shall be float finished with wood or metal floats or with a finishing machine using float blades. Excessive floating of surfaces while the concrete is plastic and dusting of dry cement and sand on the concrete surface to absorb excess moisture will not be permitted. Floating shall be the minimum necessary to produce a surface that is free from screed marks and is uniform in texture. Surface irregularities shall not exceed 1/4-inch. Joints and edges shall be tooled where shown or as determined by the CONSTRUCTION MANAGER.

3. FINISH U3: After the floated surface (as specified for Finish U2) has hardened sufficiently to prevent excess of fine material from being drawn to the surface, steel troweling shall be performed with firm pressure such as will flatten the sandy texture of the floated surface and produce a dense, uniform surface free from blemishes, ripples, and trowel marks. The finish shall be smooth and free of all irregularities.

4. FINISH U4: Steel trowel finish (as specified for Finish U3) without local depressions or high points. In addition, the surface shall be given a light hairbroom finish with brooming perpendicular to drainage unless otherwise shown. The resulting surface shall be rough enough to provide a nonskid finish.

Unformed surfaces shall be finished according to the following schedule:

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-33 UNFORMED SURFACE FINISH SCHEDULE

Area Finish

Grade slabs and foundations to be covered with concrete or fill U1 material

Floors to be covered with grouted tile or topping grout U2

Slabs which are water bearing with slopes 10 percent and less U3

Sloping slabs which are water bearing with slopes greater than 10 percent U4

Slabs not water bearing U4

Slabs to be covered with built-up roofing U2

Interior slabs and floors to receive architectural finish U3

Top surface of walls U3

D. FLOOR HARDENER (SURFACE APPLIED)

Where hardener for floors is indicated, provide concrete with the following additional requirements:

1. Maximum slump of 4 inches when peak ambient temperatures are expected to be more than 65 degrees F, and no more than 3 inches when ambient temperatures are below 65 degrees F.

2. Maximum air content of 3 percent.

3. Do not use calcium chloride or set-accelerating admixtures containing calcium chloride.

4. Do not use admixtures that increase bleeding.

After the concrete has been leveled and as soon as the concrete will support an operator and machine without disturbing the level or working up excessive fines, float the surface of the slab with a mechanical float fitted with float shoes. Following floating, apply 2 to 2/3 of the total amount of dry shake surface hardener so that a uniform distribution of surface hardener is obtained. The use of a mechanical spreader is recommended. Once the shake has absorbed sufficient moisture (indicated by the darkening of the shake), float the surface. Immediately apply the remaining 1/3 to 2 of the shake and allow to absorb moisture. Do not place dry shake on concrete surface when bleed water is present.

CAST-IN-PLACE CONCRETE 03300-34 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 Use finishing machines with detachable float shoes. Compact surface by a third mechanical floating if time and setting characteristics of the concrete will allow. Do not add water to the surface.

As surface further stiffens, indicated by loss of sheen, hand or mechanically trowel with blades set relatively flat. Remove all marks and pinholes in the final raised trowel operation.

Follow all application instructions of the floor surface hardener manufacturer.

Cure finished floors using fill-forming curing compound recommended by surface hardener manufacturer. Uniformly apply curing compound over the entire surface at a coverage that will provide moisture retention in excess of the requirements of ASTM C 309. Maintain ambient temperature of 50 degrees F or above during the curing period.

Keep floors covered and free of traffic and loads for a minimum of 14 days after completion.

Immediately upon the removal of forms, voids shall be neatly filled with cement mortar, non-shrink grout, or epoxy bonding agent and repair mortar as required for the application.

The surfaces of concrete exposed to view shall be smooth and free from projections or depressions.

Dusting with dry cement or sand to absorb excess moisture will not be permitted.

3.13 ARCHITECTURAL FINISH

A. GENERAL:

Architectural finishes shall be required only where specifically called out on the Drawings. In all other cases, the paragraph above, entitled Finishing Concrete Surfaces, shall apply.

Immediately after the forms have been stripped, the concrete surface shall be inspected and any poor joints, voids, rock pockets, or other defective areas shall be repaired and all form- tie holes filled as indicated herein. voids shall be neatly filled with cement mortar, non-shrink grout, or epoxy bonding agent and repair mortar as required for the application and as directed by the City.

Architectural finishes shall not be applied until the concrete surface has been repaired as required and the concrete has cured at least 14 days.

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-35 The surfaces of concrete exposed to view shall be smooth and free from projections or depressions.

All architecturally treated concrete surfaces shall conform to the accepted sample required herein in texture, color, and quality. It shall be the CONTRACTOR's responsibility to maintain and protect the concrete finish.

B. SMOOTH CONCRETE FINISH:

The concrete surface shall be wetted, and a grout shall be applied with a brush. The grout shall be made by mixing one part Portland cement and one part of fine sand that will pass a No. 16 sieve with sufficient water to give it the consistency of thick paint. The cement used in said grout shall be 2 gray and 2 white Portland cement, as determined by the CONSTRUCTION MANAGER. White Portland cement shall be Atlas white, or equal. Calcium chloride in the amount of 5 percent by volume of the cement shall be used in the brush coat. The freshly applied grout shall be vigorously rubbed into the concrete surface with a wood float filling all small air holes. After all the surface grout had been removed with a steel trowel, the surface shall be allowed to dry and, when dry, shall be vigorously rubbed with burlap to remove completely all surface grout so that there is no visible paint-like film of grout on the concrete. The entire cleaning operation for any area shall be completed the day it is started, and no grout shall be left on the surface overnight.

Cleaning operations for any given day shall be terminated at panel joints. It is essential that the various operations be carefully timed to secure the desired effect which is a light-colored concrete surface of uniform color and texture without any appearance of a paint or grout film.

In the event that improper manipulation results in an inferior finish, rub such inferior areas with carborundum bricks.

Before beginning any of the final treatment on exposed surfaces, treat in a satisfactory manner a trial area of at least 200 square feet in some inconspicuous place selected by the CONSTRUCTION MANAGER and shall preserve said trial area undisturbed until the completion of the job.

C. SANDBLASTED CONCRETE FINISH.

Sandblasting shall be done in a safe manner acceptable to local authorities and per OSHA requirements. The sandblasting shall be a light sandblast to remove laitance and to produce a uniform fine aggregate surface texture with approximately 1/32 to 1/16 inch of surface sandblasted off. Corners, patches, form panel joints, and soft spots shall be sandblasted with care.

CAST-IN-PLACE CONCRETE 03300-36 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 A 3-square foot sample panel of the sandblasted finish shall be provided by the CONTRACTOR for acceptance by the CONSTRUCTION MANAGER before starting the sandblasting Work. The sample panel shall include a corner, plugs, and joints and shall be marked after approval. All other sandblasting shall be equal in finish to the sample panel.

Protection against sandblasting shall be provided on all surfaces and materials not requiring sandblasting but within or adjacent to areas being sandblasted. After sandblasting, the concrete surfaces shall be washed with clean water and excess sand removed.

3.14 CURING AND DAMPPROOFING

A. GENERAL:

All concrete shall be cured for not less than 14 days after placing, in accordance with the methods specified herein for the different parts of the Work, and described in detail in the following paragraphs:

Surface to be Cured or Dampproofed Method

Unstripped forms 1

Wall sections with forms removed 6

Construction joints between footings and walls, and between floor slab and columns 2

Encasement concrete and thrust blocks 3

All concrete surfaces not specifically provided for elsewhere in this Paragraph 4

Floor slabs on grade 5

Slabs not on grade 6

B. METHOD 1:

Wooden forms shall be wetted immediately after concrete has been placed and shall be kept wet with water until removed. If steel forms are used the exposed concrete surfaces shall be kept continuously wet until the forms are removed. If forms are removed within 14 days of placing the concrete, curing shall be continued in accordance with Method 6, herein.

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-37 C. METHOD 2:

The surface shall be covered with burlap mats which shall be kept wet with water for the duration of the curing period, until the concrete in the walls has been placed. No curing compound shall be applied to surfaces cured under Method 2.

D. METHOD 3:

The surface shall be covered with moist earth not less than 4 hours, nor more than 24 hours, after the concrete is placed. Earthwork operations that may damage the concrete shall not begin until at least 7 days after placement of concrete.

E. METHOD 4:

The surface shall be sprayed with a liquid curing compound.

1. It shall be applied in accordance with the manufacturer's printed instructions at a maximum coverage rate of 200 square feet per gallon and in such a manner as to cover the surface with a uniform film which will seal thoroughly.

2. Where the curing compound method is used, care shall be exercised to avoid damage to the seal during the curing period. Should the seal be damaged or broken before the expiration of the curing period, the break shall be repaired immediately by the application of additional curing compound over the damaged portion.

3. Wherever curing compound may have been applied by mistake to surfaces against which concrete subsequently is to be placed and to which it is to adhere, said compound shall be entirely removed by wet sandblasting just before the placing of new concrete.

4. Where curing compound is specified, it shall be applied as soon as the concrete has hardened enough to prevent marring on unformed surfaces, and within 2 hours after removal of forms from contact with formed surfaces. Repairs required to be made to formed surfaces shall be made within the said 2-hour period; provided, however, that any such repairs which cannot be made within the said 2-hour period shall be delayed until after the curing compound has been applied. When repairs are to be made to an area on which curing compound has been applied, the area involved shall first be wet-sandblasted to remove the curing compound, following which repairs shall be made as specified herein.

CAST-IN-PLACE CONCRETE 03300-38 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 5. At all locations where concrete is placed adjacent to a panel which has been coated with curing compound, the previously coated panel shall have curing compound reapplied to an area within 6 feet of the joint and to any other location where the curing membrane has been disturbed.

6. Before final acceptance of the Work, all visible traces of curing compound shall be removed from all surfaces in such a manner that does not damage surface finish.

F. METHOD 5:

Until the concrete surface is covered with curing compound, the entire surface shall be kept damp by applying water using nozzles that atomize the flow so that the surface is not marred or washed. The concrete shall be given a coat of curing compound in accordance with Method 4, herein. Not less than 1 hour nor more than 4 hours after the coat of curing compound has been applied, the surface shall be wetted with water delivered through a fog nozzle, and concrete- curing blankets shall be placed on the slabs. The curing blankets shall be polyethylene sheet, polyethylene-coated waterproof paper sheeting or polyethylene-coated burlap. The blankets shall be laid with the edges butted together and with the joints between strips sealed with 2-inch wide strips of sealing tape or with edges lapped not less than 3 inches and fastened together with a waterproof cement to form a continuous watertight joint.

The curing blankets shall be left in place during the 14-day curing period and shall not be removed until after concrete for adjacent Work has been placed. Should the curing blankets become torn or otherwise ineffective, replace damaged sections. During the first 3 days of the curing period, no traffic of any nature and no depositing, temporary or otherwise, of any materials shall be permitted on the curing blankets. During the remainder of the curing period, foot traffic and temporary depositing of materials that impose light pressure will be permitted only on top of plywood sheets 5/8-inch minimum thickness, laid over the curing blanket. Add water under the curing blanket as often as necessary to maintain damp concrete surfaces at all times.

G. METHOD 6:

This method applies to both walls and slabs.

1. The concrete shall be kept continuously wet by the application of water for a minimum period of at least 14 consecutive days beginning immediately after the concrete has reached final set or forms have been removed.

2. Until the concrete surface is covered with the curing medium, the entire surface shall be kept damp by applying water using nozzles that atomize the flow so that the surface is not marred or washed.

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-39 3. Heavy curing mats shall be used as a curing medium to retain the moisture during the curing period. The curing medium shall be weighted or otherwise held in place to prevent being dislodged by wind or any other causes and to be substantially in contact with the concrete surface. All edges shall be continuously held in place.

4. The curing blankets and concrete shall be kept continuously wet by the use of sprinklers or other means both during and after normal working hours.

5. Immediately after the application of water has terminated at the end of the curing period, the curing medium shall be removed, any dry spots shall be rewetted, and curing compound shall be immediately applied in accordance with Method 4, herein.

6. Dispose of excess water from the curing operation to avoid damage to the Work.

H. DAMPPROOFING:

The exterior surface of all buried roof slabs shall be dampproofed as follows:

1. Immediately after completion of curing the surface shall be sprayed with a damp-proofing agent consisting of an asphalt emulsion. Application shall be in two coats. The first coat shall be diluted to 2 strength by the addition of water and shall be sprayed on so as to provide a maximum coverage rate of 100 square feet per gallon of dilute solution. The second coat shall consist of an application of the specified material, undiluted, and shall be sprayed on so as to provide a maximum coverage rate of 100 square feet per gallon. Dampproofing material shall be as specified herein.

2. As soon as the asphalt emulsion, applied as specified herein, has taken an initial set, the entire area thus coated shall be coated with whitewash. Any formula for mixing the whitewash may be used which produces a uniformly coated white surface and which so remains until placing of the backfill. Should the whitewash fail to remain on the surface until the backfill is placed, apply additional whitewash.

3.15 PROTECTION

Protect all concrete against injury until final acceptance by the OWNER.

Fresh concrete shall be protected from damage due to rain, hail, sleet, or snow. Provide such protection while the concrete is still plastic and whenever such precipitation is imminent or occurring.

CAST-IN-PLACE CONCRETE 03300-40 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 The Contractor shall protect all concrete against damage. Exposed surfaces of new concrete shall be protected from the direct rays of the sun by covering them with plastic film wrap and by keeping them damp for at least 7 days after the concrete has been placed, or by using an approved curing process. Exposed surfaces shall be protected from frost by covering with tarps for at least 5 days after pouring.

3.16 CURING IN COLD WATER

Water curing of concrete may be reduced to 6 days during periods when the mean daily temperature in the vicinity of the worksite is less than 40 degrees F; provided that, during the prescribed period of water curing, when temperatures are such that concrete surfaces may freeze, water curing shall be temporarily discontinued.

Concrete cured by an application of curing compound will require no additional protection from freezing if the protection at 50 degrees F for 72 hours is obtained by means of approved insulation in contact with the forms or concrete surfaces; otherwise the concrete shall be protected against freezing temperatures for 72 hours immediately following 72 hours protection at 50 degrees F. Concrete cured by water curing shall be protected against freezing temperatures for 3 days immediately following the 72 hours of protection at 50 degrees F.

Discontinuance of protection against freezing temperatures shall be such that the drop in temperature of any portion of the concrete will be gradual and will not exceed 40 degrees F in 24 hours. In the spring, when the mean daily temperature rises above 40 degrees F for more than 3 successive days, the specified 72-hour protection at a temperature not lower than 50 degrees F may be discontinued for as long as the mean daily temperature remains above 40 degrees F; provided, that the concrete shall be protected against freezing temperatures for not less than 48 hours after placement.

Where artificial heat is employed, special care shall be taken to prevent the concrete from drying. Use of unvented heaters will be permitted only when unformed surfaces of concrete adjacent to the heaters are protected for the first 24 hours from an excessive carbon dioxide atmosphere by application of curing compound; provided, that the use of curing compound for such surfaces is otherwise permitted by these Specifications.

3.17 TREATMENT OF SURFACE DEFECTS

As soon as forms are removed, all exposed surfaces shall be carefully examined and any irregularities shall be immediately rubbed or ground in a satisfactory manner in order to secure a smooth, uniform, and continuous surface. Plastering or coating of surfaces to be smoothed will not be permitted. No repairs shall be made until after inspection by the CONSTRUCTION MANAGER. In no case will extensive patching of honeycombed concrete be permitted. Concrete containing minor voids, holes, honeycombing, or similar depression defects shall have them repaired as specified herein. Concrete containing extensive voids, holes, honeycombing, or similar depression defects, shall be completely removed and replaced. All repairs and

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-41 replacements herein specified shall be promptly executed by the CONTRACTOR at its own expense.

Defective surfaces to be repaired shall be cut back from trueline a minimum depth of 2 inch over the entire area. Feathered edges will not be permitted. Where chipping or cutting tools are not required in order to deepen the area properly, the surface shall be prepared for bonding by the removal of all laitance or soft material, and not less than 1/32-inch depth of the surface film from all hard portions, by means of an efficient sandblast. After cutting and sandblasting, the surface shall be wetted sufficiently in advance of shooting with shotcrete or with cement mortar so that while the repair material is being applied, the surfaces under repair will remain moist, but not so wet as to overcome the suction upon which a good bond depends. The material used for repair proposed shall consist of a mixture of one sack of cement to 3 cubic feet of sand. For exposed walls, the cement shall contain such a proportion of Atlas white Portland cement as is required to make the color of the patch match the color of the surrounding concrete.

Holes left by tie-rod cones shall be reamed with suitable toothed reamers so as to leave the surfaces of the holes clean and rough. These holes then shall be repaired in an approved manner with dry-packed cement grout. Holes left by form-tying devices having a rectangular cross-section, and other imperfections having a depth greater than their least surface dimension, shall not be reamed but shall be repaired in an approved manner with dry-packed cement grout.

All repairs shall be built up and shaped in such a manner that the completed Work will conform to the requirements of this Section, as applicable, using approved methods which will not disturb the bond, cause sagging, or cause horizontal fractures. Surfaces of said repairs shall receive the same kind and amount of curing treatment as required for the concrete in the repaired section.

Before filling any structure with water, all cracks that may have developed shall be "vee'd" and filled with construction joint sealant for water-bearing structures conforming to the materials and methods specified in Section 03290 - Joints in Concrete Structures. This repair method shall be done on the water bearing face of members. Before backfilling, faces of members in contact with fill, which are not covered with a waterproofing membrane, shall also have cracks repaired as specified herein.

3.18 PATCHING HOLES IN CONCRETE

A. PATCHING SMALL HOLES:

Holes which are less than 12 inches in their least dimension and extend completely through concrete members, shall be filled as specified herein.

Small holes in members which are water-bearing or in contact with soil or other fill material, shall be filled with nonshrink grout. Where a face of the member is exposed to view, the nonshrink grout shall be held back 2 inches from the finished surface. The remaining

CAST-IN-PLACE CONCRETE 03300-42 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 2 inches shall then be patched according to the paragraph in Part 3 entitled "Treatment of Surface Defects."

Small holes through all other concrete members shall be filled with nonshrink grout, with exposed faces treated as above.

B. PATCHING LARGE HOLES:

Holes which are larger than 12 inches in their least dimension, shall have a keyway chipped into the edge of the opening all around, unless a formed keyway exists. The holes shall then be filled with concrete as specified herein.

Holes which are larger than 24 inches in their least dimension and which do not have reinforcing steel extending from the existing concrete, shall have reinforcing steel set in grout in drilled holes. The reinforcing added shall match the reinforcing in the existing wall unless shown.

Large holes in members which are water bearing or in contact with soil or other fill, shall have a bentonite type waterstop material placed around the perimeter of the hole as specified in the Section 03290 - Joints in Concrete Structures, unless there is an existing waterstop in place.

3.19 CARE AND REPAIR OF CONCRETE

The CONTRACTOR shall protect all concrete against injury or damage from excessive heat, lack of moisture, overstress, or any other cause until final acceptance by the OWNER. Particular care shall be taken to prevent the drying of concrete and to avoid roughening or otherwise damaging the surface. Any concrete found to be damaged, or which may have been originally defective, or which becomes defective at any time before the final acceptance of the completed Work, or which departs from the established line or grade, or which, for any other reason, does not conform to the requirements of the Contract Documents, shall be satisfactorily repaired or removed and replaced with acceptable concrete at the CONTRACTOR's expense.

Minor surface damage to hardened cast-in-place or precast concrete may be repaired, at the discretion of the City, using the specified materials in accordance with the manufacturer's recommendations and the following procedures:

A. CAST-IN-PLACE OR PRECAST CONCRETE FOR MANHOLES AND VAULTS:

Remove loose or deteriorated concrete to expose a fractured aggregate surface with an edge cut to a ninety degree angle to the existing surface. Clean all debris from the area, apply a 20 mil coat of epoxy bonding agent to the prepared surface, and place repair mortar while the epoxy is still wet and tacky. On horizontal surfaces, for repair depths greater than 2-inches, add aggregate to the repair mortar as recommended by the manufacturer. On vertical or overhead surfaces, for repair depths greater than 2-inches, apply the repair mortar in successive lifts,

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-43 scarifying the lifts, allowing them to harden, and applying a scrub coat of the material prior to proceeding with the next lift. Cure the material as for concrete in accordance with this specification.

B. GENERAL PURPOSE:

Remove loose and deteriorated concrete by mechanical means, sandblasting, or high- pressure water blasting. Clean all debris from the area and apply non-shrink grout in a 1/4-inch minimum thickness, at the desired consistency, ranging from a dry pack, to a fluid-poured into a formed area, according to the application. Cure the material as for concrete in accordance with this specification.

3.20 EPOXY ADHESIVES FOR ANCHOR BOLT INSTALLATION

Anchor bolts grouted in place with an epoxy adhesive shall be installed using the specified materials in accordance with the manufacturer's recommendations and the following general procedures: Drill the hole with a rotary percussion drill to produce a rough, unpolished hole surface. the hole shall be sized to the manufacturer's recommendations and should be approximately 1/4-inch wider than the diameter of the bolt, with a depth equal to 10 to 15 times the bolt diameter. Remove debris and dust with a stiff bristle brush and clean using compressed air. Utilizing a medium-viscosity epoxy for horizontal surfaces, and a gel-type non-sag epoxy for vertical surfaces, apply the material to fill the hole to approximately half its depth. Insert the bolt, forcing it down until the required embedment depth and projection length are attained and then twist the bolt to establish a bond. Secure the bolt firmly in place in the permanent position until the epoxy sets.

3.21 PROTECTIVE EPOXY COATING

Following core drilling at existing concrete structures, clean the exposed concrete surface and ends of reinforcing steel and apply two coats of protective epoxy coating for a total dry film thickness of 10-15 mils. Allow the material to cure between coats and prior to continuing the installation through the penetration.

3.22 DAMP-PROOFING FOR THE EXTERIOR OF CONCRETE STRUCTURES

Following completion of the exterior surfaces of manholes and vaults, including necessary repairs and piping penetrations into the structure, apply the specified material to prepared concrete surfaces in accordance with the manufacturer's recommendations. The surfaces to be coated shall be fully-cured and free of laitance and contamination. The material shall be applied to all exterior surfaces below a point 12-inches above the water table or indications of seepage or moisture as directed by the Engineer. Apply two 15 mil coats, curing between coats, prior to backfill and/or immersion in accordance with the manufacturer's recommendations.

CAST-IN-PLACE CONCRETE 03300-44 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 3.23 THRUST AND ANCHOR BLOCKS

Concrete thrust and anchor blocks shall be poured against wetted, undisturbed soil in accordance with the Standard Drawings and as directed by the City. The concrete shall be placed so that fittings and valves will be accessible for repairs or replacement. Prior to filling the pipeline with water, the concrete for thrust and anchor blocks shall cure for the following number of days:

1. Thrust Blocks 3 days minimum 2. Anchor Blocks 7 days minimum

A. SAFE SOIL BEARING LOAD:

Soil Safe Bearing Load Muck, peat, etc.*** 0 PSF Soft Clay 500 PSF Fine Sand 1,000 PSF Decomposed Granite (D.G.) 1,500 PSF Sandy Gravel 2,000 PSF Cemented Sandy Gravel 2,000 PSF Hard Shale 2,500 PSF Granite 10,000 PSF ***In muck or peat soils, competent resistance shall be achieved by removal and replacement with ballast or sufficient stability to resist the intended thrusts. Consult the project geotechnical consultant.

B. THRUST BLOCK PLACEMENT AND SIZING:

Thrust blocks shall be located at all unrestrained pipe fittings and bear against firm, undisturbed soil. The thrust blocks shall be centered on the fitting so that the bearing area is exactly opposite the resultant direction of the thrust, refer to the Standard Drawings. Care shall be taken to prevent the placed thrust block concrete from eliminating maintenance access to the valve operators. All thrust block excavation location, shape, and the City prior to pouring the concrete shall verify size. The size, in sq. ft., of the thrust block can be calculated by dividing the thrust by the safe bearing load.

For instance, use a 12-inch pipe, 45° end, at 200 psi test pressure with a D.G. trench the value of 11,720# of thrust can be obtained from the upper chart and 1,500#/sq. ft. safe bearing load from the lower chart as follows:

11,720# x 2 / 1,500#/Sq. ft. = 15.6 sq. ft. or 16 sq.

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-45 Therefore, for this example, the trench wall adjacent to the fitting shall be excavated to the dimensions of 4 ft. x 4 ft. or 3.5 ft. x 5 ft. or some closely approximate multipliers to achieve the minimum required 16 sq. ft. bearing area.

C. ANCHOR BLOCK PLACEMENT AND SIZING:

For all vertical bends in pipelines (downward bends) that do not have restrained joints, the fittings shall be retained in place by means of an anchor block. The block shall be sized to withstand the thrust exerted for the particular deflection angle at the required test pressure plus 10%. (Do not rely on the restraining benefit from the soil). The City shall verify the size chosen and the reinforcing steel required.

The size, in cu. ft. of the anchor block can be calculated by dividing the thrust by the unit weight of concrete (i.e., one cu. ft. or concrete weighs approximately 145#). For instance, use the same 12-inch pipe, 45° bend, at 200 psi test pressure – the value of 11,720# of thrust can be obtained from the upper chart:

11,720# x 2 / 145# = 162 cu. ft. (plus 10%) = 178 cu. ft. or 6.6 cu. yd.

Therefore, for this example, the anchor block shall be 5.5' x 5.5' x 6' or 6' x 6' x 5', or some closely approximate multipliers to achieve a minimum of 178 cu. ft. of concrete.

3.24 VALVE SUPPORT BLOCKS

Valve support blocks shall be installed as described below and in accordance with the Standard Drawings:

1. Support blocks below valves shall be cut into the side of the trench a minimum of 12-inches.

2. Support blocks shall extend up to a height of adjoining pipe and shall have a minimum depth below the valve of 12-inches.

3. Support blocks shall be installed so that the valves will be accessible for repairs.

3.25 ACCEPTANCE OF CONCRETE

Completed cast-in-place concrete work shall conform to the applicable requirements of ACI 301 and the Contract Documents.

Concrete work that fails to meet the requirements of ACI 301 or the Contract Documents shall be repaired as approved by the Engineer to bring the concrete into compliance.

CAST-IN-PLACE CONCRETE 03300-46 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 Concrete that cannot be brought into compliance by approved repair methods will be rejected. Rejected concrete work shall be removed and replaced. Repair methods shall be in accordance with ACI standards and are subject to the approval of the Engineer. The cost of repairs and replacement of defective concrete shall be borne by the Contractor.

** END OF SECTION **

CAST-IN-PLACE CONCRETE DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03300-47 SECTION 03365

CONCRETE STAIN

PART 1 – GENERAL

1.01 SECTION INCLUDES

Concrete wall stain.

1.02 RELATED SECTIONS

Section 03300 - Cast-in-Place Concrete.

Section 04220 - Concrete Masonry Units.

1.03 SUBMITTALS

Comply with Section 01300 – Submittals.

A PRODUCT DATA:

Submit manufacturer's product data, including surface preparation and application instructions.

B. COLOR SAMPLES:

Submit manufacturer's standard color chart.

C. APPLICATOR'S PROJECT REFERENCES:

Submit list of successfully completed projects, including project name and location, name of architect, and type and quantity of concrete floor stain applied.

D. MAINTENANCE INSTRUCTIONS:

Submit manufacturer's maintenance and cleaning instructions.

1.04 QUALITY ASSURANCE

A. APPLICATOR'S QUALIFICATIONS:

Successful experience in application of similar concrete floor stains.

Employ persons trained for application of concrete floor stains.

CONCRETE STAIN DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03365-1 B. PRE-INSTALLATION MEETING:

Convene a pre-installation meeting 2 weeks before start of application of concrete floor stain.

Require attendance of parties directly affecting work of this section, including Contractor, Architect, manufacturer's representative, and applicator.

Review surface preparation, application, field quality control, protection, and coordination with other work.

1.05 DELIVERY, STORAGE, AND HANDLING

A. DELIVERY:

Deliver materials to site in manufacturer's original, unopened containers and packaging, with labels clearly identifying manufacturer, product name, and color.

B. STORAGE:

1. Store materials in clean, dry area indoors in accordance with manufacturer's instructions.

2. Keep containers sealed until ready for use.

3. CONCRETE CLEANER: Keep from freezing.

C. HANDLING:

Protect materials during handling and application to prevent damage or contamination.

1.06 ENVIRONMENTAL REQUIREMENTS

Apply concrete stain when air and surface temperatures are between 40 degrees F and 90 degrees F during application and a minimum of 48 hours after application.

A. EXTERIOR SURFACES:

Do not apply materials in wet weather.

1.07 SEQUENCING

Prepare surface and apply concrete stain before finish work is completed. Protect surface after application, for the duration of the construction.

CONCRETE STAIN 03365-2 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 PART 2 – PRODUCTS

2.01 MANUFACTURER

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

1. Solomon Colors 2. Or Equal

2.02 COLOR

A. STAIN 1:

1. 385 Lava

B. STAIN 2:

1. 750 Desert Tan

2.03 ACCESSORIES

A. CONCRETE CLEANER:

Solomon Colors Concrete Cleaner:

1. Biodegradable, natural, citrus-based, enzyme solvent cleaner. 2. Free of acids and petroleum-based chemicals.

B. CLEAR STAIN REDUCER:

Solomon Colors Concrete Stain Reducer.

C. CONCRETE SEALER:

1. Compatible with concrete stain. 2. Clear, nonyellowing.

PART 3 – EXECUTION

3.01 EXAMINATION

Examine surfaces to receive concrete stain. Notify Architect if surfaces are not acceptable. Do not begin surface preparation or application until unacceptable conditions have been corrected.

CONCRETE STAIN DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03365-3 3.02 SURFACE PREPARATION

A. PROTECTION:

Protect floors, adjacent surfaces, surrounding areas, and vegetation from overspray, runoff, and contact with concrete stain.

Prepare concrete surface in accordance with manufacturer's instructions.

B NEW CONCRETE:

1. Concrete shall be as specified in Section 03300. 2. Do not apply curing compounds, sealers, or water repellents. 3. Remove excess release agents. 4. Allow concrete to cure a minimum of [30] [90] days.

Ensure concrete surface is clean, dry, structurally sound, and free from dirt, dust, debris, oil, grease, tar, adhesive, paint, curing compounds, sealers, wax, and other surface coatings.

C. CONCRETE CLEANER:

1. Dilute and apply concrete cleaner in accordance with manufacturer's instructions to clean concrete.

2. Rinse surface clean with water to remove concrete cleaner residue.

3. Ensure concrete is free of residue.

4. Allow concrete to dry before applying concrete floor stain.

F. TESTING CONCRETE:

Test concrete by wetting with water to see if it beads up on surface.

If water beads up, additional surface preparation is required.

G. PRE-CLEANING CONCRETE:

Do not use acid to pre-clean concrete.

3.03 APPLICATION

Apply concrete floor stain in accordance with manufacturer's instructions at locations indicated on the drawings.

Keep material containers closed when not in use to avoid contamination.

CONCRETE STAIN 03365-4 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 Apply 2 coats of undiluted stain.

Dilute stain with clear stain reducer if colors are too strong.

Allow first coat of stain to dry before applying second coat.

Allow second coat of stain to dry overnight before neutralizing and washing surface to remove stain residue.

A. CONCRETE CLEANER:

Dilute and apply concrete cleaner in accordance with manufacturer's instructions to neutralize stain residue left after stain has dried.

Rinse surface clean with water to remove concrete cleaner residue.

B. CONCRETE SEALER:

Seal concrete with concrete sealer after it is completely dry.

Apply sealer in accordance with sealer manufacturer's instructions.

3.04 FIELD QUALITY CONTROL

Test inconspicuous area of concrete for color and reactivity of concrete floor stain for approval by Architect.

Test concrete surface after surface preparation and before application.

3.05 PROTECTION

Protect stained concrete from damage during construction.

Protect concrete surfaces for a minimum of 24 hours after application of concrete sealer.

**END OF SECTION**

CONCRETE STAIN DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03365-5 THIS PAGE INTENTIONALLY LEFT BLANK

CONCRETE STAIN 03365-6 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 SECTION 03400

PRECAST CONCRETE STRUCTURES

PART 1 -- GENERAL

1.01 DESCRIPTION

A. SCOPE:

This section specifies the materials and labor required for the manufacture and erection of precast concrete structures including valve and meter vaults, crossover assembly vault, and precast utility trenches as specified and in accordance with the San Diego Regional Standard Drawings and Specifications as accepted and modified by the City of Carlsbad and CMWD. In the case of conflict between the listed Agency's requirements and as required herein, the requirements affording the greatest protection to the Owner shall apply, as determined by the Construction Manager.

Precast concrete manholes and maintenance holes for sewer and storm drains shall be in accordance with Section 03460,

1.02 QUALITY ASSURANCE

A. REFERENCES:

This Section includes references to the following standards. They are a part of this Section as specified and modified. In case of conflict between the requirements of this Section and those of the listed documents, the requirements affording the greatest protection to the Owner shall apply, as determined by the Construction Manager.

Reference Title ASTM A48 Standard Specification for Gray Iron Castings. ASTM A1011 Standard Specification for Steel, Sheet and Strip, Hot-Rolled, Carbon, Structural, High-Strength Low-Alloy and High- Strength Low Alloy with Improved Formability. ASTM C109 Test Method for Compressive Strength of Hydraulic Cement Mortars (Using 2 inch or 50-mm Cube Specimens). ASTM C478 Standard Specification for Precast Reinforced Concrete Manhole Sections. ASTM C857 Standard Practice for Minimum Structural Design Loading for Underground Precast Concrete Utility Structures. ASTM C858 Standard Specification for Underground Precast Concrete PRECAST CONCRETE STRUCTURES DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03400-1 Reference Title Utility Structures. ASTM C990 Standard Specification for Joints for Concrete Pipe, Manholes, and Precast Box Sections Using Preformed Flexible Joint Sealants. NPCA National Precast Concrete Association, Plant Certification Program AASHTO American Association of State Highway and Transportation Officials AWS D1.1 Structural Welding Code Steel ACI 318 Building Code Requirements for Reinforced Concrete MNL-116 Prestressed Concrete Institute's Manual for Quality Control for Plants and Production of Precast and Prestressed Concrete Products, latest edition

B. MANUFACTURING:

1. PRECAST CONCRETE MANUFACTURER: NPCA Plant Certified.

The Contractor shall provide certification from the precast concrete manufacturer that the materials and manufacture of precast work supplied conforms to these specifications. The certification shall be signed by an officer of the manufacturer's corporation.

The responsibility for furnishing and installing precast concrete conforming to the specifications is solely that of the Contractor.

C. TESTING LABORATORY:

All testing shall be performed by recognized independent laboratories specializing in the particular test to be performed, and conforming to the requirements of the National Bureau of Standards and ASTM E329.

1.03 SUBMITTALS

Submittals in accordance with the General Conditions and Section 01300:

1. CONCRETE MIX: Prior to casting any precast elements, concrete mix design shall be submitted to the Engineer for acceptance.

2. SHOP DRAWINGS: Shop drawings shall be provided showing product location, material and fabrication details, number identification marks, reinforcement, connection details including field installed anchor sizes and locations, if required, openings, loose or PRECAST CONCRETE STRUCTURES 03400-2 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 embedded items and inserts, dimensions and relationship to adjacent materials in sufficient detail to cover manufacture, handling, and erection. Materials provided shall be reference to the applicable ASTM Standards with supporting documentation demonstrating compliance.

Shop drawings shall be accompanied by a letter signed by a California Registered Civil or Structural Engineer, certifying that, the shop drawings submitted represent construction which meets or exceeds the requirements of the Contract Documents and the requirements of codes and agencies having jurisdiction over the Work.

1.04 LABELING

Each panel or member shall have an identification mark indicating its location in the structure as shown on the placing diagrams and date of casting.

1.05 HANDLING AND STORAGE

Unless specified otherwise herein, fabrication, handling, and erection of precast elements shall be in accordance with the recommendations made by ACI 318 and ACI Committee 533.

Precast elements shall be properly supported off the ground to avoid damage during curing, storage, handling and hauling. Lateral support shall be sufficient to prevent bowing, warping, or permanent set due to creep. Edges of the units shall be adequately protected by padding or other means to prevent staining, chipping or spalling of concrete. Lifting devices shall have a minimum safety factor of 4.

PART 2 -- PRODUCTS

2.01 DESIGN AND PERFORMANCE REQUIREMENTS

A. DESIGN:

1. LOADING: In accordance with ASTM C857, A-16.

2. PRECAST CONCRETE: Minimum compressive strength 4,000 psi; in accordance with ASTM C858; Portland Cement, Type V.

3. POLYMER CONCRETE: Minimum compressive strength 5,000 psi; in accordance with Western Underground Committee Guide 3.6.

B. PERFORMANCE:

Precast concrete assemblies, including frames and covers: Consist of materials suitable for full on-street AASHTO H-20 wheel load traffic rating.

PRECAST CONCRETE STRUCTURES DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03400-3 Polymer concrete assemblies, including covers: Consist of materials containing aggregate matrix bound with a UV resistant polymer resin suitable for incidental 20,000 lb. wheel load traffic.

The Contractor shall furnish the precast supplier with locations and loads of mechanical equipment. The precast units shall be designed for the actual mechanical equipment to be supplied.

2.02 PRECAST CONCRETE MATERIALS

A. CEMENT:

Concrete in contact with soil or liquids shall be formulated using Type II or Type V Portland Cement conforming to ASTM C150. Concrete not in contact with soil or liquids may be formulated using Type I or Type III Portland cement. Cement shall contain less than .60% alkalies and shall be from one source throughout the entire project.

B. AGGREGATES:

Aggregates for normal weight concrete shall conform to ASTM C33 with a maximum size of ¾-inch.

C. WATER:

Water shall be clean, potable, free from injurious amounts of oil, alkalies, organic materials, and other deleterious substances.

D. ADMIXTURE:

Admixture shall be Pozzolith 300-R manufactured by Master Builders, Plastiment manufactured by Sika Chemical Corp., or equal. Admixture shall be used in strict accordance with manufacturer's recommendations. Calcium chloride or any admixture containing calcium chloride shall not be used.

E. REINFORCING STEEL:

Reinforcing steel shall conform to ASTM A615, including supplementary requirements, and shall be Grade 60 except that bars to be welded shall be Grade 40 or ASTM A706.

F. EMBEDDED ITEMS AND ANCHORAGE DEVICES:

All embedded items, inserts, and anchorage devices exposed to view, moisture, or weather shall be hot-dipped galvanized steel. Anchorage devices shall be fabricated from ASTM A36 steel.

PRECAST CONCRETE STRUCTURES 03400-4 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 G. PENETRATIONS:

All required penetrations and openings larger than 6 inches in diameter or 6 inches square shall be formed in place at the time of casting. Additional reinforcing shall be added where required to meet loading requirements. Openings and penetrations smaller than 6 inches may be core drilled.

H. MOLDS:

Material from which molds are to be fabricated shall be steel, concrete, fiberglass, reinforced plastic or wood. The selection of materials for molds shall be at the manufacturer's option, except that wood shall not be used without the express approval of the Engineer. All elements shall be cast in molds of rigid construction, accurate in detail with precise corners and arises, and designed to provide a close control of dimensions and details as indicated on the drawings.

Prior to casting of precast elements, molds shall have all surface joints, radii, corners, etc., filled, ground, filed, straightened or otherwise removed to provide a finished concrete surface that is smooth and dense, free of honeycombing, large air pockets, offsets, sink ages, or other irregularities.

I. PARTING COMPOUND:

All molds shall be coated with parting compound to facilitate removal of elements from molds. Parting compound shall be non-petroleum, no staining and shall be of a nature and composition not deleterious to concrete.

2.03 PRODUCT DATA

The following information shall be provided:

1. LABORATORY TEST REPORTS: Before delivery of materials, three copies of the reports of the tests specified herein shall be provided. Test reports on previously tested materials shall be accompanied by the manufacturer's statement that the previously tested material is the same type, quality, manufacture, and make as that proposed for use in this project. Test reports are required for the following:

a. Cement b. Aggregates c. Pozzolan d. Admixtures e. Curing compounds f. Waterstops g. Concrete mix designs

PRECAST CONCRETE STRUCTURES DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03400-5 2.04 UTILITY TRENCH (NOT USED)

2.05 PRECAST CONCRETE VAULT

The precast concrete vault shall be precast with a 28-day, 4000 psi minimum compressive strength concrete and designed for AASHTO H-20 loading. Dimensions are as shown on the Contract Drawings. Provide openings for pipes and grating as shown on the Contract Drawings.

Pipe stubouts for future connections shall be provided as specified. Pipe stubouts shall be the same type as approved for use in lateral, main, or trunk sewer construction. Strength classifications shall be the same class as in adjacent trenches. Where there are two different classes of pipe at a maintenance hole, the higher strength pipe will govern strength classification. Rubber gasketed watertight plugs shall be furnished with each stubout adequately braced against all hydrostatic or air test pressures.

PART 3 -- EXECUTION

3.01 INSTALLATION

A. CASTING:

Casting shall be accomplished by methods and equipment that are in conformance with generally acceptable systems for this type of Work. All precast concrete shall be manufactured by a plant thoroughly experienced in this type of Work. The manufacturer shall meet all production schedules. Surfaces on which units are cast shall be level and free from any imperfections detrimental to the surface appearance of the finished units. Parting compound shall be applied evenly as per manufacturer's recommendations.

Concrete shall be so handled as to prevent segregation of materials and shall be continuously vibrated during casting, either internally or externally, to achieve proper compaction, finish, and distribution of concrete. All precautions must be taken to keep the reinforcing steel in the proper location during placing and consolidation of the concrete. Unless shown otherwise and except at concrete faces exposed to soil or liquids, all reinforcing steel shall have a minimum cover of ¾-inch. At concrete faces exposed to soil or liquids, cover shall be 1-½ inches minimum. Embedded items shall be accurately placed and maintained in their proper location during the casting operation. Special inserts or other devices for handling of panels for the convenience of the manufacturer shall not be exposed to view after members are erected. Embedded anchors, inserts, plates, angles and other cast-in items shall have sufficient anchorage and embedment for design requirements.

Casting, bowing, warpage, and dimensional tolerances shall be in accordance with MNL-116, Third Edition.

PRECAST CONCRETE STRUCTURES 03400-6 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 B. CURING:

All precast units shall be steam cured for a period of at least 12 hours. Fog spraying may be used when reviewed by the Engineer. Precast elements shall not be removed from molds for a minimum period of 12 hours after casting, or until concrete has attained a minimum compressive strength of 3,500 pounds per square inch, whichever governs. After removal from the forms, curing by steam or fog spraying shall be continued until concrete has attained specified strength and confirmed by standard tests. Curing procedures shall be consistent and uniform throughout the entire project.

C. WELDING:

The quality of material and fabrication of all welded connections shall conform to the latest AISC "Specification for the Design, Fabrication, and Erection of Structural Steel for Buildings." All weldments shall be made in accordance with the applicable provisions of AWS. All welding, other than tacks, shall be done by certified welders. All units shall be protected from damage by field welding or cutting operations. Noncombustible shields shall be provided as necessary for this purpose.

D. JOINTS AND JOINT SEALANTS:

In all instances, the edges of precast concrete units and of adjacent material shall be sound, smooth, clean, and free of all contaminants prior to joint treatment.

Sealant and primer shall be supplied by the same manufacturer and the primer, when required, shall be as recommended for the particular sealant used. All sealant compounds shall be delivered to the job in the manufacturer's original sealed containers with labels intact and shall be applied in strict accordance with the manufacturer's recommendations. Sealant shall be as specified in specification Section 07900 of these specifications.

E. WATERPROOFING AND MOISTUREPROOFING:

Waterproofing and moistureproofing shall be as specified in section 07100.

3.02 ERECTION

Any errors or misalignment in the structure, which would prevent the proper setting of the elements shall be corrected by the Contractor before the erection is commenced. Erection shall be supervised and performed by workmen skilled in this type of Work. Each element shall be set in the proper position, carefully plumbed, and anchored securely to the structural frame. Adjustments or changes in connections, which could involve additional stresses in the products or connections, shall not be permitted without approval of the Engineer. All bearing surfaces shall be true to line and grade. Erection tolerances shall be in accordance with MNL-116. All joints shall be uniform and straight.

PRECAST CONCRETE STRUCTURES DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03400-7 Precast elements shall be protected from all damage until final acceptance by the Construction Manager. Precast units with cracks, spalls, and other defects shall be subject to rejection. Units reviewed for repair shall be repaired to the satisfaction of the Engineer.

3.03 INSPECTION

After installation, the Contractor shall demonstrate that all structures have been properly installed, level, with tight joints, at the correct elevations and orientations, and that the backfilling has been carried out in accordance with the Contract Documents.

3.04 ALTERNATIVE DESIGN

The Contractor may offer an alternative design for any precast element. Such design shall be comparable in terms of strength, deflection, finish, and all other design criteria indicated. Complete drawings prepared and sealed by a civil or structural engineer registered in the State of California where applicable shall be submitted to the Engineer for his review in accordance with specification Section 01300 of this project manual. No alternative design will be permitted, unless it has been specifically accepted in writing by the Engineer. If an alternative design is accepted, all expenses resulting there shall be borne by the Contractor.

** END OF SECTION **

PRECAST CONCRETE STRUCTURES 03400-8 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 SECTION 03460

PRECAST CONCRETE MANHOLES

PART 1 – GENERAL

1.01 SCOPE OF WORK

The Contractor shall provide precast concrete manholes also referred to as access maintenance holes, complete and in place.

Furnish all labor, materials and equipment required to provide precast concrete manholes, grade rings, frames and covers, and appurtenances as shown on the Drawings and as specified herein.

New and replacement precast manholes placed on sanitary sewers less than 12-inch in diameter and storm drains maintenance holes shall be constructed and installed per the City of Carlsbad and CMWD Standard Drawings and Specifications and as shown. In case of conflict between the requirements of this Section and those of the listed documents, the requirements affording the greatest protection to the Owner shall apply, as determined by the Construction Manager.

1.02 QUALITY ASSURANCE

A. REFERENCE STANDARDS:

Reference Title ASTM A48 Standard Specification for Gray Iron Castings. ASTM C150 Standard Specification for Portland Cement. ASTM C387 Standard Specification for Packaged, Dry, Combined Materials for Mortar and Concrete. ASTM C478 Standard Specification for Precast Reinforced Concrete Manhole Sections. ASTM C595 Standard Specification for Blended Hydraulic Cements. ASTM C923 Standard Specification for Resilient Connectors between Reinforced Concrete Manhole Structures, Pipes and Laterals.

PRECAST CONCRETE MANHOLES DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03460-1 Reference Title ASTM C990 Standard Specification for Joints for Concrete Pipe, Manholes, and Precast Box Sections Using Preformed Flexible Joint Sealants

A. MANUFACTURE :

Materials' quality, manufacturing process and finished sections are subject to inspection and approval by Owner. Inspection may be made at place of manufacture, at work site following delivery, or both.

Materials will be examined for compliance with ASTM specifications, these specifications and approved manufacturer's shop drawings. Additional inspection criteria shall include: appearance, dimensions(s), blisters, cracks and soundness. Repair minor damage to precast concrete sections by approved method, if repair is authorized by Owner.

Materials shall be rejected for failure to meet any Specification requirement. Rejection may occur at place of manufacture, at work site, or following installation. Mark for identification rejected materials and remove from work site immediately. Rejected materials shall be replaced at no cost to Owner.

All material shall be new and unused.

1.03 SUBMITTALS

Submittals in accordance with the General Conditions and Section 01300:

1. Manufacturer’s shop drawings of manhole sections, base units and construction details, jointing methods, materials, and dimensions. Base sections, riser sections, eccentric and concentric conical top sections, flat slab tops, grade rings with notarized certificate indicating compliance with ASTM C478.

2. Shop drawings for each manhole to be provided. Drawings shall clearly identify the manhole by station, location, and show pipe connections to manhole, manhole inverts, depth, dimensions, and corrosion protection.

3. Submit Design calculations for manholes to be installed on sanitary sewers greater than 12-inches in diameter. Calculations shall be sealed by a Professional Engineer licensed in the State of California, indicating adequate strength to resist the vertical and lateral loadings including “H-

PRECAST CONCRETE MANHOLES 03460-2 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 20" wheel loadings, and buoyancy forces and criteria used in manhole design, including material properties, loading, and dimensions.

4. Manhole frame and cover style and finish with notarized certificate indicating compliance with ASTM A48, Class 30.

5. Method of repair for minor damage to precast concrete sections.

6. Test reports for precast concrete structures: concrete test cylinder reports from an approved testing laboratory certifying conformance with specifications.

7. Manufacturers Installation (or Application) Instructions

1.05 SCHEDULES

Precast manholes shall be provided as shown and specified

PART 2 – PRODUCTS

2.01 GENERAL

Like items of materials/equipment shall be the end products of one manufacturer in order to provide standardization for appearance, operation, maintenance, spare parts and manufacturer's service.

2.02 PRECAST CONCRETE MANHOLE SECTIONS

Precast concrete base sections, riser sections, transition top sections, flat slab tops and grade rings shall conform to ASTM C478 and meet the following requirements:

1. Bottom slab thickness shall equal the riser wall thickness or flat slab top thickness, whichever is greater.

2. Unless otherwise specified, top section shall be eccentric cone where cover over pipe exceeds 4 feet; top section shall be flat slab where cover over top of pipe is 4 feet or less, or where shown.

3. Base, riser and transition top sections shall have tongue and groove joints.

4. Ship precast concrete only after concrete has attained 3,000 psi compressive strength.

5. Design precast concrete base, riser, transition top, flat slab top and grade ring for a minimum H-20 loading plus earth load. Calculate earth load with a unit weight of 130 pcf. Calculate buoyancy forces based on groundwater depth 1-foot below the ground surface. PRECAST CONCRETE MANHOLES DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03460-3 6. The minimum clear distance between the edges of any 2 wall penetrations shall be 6-inches.

7. Mark date of manufacture, name and trademark of manufacturer on the inside of each precast section.

8. Precast Concrete Base: Base sections shall have the base slab integral with sidewalls. Base slab shall be constructed in accordance with City of Carlsbad Standard Drawing S-1A. Tie reinforcing steel to wall steel.

9. Portland cement shall be Type II containing not more than 5 percent tricalcium aluminate, or Type V per ASTM C150. 2. Minimum Compressive 28 Day Strength: 4000 psi

2.03 MANHOLE FRAME AND COVER

Manhole frames and covers shall be of good quality, strong, tough, even grained cast iron, smooth, free from scale, lumps, blisters, sand holes and defects of any kind which render them unfit for the service for which they are intended. Manhole covers and frame seats shall be machined to a true surface. Castings shall be thoroughly cleaned and subject to hammer inspection. Cast iron shall conform to ASTM A48, Class 30. Locking frames and covers shall be required in areas located outside the public right of way.

All castings shall be dipped twice in a preparation of asphalt or coal tar and oil applied at a temperature of not less than 290 degrees F nor more than 310 degrees F and in such a manner as to form a firm and tenacious coating.

Frames shall have a minimum opening of 30 inches. Manhole covers shall be Alhambra Foundry, South Bay Foundry, or equal. Approved models shall be per the City of Carlsbad’s Approved Materials List.

Covers shall be cast with the words “CITY OF CARLSBAD” and “SEWER” or “STORM” in raised letters as shown in City of Carlsbad Standard Drawing S-4. No other lettering will be permitted on the top portion of the cover.

2.04 JOINTING PRECAST MANHOLE SECTIONS AND STRUCTURES

Seal tongue and groove joints of precast manhole and structure sections with either rubber "O"-ring gasket or preformed flexible joint sealant. "O"-ring gasket shall conform to ASTM C443. Preformed flexible joint sealant shall be Kent Seal No. 2 as manufactured by Hamilton-Kent; Ram-Nek as manufactured by K.T. Snyder Company or equal.

Completed joint shall withstand 15 psi internal water pressure without leakage or displacement of gasket or sealant.

PRECAST CONCRETE MANHOLES 03460-4 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 2.05 PIPE CONNECTIONS TO MANHOLE

Connect pipe to manhole in the following ways:

1. Precast manhole connections shall be watertight in accordance with ASTM C-923.

A. FLEXIBLE SLEEVE:

Integrally cast sleeve in precast manhole section or install sleeve in a formed or cored opening. Fasten pipe in sleeve with stainless steel clamp(s). Coat stainless steel clamp(s) with bitummous material to protect from corrosion. Flexible sleeve shall be Lock Joint Flexible Manhole Sleeve; Kor-N-Seal connector; PSX Press-Seal Gasket or equal.

B. COMPRESSION GASKET:

Integrally cast compression gasket in precast manhole section. Insert pipe into compression gasket. Compression gasket shall be A-Lok, or equal.

2.06 CORROSION PROTECTION

A. PVC LINERS:

Factory-installed corrosion protection lining for pre-cast concrete manholes and structures shall be PVC liner in accordance with Section 09881. As a minimum corrosion protection shall be provided with PVC lining in the following locations:

1. All manholes for sewers 15-inches in diameter and larger;

2. Drop manholes

3. Force main terminal manholes

4. Manholes where incoming pipe slopes are 7% or greater or where a slope change from steep to flat of 5% or greater occurs. Manhole at the grade change and the next manhole upstream shall also be lined.

5. Manholes constructed upstream of connections to the 54” trunk sewer.

6. Sewer junction structures

B. COATINGS

Manhole bases, channels and any exposed concrete within the manhole interior not protected by PVC liner shall be protected in accordance with Section 02605.

PRECAST CONCRETE MANHOLES DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03460-5 2.07 MANHOLE APPURTENANCES

Sewer manhole sections shall be cast without ladder rungs.

2.08 CONCRETE

The concrete class for maintenance hole and precast vault work shall be 560-C-3250. Maximum size of aggregate shall be 1.5 inches. Slump shall be between 2 and 5 inches.

PART 3 – EXECUTION

3.01 GENERAL

Pre-cast concrete sections shall be transported and handled with care in accordance with the manufacturer’s written recommendations. Where lifting devices are provided in pre-cast sections, such lifting devices shall be used as intended. Where no lifting devices are provided, the Contractor shall follow the manufacturer’s recommendations for lifting procedures to provide proper support during lifting.

3.02 FINISHED GRADE

Manhole frames and covers shall be set flush with the existing surface in existing pavement or in the traveled way of the existing road shoulder, it is to be placed flush with the existing surface. When the structure is outside the limits of the traveled shoulder but not in the roadside ditch, it should be placed 1/10-foot above the existing ground surface.

Where the manhole cover falls in the existing roadside ditch or easement right-of-way “offsite”, it is to be placed approximately 6-inches above the existing ground surface. Manhole frames shall be set at the required grade and shall be securely attached to the top precast manhole shaft unit with a cement-mortar bed and fillet. After the frames are securely set in place, covers shall be installed and all necessary cleaning and scraping of foreign materials from the frames and covers shall be accomplished to ensure a satisfactory fit.

3.03 PRECAST MANHOLES

Precast concrete manhole riser sections shall be installed plumb and true on the precast concrete base sections as shown on the Contract Drawing. Before placing the O-ring gasket in the spigot groove, the gasket and all bearing surfaces of the tongue and groove shall be wiped clean, and a lubricant as recommended by the manufacturer shall be applied to the gasket and the inside bell surface. Care shall be taken when lowering any precast unit into the trench that no dirt gets on the gasket or into the joint. Top sections of precast manholes shall be flat slab-type or eccentric cone sections cast to the proper dimensions to receive the manhole casting shown on the Contract Drawings.

PRECAST CONCRETE MANHOLES 03460-6 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 All manhole riser section joints more than 20 feet below the manhole rim shall be provided with an exterior joint collar and be installed according to the manufacturer's recommendations. After removing the protective paper, the band shall be placed around the manhole riser, mastic side to the riser and spanning the joint. The steel straps shall be secured with the proper tools. The closing flap shall cover all remaining exposed strap.

The top of the wall of all manholes shall be properly leveled off with mortar so as to form a flat surface upon which the manhole rim is to rest, and manholes shall be carried to such height above the sewer as shown, as necessary to meet grade.

When there is not enough room for a full length of precast concrete riser section to be installed under the manhole frame, precast reinforced concrete grade rings and mortar shall be used for sanitary manholes.

In order to allow for a future adjustment of roadway grade or widening of existing roadway, shorter lengths of riser sections when used should be installed immediately below the cone section. Also, a minimum of one precast concrete grade ring will be required on top of the cone or flat slab top section to effect the proper elevation for the manhole rim. The total height of precast concrete grade rings and mortar shall not exceed 12 inches.

Precast bottom sections with integral bases when used shall be set plumb on a firm foundation in the trench. Height of the bottom section shall be provided to admit the various pipes at the elevations shown on the drawings and still contain sufficient material for structural integrity across the top of these openings. Pipe openings shall be cast into the unit at the time of manufacture. All pipe connections to precast concrete manholes shall be made with resilient connectors conforming to ASTM C923.

The manhole frames shall be properly set in place in a full bed of mortar and so adjusted as to make the top of the rim a few inches higher than the surrounding ground so as not to act as a surface drain, or flush with paved surfaces.

Precast man-holes and structures shall be water tight and free from infiltration. Joints shall use sealant material to provide a water tight seal. Where manholes are to be given a protective lining or coating, they shall be free of any seeping or surface moisture. Sections of manholes below ground water levels or anticipated ground water levels shall have sealant material installed on the external surface per City of Carlsbad Standard Drawing S-1A or as approved by the Construction Manager.

3.04 CLEANING

Thoroughly clean all new manholes of all silt, debris and foreign matter of any kind, prior to final inspections.

PRECAST CONCRETE MANHOLES DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03460-7 3.05 INSPECTION

Inspection: after installation, the Contractor shall demonstrate that manholes have been properly installed, level, with tight joints, at the correct elevations and orientations, and that the backfilling has been carried out in accordance with the contract documents.

3.06 VACUUM TESTING

All sewer manholes shall be vacuum tested in accordance with the requirements specified herein. Vacuum testing equipment shall be as manufactured by P.A. Glazier, Inc. or approved equal.

Manholes shall be tested after assembly and prior to mortaring the joints or backfilling. In case of manholes incorporating a PVC liner, the testing is to take place prior to mortaring the joints, welding the liner seams between sections, and backfilling.

All lift holes shall be plugged with an approved grout prior to testing. All pipes entering the manhole shall be plugged and bracing installed to prevent the plug from being drawn into the manhole. The test head shall be placed inside the top of the cone section and the seal inflated in accordance with the manufacture’s recommendations. A vacuum of 10 inches of mercury shall be drawn. The time shall be measured for the vacuum to drop 9-inches. The manhole shall pass the test if the time taken for the drop is greater than 60 seconds. If the manhole fails the test, necessary repairs shall be made and the test repeated until acceptable results are obtained. The leak(s) shall be located and repaired, according to the type of leak, with material-in-kind.

3.07 PVC LINER TESTING

A. PULL-TESTING PVC-lined manholes shall have field-welded joints pull tested. Field welds shall withstand a pull test of at least 100 pounds per linear inch applied perpendicularly to the concrete surface for a period of one-minute without evidence of cracks or separation. This test shall be conducted at a temperature of 70°f to 80°f, inclusive.

B. HOLIDAY TESTING

PVC-lined surfaces shall be holiday tested with an electrical holiday detector as manufactured by Tinker and Rasor (model no. Ap-w with power pack) with the instrument set at 20,000 volts. All imperfections identified shall be repaired and the test shall be repeated until no holidays are evident.

** END OF SECTION **

PRECAST CONCRETE MANHOLES 03460-8 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014

SECTION 03481

PRECAST, PRESTRESSED CONCRETE PILES

PART 1 - GENERAL

1.01 DESCRIPTION

Provide precast, prestressed concrete piling, complete, as shown and specified per the contract documents.

1.02 RELATED WORK SPECIFIED ELSEWHERE

Section 03100, Concrete Formwork

Section 03200, Concrete Reinforcing

Section 03300, Cast-In-Place Concrete

1.03 REFERENCES

Reference Title

American Concrete Institute (ACI)

American Institute of Steel Construction (AISC)

American Society for Testing and Materials (ASTM) ASTM A36 Standard Specification for Carbon Structural Steel ASTM A416 Standard Specification for Steel Strand, Uncoated Seven-Wire for Prestressed Concrete ASTM D3441 Standard Test Method for Mechanical Cone Penetration Tests of Soil California Building Code Prestressed Concrete Institute (PCI) PCI Manual Manual for Quality Control for Plants and Production of Precast Prestressed Concrete Products

1.04 QUALIFICATIONS

Manufacture of prestressed concrete piles shall be carried out under the direct supervision of an experienced and competent supervisor who has had a minimum of 5 years experience in charge of the production and quality control of prestressed concrete products.

PRECAST, PRESTRESSED CONCRETE PILES DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03481-1

Quality control shall be in accordance with PCI Manual, MNL 116-77, Manual for Quality Control for Plants and Production of Precast Prestressed Concrete Products. In the absence of a designation as a “PCI Certified Plant” under the Prestressed Concrete Institute Certification Program, submit written evidence of experience, plant facilities, quality control procedures, staff, and any qualifications for manufacturer of piles.

1.05 SUBMITTALS

Prior to manufacture of prestressed concrete piles, submit shop drawings, casting procedure, and prestressing methods for approval.

At least two weeks prior to mobilization at the site, submit proposed pile installation equipment data form for review.

Submit details of all pile extensions and splices for approval.

Submit written reports of proposed mix for each type of concrete at least 15 days prior to start of precast unit production. Do not begin concrete production until mixes and evaluations have been reviewed by the Engineer.

Submit a traffic control plan for pile and equipment delivery.

Provide a minimum 48-hour notification of any activity (i.e., crane heights, excessive noise and vibrations, etc.) that may potentially impact operations.

Submit as-built locations and elevations (final tip and top cut-off) for review.

1.06 DESIGN REQUIREMENTS

Piles shall be designed to not less than the requirements of the California Building Code with regard to material, reinforcement and allowable stresses. In addition to design loads, splices shall be designed to carry impact and rebound loads during driving. Handling and transportation loads shall not exceed allowable stresses.

Piles shall be designed to carry vertical downward (compression) load of 82.5 tons and uplift (tension) loads indicated on the drawings.

1.07 INDICATOR PILE INSTALLATION PROGRAM

Test drive piles under observation. Furnish pile dynamic analyzer instrumentation to monitor pile behavior during driving. The instrumentation shall consist of gages with wire leads which shall be attached to the concrete piles with concrete screws. The Contractor shall pre-drill holes. Lifting the pile or pile segments into the hammer leads with the gages mounted will not be allowed. The gages shall be mounted into the pre-drilled holes after the pile is mounted in the leads. The Contractor shall assist and cooperate with installing and observing instruments.

Pile driving during monitoring is typical of ordinary driving except that they may temporarily stop driving at any time due to dynamic monitoring performance.

Pile driving equipment proposed for driving of production piles shall be used for indicator pile installation program.

PRECAST, PRESTRESSED CONCRETE PILES 03481-2 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014

The minimum program shall consist of one indicator driven at each abutment.

Information obtained by the indicator pile installation program will be used to determine production pile lengths, and final penetration and driving criteria.

The length of indicator piles shall be the length shown on the drawings plus 10 feet.

After completing the driving of the indicator piles, the owner may request a re-strike of the indicator piles. Dynamic monitoring will be performed during re-strike. A minimum of 24 to 48 hours will be required between the initial driving and re-strike.

Test piles shall be incorporated in the permanent construction. No additional payment will be made to reinstall piling at test pile location.

Complete indicator pile installation program prior to the installation of production piles unless approved otherwise.

PART 2 -- PRODUCTS

2.01 CONCRETE

For precast prestressed piling, use minimum Class 5000-3/4.

2.02 REINFORCING STEEL

Concrete reinforcement as specified in Section 03200, Concrete Reinforcing, and as shown on the drawings

2.03 STRUCTURAL STEEL

Meet the requirements of ASTM A36.

2.04 PRESTRESSING STRAND

270K tensile strength, seven-wire prestressing strand, conforming to requirements of ASTM Designation A416. Furnish the manufacturer’s mill certificates of each heat used.

2.05 ANCHORS AND LIFTING BOLTS

The Manufacturer shall design and furnish pick-up points of the type required to pick up and handle units. Calculations submitted by the Contractor shall include handling of pile and lifting bolt design.

2.06 CURING MATERIAL

As specified in Section 03300, Cast-in-Place Concrete.

2.07 FORMWORK

As specified in Section 03100, Concrete Formwork.

PRECAST, PRESTRESSED CONCRETE PILES DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03481-3

2.07.1.1 DIMENSIONS AND DETAILS

Minimum dimensions and details are shown on the drawings. Design by manufacturer.

PART 3 -- EXECUTION

3.01 GENERAL

The methods and equipment used in the prestressing operations shall generally conform to patterns being used by currently accepted systems of pretensioning and PCI Manual MNL-116-77, but proposed variations from these methods and equipment may be acceptable, provided equally satisfactory results are obtained.

Each pile shall be designed for precasting as a monolithic unit with the prestressing force applied by pretensioning methods, using uncoated, stress-relieved, high-tensile steel strand. Place the pretensioning strands symmetrically in the piles, extending through the length of the pile in straight parallel lines.

Provide prestressing jacks with means for determining the stresses in the strand at any time or phase of the stressing operation and with certified calibration curves and tables for each jack.

Complete the placing and tying of reinforcement, forms, and other details prior to casting concrete into an individual pile.

If, after placement of the concrete and before release is authorized of the externally applied prestressing force, readings indicate a reduction in the specified prestressing force due to steel failure or slippage, movement of abutments, or other cause, whether determined or not, the entire group of piles in which failure occurred will be rejected.

Keep dowel openings clean and plug interior voids to 2 feet below reinforcing steel prior to concrete placement.

3.02 PILE DRIVING PLANT

Provide equipment of adequate size and capacity to handle, place, and hold the piles to the designed alignment. This equipment must be able to maintain the alignment of pile and hammer without damage to either.

Maintain all pile driving equipment in safe operating condition at all times.

Driving hammers shall be in good repair and operating condition and shall be capable of being operated at the manufacturer’s rated number of blows per minute except when necessary to reduce the speed to avoid damage to the piles, e.g., at the beginning of driving long piles.

Equipment or methods which result in regular or repeated damage to piles during driving or is detrimental to the bearing capacity of piling already driven will be rejected.

Use air, steam, or diesel driving hammers capable of driving the piles to the depths shown on the drawings. The suitability of a proposed driving hammer must be demonstrated during the indicator pile program. If the Contractor proposes a different driving hammer during the installation of production

PRECAST, PRESTRESSED CONCRETE PILES 03481-4 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014

piles, the cost for the dynamic pile analyzer instrumentation for the proposed hammer tried by the Contractor shall be borne by the Contractor.

3.03 PILE INSTALLATION AND DRIVING CRITERIA

Locate each pile accurately in accordance with the plans. Reference cut-off elevation of each pile to benchmarks established.

Specify production pile lengths based on indicator pile installation program. Production lengths may be modified based on observations made during production pile installation. Specify lengths of piling in adequate numbers to maintain continuity of pile production and installation procedures.

Specify terminal penetration and driving criteria based upon wave equation and indicator pile installation program. The local authority reserves the right to modify terminal driving criteria based on driving experience of indicator or production piles without additional compensation to the Contractor.

Maintain hammer and pile cushions in satisfactory condition. Cushions burned, charred or compressed to less than 60 percent of their original thickness shall be replaced.

During driving of the production piles, the local authority may monitor the production piles with the pile dynamic analyzer instrumentation. The local authority will furnish the instrumentation. The Contractor shall assist and cooperate with the local authority in installing and observing instruments. The Contractor shall assist the local authority at no added cost.

Spuds may be used to assist pile installation.

Jetting for installation of piling shall not be allowed.

3.04 TOLERANCES

Deviation of pile head under the pile caps may be 3 inches from plan position, in any direction, and +/- 1 inch from cut-off elevation shown on the drawings.

Tolerances shall be measured after cut-off.

3.05 DRIVING RECORDS

Render such assistance as may be required in keeping records of the piles driven. This includes marking the piles with marks at 1-foot intervals and number at 5-foot intervals to show the dimension from the pile tip. Place marks prior to the start of driving. Marks and numbers shall be readily seen from a minimum distance of 15 feet.

The Contractor will not be responsible for counting blows per foot.

3.06 OBSTRUCTIONS DURING DRIVING

Minor obstructions are obstructions encountered within 5 feet of mud line/bottom of pile cap. Should an obstruction stop the advancement of a pile, it will still be classed as a minor obstruction unless the same obstruction also stops the advancement of a second pile adjacent to the first. No extra payment will be made for the removal of a minor obstruction.

PRECAST, PRESTRESSED CONCRETE PILES DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03481-5

Major obstructions are obstructions not classed as minor. Additional work directed to acceptably complete the installation of the pile after encountering a major obstruction will be considered extra work under the terms of the General Conditions. A major obstruction will be determined as such after engineering review of pertinent field conditions and driving data. In addition, the Owner reserves the right to require the Contractor to demonstrate, at no additional cost, that the pile cannot be driven by conventional means.

3.07 REJECTED PILES

No payment for furnishing, driving, cut off, or extension will be made for any piling installed by the order of the Owner to correct or replace piles which are out of tolerance, broken, misoriented, or otherwise violate these specifications, or for pulling or reinstallation of any piling incorrectly installed.

*** END OF SECTION ***

PRECAST, PRESTRESSED CONCRETE PILES 03481-6 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014

PRECAST, PRESTRESSED CONCRETE PILES DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03481 Attachment 1-1

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PRECAST, PRESTRESSED CONCRETE PILES 03481 Attachment 1-2 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 SECTION 03600

GROUT

PART 1--GENERAL

1.01 DESCRIPTION

This section specifies grout for column and other structural support bases, equipment bases, crack repair, surface repair and uses other than masonry.

Materials for grouting the interior or exterior annular space of casings or to address ground movement shall be per Section 02342.

1.02 QUALITY ASSURANCE

A. QUALITY CONTROL BY CONTRACTOR:

To demonstrate conformance with the specified requirements for grout, the Contractor shall provide the services of an independent testing laboratory conforming to Section 01400. Costs of testing laboratory services shall be borne by the Contractor.

1. Testing shall be performed in accordance with SSPWC.

2. Costs of testing services shall be borne by the Contractor.

3. The Contractor shall require that the laboratory provide evidence of the most recent inspection of its facilities by the Cement and Concrete Reference Laboratory of the National Bureau of Standards. The evidences shall show that deficiencies mentioned in the report of that inspection have been corrected. The evidence of inspection shall be provided prior to delivery of materials to the job site.

1.03 WORK OF THIS SECTION

The WORK of this Section includes providing grout other than that required for masonry work, complete.

The following types of grout are included in the WORK of this Section:

1. Non-Shrink Grout: This type of grout shall be used wherever grout is required, unless another type is specifically indicated.

2. Cement Grout

3. Epoxy Grout

GROUT DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03600-1 4. Topping Grout and Concrete Fill

1.04 RELATED SECTIONS

The WORK of the following Sections applies to the WORK of this Section. Other Sections of the Specifications not referenced below, shall also apply to the extent required for proper performance of this WORK.

1. Section 03300 Cast-in-Place Concrete

A. SPECIAL INSPECTION:

Where Special Inspection is specified, noted on the drawings, required by Code or product manufacturer, Owner shall provide the services of a qualified Special Inspector according to Section 01400.

B. REFERENCES:

Reference Title ASTM C33 Concrete Aggregates ASTM C40 Organic Impurities in Fine Aggregates for Concrete ASTM C88 Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate ASTM C94 Standard Specifications for Ready-Mixed Concrete. ASTM C109 Test Method for Compressive Strength of Hydraulic Cement Mortars (Using 2-in or 50-mm Cube Specimens) ASTM C117 Material Finer Than 75 µm (No. 200) Sieve in Mineral Aggregates by Washing

GROUT 03600-2 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 Reference Title ASTM C136 REV A Sieve Analysis of Fine and Coarse Aggregates ASTM C150 Portland Cement ASTM C289 Potential Reactivity of Aggregates (Chemical Method) ASTM C531 Test Method for Linear Shrinkage and Coefficient of Thermal Expansion of Chemical-Resistant Mortars, Grouts, and Monolithic Surfacings ASTM C579 Test Methods for Compressive Strength of Chemical- Resistant Mortars and Monolithic Surfacings ASTM C827 Standard Test Method for Change in Height at Early Ages of Cylindrical Specimens for Cementitious Mixtures. ASTM C881 Epoxy-Resin-Base Bonding Systems for Concrete ASTM C1107 Packaged Dry, Hydraulic-Cement Grout (Nonshrink) ASTM D2419 Standard Test Method for Sand Equivalent Value of Soils and Fine Aggregate ASTM D696 Test Method for Coefficient of Linear Thermal Expansion of Plastics CRD-C 621 Corps of Engineers Specification for Non-shrink Grout

1.05 SUBMITTALS

The following information shall be provided in accordance with Section 01300:

1. Complete product literature and installation instructions for epoxy grout (all uses) and cementitious non-shrink grout.

2. Current ICBO Evaluation Report, or equivalent in other jurisdictions, for adhesives used for dowel and anchor setting.

The Contractor shall submit the following in compliance with SSPWC Subsection-2-5.3.

1. Submit product data and manufacturer’s installation instructions for all materials intended for use in this section.

2. Submit laboratory test reports. Test reports on previously tested materials shall be accompanied by the manufacturer's statement that the previously tested material is the same type, quality, manufacture, and make as that proposed for use in this project. Test reports are required for the following:

GROUT DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03600-3 a. Cement b. Aggregates c. Retardants d. Bonding compounds e. Epoxy resin

3. Submit evidence of testing laboratory competence.

1.06 SHOP DRAWINGS AND SAMPLES

The following shall be submitted in compliance with Section 01300:

1. Manufacturer's literature containing instructions and recommendations on the mixing, handling, placement, and appropriate uses for each type of non-shrink and epoxy grouts proposed for use in the WORK.

2. Certified test results verifying the compressive strength, shrinkage, and expansion properties for proposed non-shrink and epoxy grouts.

1.07 TESTING DURING CONSTRUCTION

A. FIELD TESTS:

Compression test specimens will be taken during construction from the first placement of each type of grout, and at intervals thereafter as selected by the CONSTRUCTION MANAGER to insure continued compliance with these specifications. The specimens will be made by the CONSTRUCTION MANAGER or its representative.

Compression tests and fabrication of specimens for cement grout and non-shrink grout will be performed as specified in ASTM C 109 at intervals during construction as selected by the CONSTRUCTION MANAGER. A set of three specimens will be made for testing at 7 days, 28 days, and each additional time period as appropriate.

Compression tests and fabrication of specimens for epoxy grout will be performed as specified in ASTM C 579, Method B, at intervals during construction as selected by the CONSTRUCTION MANAGER. A set of three specimens will be made for testing at 7 days, and each earlier time period as appropriate.

All grout, already placed, which fails to meet the requirements of these specifications, is subject to removal and replacement at the cost of the CONTRACTOR.

The cost of all laboratory tests on grout will be borne by the OWNER, but the CONTRACTOR shall assist the CONSTRUCTION MANAGER in obtaining specimens for testing. However, the CONTRACTOR shall be charged for the cost of any additional tests and investigation on work performed which does not meet the specifications. The CONTRACTOR shall supply all materials necessary for fabricating the test specimens.

GROUT 03600-4 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 PART 2--PRODUCTS

2.01 MATERIALS

A. CEMENT:

Portland cement shall be ASTM C150, Type V, low alkali, containing less than 0.60 percent alkalies. or equivalent high sulfide resistant

B. AGGREGATE:

1. GENERAL: Aggregate shall be nonreactive and shall be washed before use.

When sources of aggregate are changed, test reports shall be provided for the new material. The tests specified shall be performed prior to commencing grout work.

2. FINE AGGREGATE: Fine aggregate shall be hard, dense, durable particles of either sand or crushed stone regularly graded from coarse to fine and shall conform to ASTM C33 as modified herein. When tested in accordance with ASTM C136, gradation shall be such that 100 percent by weight will pass a standard No. 8 mesh sleeve and no less than 45 percent by weight will pass a standard No. 40 mesh sieve.

Variation from the specified gradations in individual tests will be acceptable if the average of three consecutive tests is within the specified limits and the variation is within the permissible variation listed below:

U.S. standard Permissible variation in sieve size individual tests, percent 30 or coarser 2 50 or finer 0.5

Other tests shall be in accordance with the following specifications:

Test Test method Requirements Organic Impurities ASTM C40 Color lighter than standard Amount of Material Passing ASTM C117 3% maximum by weight No. 200 Sieve Soundness ASTM C88 10% maximum loss with sodium sulfate Reactivity ASTM C289 Innocuous aggregate Sand Equivalent ASTM D2419 Minimum 80

GROUT DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03600-5 C. ADMIXTURES:

1. GENERAL: Admixtures shall be compatible with the grout. Calcium chloride or admixtures containing calcium chloride are not acceptable. Admixtures shall be used in accordance with the manufacturer's recommendations and shall be added separately to the grout mix.

2. ACCEPTABLE ADMIXTURES: Acceptable products including water reducing, water reducing and retarding, and superplasticizing are specified in Section 03300. Contractor shall select as appropriate for the use intended and in conformance with manufacturer’s recommendations and these specifications.

3. LUBRICANT FOR CEMENT PRESSURE GROUTING: Lubricant additive for cement pressure grouting shall be Intrusion Prepakt Intrusion Aid, Sika Intraplast N, or equal.

D. WATER:

Water for washing aggregate, for mixing and for curing shall be free from oil and deleterious amounts of acids, alkalies, and organic materials; shall not contain more than 1000 mg/1 of chlorides as Cl, nor more than 1300 mg/1 of sulfates as SO 4; and shall not contain an amount of impurities that may cause a change of more than 25 percent in the setting time of the cement nor a reduction of more than 5 percent in the compressive strength of the grout at 14 days when compared with the result obtained with distilled water. Additionally, water used for curing shall not contain an amount of impurities sufficient to discolor the grout.

2.02 GROUT

A. CEMENT GROUT:

Cement grout shall be composed of one part cement, three parts sand, and the minimum amount of water necessary to obtain the desired consistency. Where needed to match the color of adjacent concrete, white Portland cement shall be blended with regular cement as needed. The minimum compressive strength at 28 days shall be 5,000 psi.

Cement grout materials shall be as indicated in Section 03300.

B. DRYPACK GROUT:

Use grouts with the consistency necessary to completely fill space to be grouted for the particular application.

Grout mix shall consist of one part, Type V or equivalent high sulfide resistant Portland cement, one part fine sand, and one part additive such as Five Star Grout by U.S. Grout Corporation, or approved equal. A batch shall consist of equal portions of the above parts

GROUT 03600-6 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 established by weight; with only sufficient water added equivalent to 5.5 gallons per bag of cement.

Drypack grout shall be a mixture of approximately one part cement, 1-1/2 to 2 parts fine aggregate, water reducing retarder, and sufficient water to make a stiff workable mix. The grout shall have a consistency such that the grout is plastic and moldable but will not flow.

C. CEMENTITIOUS NONSHRINK GROUT:

Non-Shrink Grout shall be prepackaged, inorganic, non-gas-liberating, non-metallic, Type V cement-based grout with additives for protection against hydrogen sulfide (H2S) attack and requiring only the addition of water.

Cementitious nonshrink grout is available with both metallic and nonmetallic aggregate. Metallic aggregate grout shall be Master Builders Embeco 636, Burke Company Metallic Spec Grout, Sonnoborn Ferrolith G Redimix, or equal. Nonmetallic aggregate grout shall be Five Star Products, Inc. Five Star Grout, Master Builders Masterflow 713, Burke Company Non-Ferrous, Non-Shrink Grout, Hi-Flow Grout by Euclid Chemical Company, or equal.

Grout for areas where high groundwater conditions are not expected shall consist of one part Type V cement, one part of washed sand, and one part non-metallic non- shrink Type V grout, such as Masterflow 713 Grout by Master Builders, Five Star Grout by U.S. Grout Corporation with additives for protection against hydrogen sulfide (H2S) attack, or approved equal.

Grout for areas where high groundwater is expected and where directed by the Agency shall be full-strength Masterflow 713 Grout by Master Builders, Five Star Grout by U.S. Grout Corporation, or approved equal with additives for protection against hydrogen sulfide (H2S) attack.

1. GROUT FOR SEALING PIPE CONNECTIONS: Masterflow 713 Grout by Master Builders, Five Star Grout by U.S. Grout Corporation, or approved equal non-metallic, non-shrink Type V grout.

Cementitious nonshrink grouts shall exhibit no shrinkage at any time when tested in accordance with ASTM C827 and meet the requirements of ASTM C1107.

Non-shrink grout shall be a prepackaged, inorganic, non-gas-liberating, non- metallic, cement-based grout requiring only the addition of water. Manufacturer's instructions shall be printed on each bag or other container in which the materials are packaged. The specific formulation for each class of non-shrink grout indicated herein shall be that recommended by the manufacturer for the particular application.

Class A non-shrink grouts shall have a minimum 28 day compressive strength of 5000 psi; shall have no shrinkage (0.0 percent) and a maximum 4.0 percent expansion in the plastic state when tested in accordance with ASTM C 827; and shall have no shrinkage (0.0

GROUT DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03600-7 percent) and a maximum of 0.2 percent expansion in the hardened state when tested in accordance with CRD C 621.

Class B non-shrink grouts shall have a minimum 28 day compressive strength of 5000 psi and shall meet the requirements of CRD C 621.

a. APPLICATION: Class A non-shrink grout shall be used for the repair of all holes and defects in concrete members which are water bearing or in contact with soil or other fill material, grouting under all equipment base plates, and at all locations where grout is specified in the contract documents; except, for those applications for Class B non- shrink grout and epoxy grout indicated herein. Class A non-shrink grout may be used in place of Class B non-shrink grout for all applications.

Class B non-shrink grout shall be used for the repair of all holes and defects in concrete members which are not water-bearing and not in contact with soil or other fill material, grouting under all base plates for structural steel members, and grouting railing posts in place.

3. EPOXY GROUT: Epoxy grout shall be a pourable, non-shrink, 100 percent solids system. The epoxy grout system shall have three components: resin, hardener, and specially blended aggregate, all premeasured and prepackaged. The resin component shall not contain any non-reactive diluents. Resins containing butyl glycidyl ether (BGE) or other highly volatile and hazardous reactive diluents are not acceptable. Variation of component ratios is not permitted unless specifically recommended by the manufacturer. Manufacturer's instructions shall be printed on each container in which the materials are packaged.

The chemical formulation of the epoxy grout shall be that recommended by the manufacturer for the particular application.

The mixed epoxy grout system shall have a minimum working life of 45 minutes at 75 1 F.

The epoxy grout shall develop a compressive strength of 5000 psi in 24 hours and 10,000 psi in seven days when tested in accordance with ASTM C 579, Method B. There shall be no shrinkage (0.0 percent) and a maximum 4.0 percent expansion when tested in accordance with ASTM C 827.

The epoxy grout shall exhibit a minimum effective bearing area of 95 percent. This shall be determined by a test consisting of filling a 2-inch diameter by 4-inch high metal cylinder mold covered with a glass plate coated with a release agent. A weight shall be placed on the glass plate. At 24 hours after casting, the weight and plate shall be removed and the area in plan of all voids measured. The surface of the grout shall be probed with a sharp instrument to locate all voids.

The peak exotherm of a 2-inch diameter by 4-inch high cylinder shall not exceed 95 degrees F when tested with 75 degree F material at laboratory temperature. The epoxy grout

GROUT 03600-8 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 shall exhibit a maximum thermal coefficient of 30 x 10 -6 inches/inch/degree F when tested according to ASTM C 531 or ASTM D 696.

a. APPLICATION: Epoxy grout shall be used to embed all anchor bolts and reinforcing steel required to be set in grout, and for all other applications required in the Contract Documents.

D. EPOXY GROUT FOR EQUIPMENT MOUNTING:

Epoxy grout for equipment mounting shall be a non-cementitious, resin based, multi- component formulation. Epoxy grout shall be flowable, with shrinkage minimized to achieve minimum 98% effective bearing area. Acceptable products include Masterflow 648 CP Plus by Masterbuilders; Sikadur 42 by Sika Corporation; E3-G by Euclid Chemical Company; or equal.

E. EPOXY GROUT FOR CRACK REPAIR AND DOWEL ANCHORAGE:

Except as noted below, epoxy grout shall be a high modulus, two-component, moisture insensitive, 100 percent solids, thermosetting modified polyamid epoxy compound. The consistency shall be a paste form capable of not sagging in horizontal or overhead anchoring configurations. Material shall conform to ASTM C881, Type IV, Grade 3, and shall have a heat deflection temperature in excess of 130 degrees F. Candidate manufacturers include Master Builders Concresive Standard Paste or SPL, and Sika Corporation Sikadur Hi-Mod Series, or equal.

Epoxy for pressure grouting/crack injection shall be a two-component, moisture insensitive, high modulus, injection grade, 100 percent solids, blend of epoxy-resin compounds. The consistency shall be as required to achieve complete penetration in hairline cracks and larger. Material shall conform to ASTM C881, Type 1, Grade 1. Candidate manufacturers include Sika Corporation Sikadur 52, Master Builders SCB Concresive 1300 series, and Adhesive Technology Corporation SLV 300 series, or equal.

F. POLYMER CONCRETE (PROFILING MORTAR):

Polymer concrete (profiling mortar) for resurfacing or patching shall consist of a liquid binder and dry aggregate mixed together to make a mortar or grout of a consistency as required for the application. The liquid binder shall be a chemical and oil resistant, stress relieved, low modulus, moisture insensitive, two-component epoxy-resin compound. The consistency shall be similar to lightweight oil for proper mixing with aggregate. Material shall conform to ASTM C881, Type 3, Grade 1. Candidate manufacturers include Sika Corporation Sikadur Lo-Mod series, Master Builders Concresive 1490, and Adhesive Technology Corporation 400 series, or equal.

Alternatively, polymer concrete may be a one-component, shrinkage compensated, polymer-modified cement based mortar, with or without fiber reinforcement. Candidate manufacturers include Master Builders R300 series, or equal.

GROUT DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03600-9 The aggregate shall be oven dry in sealed packages until time of mixing, and shall be of size and consistency compatible with recommendations of manufacturer of liquid binder for intended application.

G. ADHESIVE FOR DOWEL AND ANCHOR SETTING:

Adhesive for setting dowels and anchoring connection/baseplate bolts may either be tube applied or capsule style. Adhesive shall evidence approval for the use intended by ICBO certification report or other recognized and Code compliant agency.

Tube-applied adhesive shall be a modified epoxy formulation. Acceptable products include HY150 Max by Hilti, SET Adhesive by Simpson Strong-Tie Company, or equal.

Adhesive resin capsules shall consist of sealed glass or foil capsules containing premeasured amounts of a polyester or vinylester resin, quartz sand aggregate and a hardener contained in a separate vial within the capsule. Acceptable adhesive capsule products include HVU by Hilti, Needle Capsule or Chem-Stud by Powers-Rawl, or equal. Capsule adhesives shall utilize the same manufacturer’s insert stud with chisel point, or Contractor shall demonstrate through submittal to the Engineer that the substitute proposed substantially meets or exceeds the geometric and material properties of same.

2.03 PRESSURE GROUTING EQUIPMENT

Pressure grouting equipment shall include a mixer and holdover agitator tanks and shall be designed to place grout at pressures up to 50 psi. Gages shall be provided to indicate pressure used. The mixer shall be provided with a meter capable of indicating to one-tenth of a cubic foot the volume of grout used.

2.04 TOPPING GROUT AND CONCRETE FILL

Grout for topping of slabs and concrete fill for built-up surfaces of tank, channel, and basin bottoms shall be composed of cement, fine aggregate, coarse aggregate, water, and admixtures proportioned and mixed as indicated herein. All materials and procedures specified for concrete in Section 03300 shall apply except as indicated otherwise herein.

Topping grout and concrete fill shall contain a minimum of 564 pound of cement per cubic yard with a maximum water cement ratio of 0.45. Where concrete fill is thicker than 3 inches, structural concrete as indicated in Section 03300 may be used when accepted by the CONSTRUCTION MANAGER.

GROUT 03600-10 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 Coarse aggregate shall be graded as follows:

U.S. Standard Percent by Sieve Size Weight Passing 1/2" 100 3/8" 90-100 No. 4 20-55 No. 8 5-30 No. 16 0-10 No. 30 0

Final mix design shall be as determined by trial mix design under supervision of the approved testing laboratory.

A. STRENGTH:

Minimum compressive strength of topping grout and concrete fill at the end of 28 days shall be 3000 psi.

2.05 CURING MATERIALS

Curing materials shall be as indicated in Section 03300 for cement grout and as recommended by the manufacturer of prepackaged grouts.

2.06 CONSISTENCY

The consistency of grouts shall be that necessary to completely fill the space to be grouted for the particular application. Dry pack consistency is such that the grout is plastic and moldable but will not flow. Where "dry pack" is called for in the Contract Documents, it shall mean a grout of that consistency; the type of grout to be used shall be as required for the particular application.

The slump for topping grout and concrete fill shall be adjusted to match placement and finishing conditions but shall not exceed 4 inches.

2.07 MEASUREMENT OF INGREDIENTS

Measurements for cement grout shall be made accurately by volume using containers. Shovel measurement shall not be allowed.

Prepackaged grouts shall have ingredients measured by means recommended by the manufacturer.

GROUT DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03600-11 2.08 PRODUCT DATA

The following information shall be provided in accordance with Section 01300.

A. MANUFACTURER'S DATA:

Manufacturer's data shall be provided for the following:

1. Bonding compounds 2. Pressure grout 3. Retardants 4. Polymer concrete

Products shall be of the following manufacture (or equal):

1. EPOXY GROUT: BurkEpoxy Anchoring Grout by the Burke Company

B. LABORATORY TEST REPORTS:

Test reports on previously tested materials shall be accompanied by the manufacturer’s statement that the previously tested material is the same type, quality, manufacture, and make as that proposed for use in this project. Test reports are required for the following:

1. Cement 2. Aggregates 3. Retardants 4. Bonding compounds 5. Epoxy resin

C. EVIDENCE OF TESTING LABORATORY COMPETENCE:

The Contractor shall require that the laboratory provide directly to the Construction Manager evidence of the most recent inspection of its facilities by the Cement and Concrete Reference Laboratory of the National Bureau of Standards. The evidences shall show that deficiencies mentioned in the report of that inspection have been corrected. The evidence of inspection shall be provided prior to delivery of materials to the job site.

PART 3--EXECUTION

3.01 GENERAL

Bonding compound for use with grout is specified in Section 03300. Primer, if required for polymer concrete, shall be provided per manufacturer's recommendation.

GROUT 03600-12 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014 All surface preparation, curing, and protection of cement grout shall be as specified in Section 03300. The finish of the grout surface shall match that of the adjacent concrete.

The manufacturer of Class A non-shrink grout and epoxy grout shall provide on-site technical assistance upon request.

Base concrete or masonry must have attained its design strength before grout is placed, unless authorized by the CONSTRUCTION MANAGER.

3.02 GROUTING PROCEDURES

A. PREPACKAGE GROUTS:

All mixing, surface preparation, handling, placing, consolidation, curing, and other means of execution for prepackaged grouts shall be done according to the instructions and recommendations of the manufacturer.

B. BASE PLATE GROUTING:

For base plates, the original concrete shall be blocked out or finished off a sufficient distance below the plate to provide for a minimum one-inch thickness of grout or a thickness as indicated.

After the base plate has been set in position at the proper elevation by steel wedges or double nuts on the anchor bolts, the space between the bottom of the plate and the original pour of concrete shall be filled with non-shrink-type grout. The mixture shall be of a trowelable consistency and tamped or rodded solidly into the space between the plate and the base concrete. A backing board or stop shall be provided at the back side of the space to be filled with grout. Where this method of placement is not practical or where required by the CONSTRUCTION MANAGER, alternate grouting methods shall be submitted for acceptance.

C. TOPPING GROUT:

All mechanical, electrical, and finish work shall be completed prior to placement of topping or concrete fill. The base slab shall be given a roughened textured surface by sandblasting or hydroblasting exposing the aggregates to ensure bonding to the base slab.

The minimum thickness of grout topping and concrete fill shall be one inch. Where the finished surface of concrete fill is to form an intersecting angle of less than 45 degrees with the concrete surface it is to be placed against, a key shall be formed in the concrete surface at the intersection point. The key shall be a minimum of 3-1/2-inches wide by 1-1/2-inches deep.

The base slab shall be thoroughly cleaned and wetted prior to placing topping and fill. No topping concrete shall be placed until the slab is complete free from standing pools or ponds of water. A thin coat of neat Type II cement grout shall be broomed into the surface of the slab just before topping of fill placement. The topping and fill shall be compacted by rolling or tamping,

GROUT DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03600-13 brought to established grade, and floated. Grouted fill for tank and basin bottoms where scraping mechanisms are to be installed shall be screeded by blades attached to the revolving mechanism of the equipment in accordance with the procedures outlined by the equipment manufacturer after the grout is brought to the established grade.

Topping grout placed on sloping slabs shall proceed uniformly from the bottom of the slab to the top, for the full width of the placement.

The surface shall be tested with a straight edge to detect high and low spots which shall be immediately eliminated. When the topping and fill has hardened sufficiently, it shall be steel troweled to a smooth surface free from pinholes and other imperfections. An approved type of mechanical trowel may be used as an assist in this operation, but the last pass over the surface shall be by hand-troweling. During finishing, no water, dry cement or mixture of dry cement and sand shall be applied to the surface.

3.03 DRYPACK GROUT

Drypack grout shall be used for small or shallow built-up surfaces and minor repairs.

Surfaces required to be built up with drypack grout shall be roughened by brushing, cleaned, and coated with the bonding compound specified in paragraph 03300-2.05 before the application of the grout. The drypack grout shall be applied immediately following the application of the bonding compound in bands or strips to form a covering of the required thickness. The covering shall be smooth. Construction joints in the grout shall be sloped and shall be cleaned and wetted before application is resumed.

Drypack grout shall be cured in accordance with Section 03300.

Grout shall not be placed during freezing weather unless adequate protection is provided.

3.04 CEMENTITIOUS NONSHRINK GROUT

Nonshrink, cementitious, nonmetallic aggregate grout shall be used for column base plates, structural bearing plates, and all locations where the general term “non-shrink grout” is indicated on the drawings. Use of this grout to support the bearing surfaces of machinery shall be as specified in Section 11002 or as detailed on the Drawings for specific locations or pieces of equipment. If guidance in not provided in locations noted above, use of non-shrink grout for equipment mounting shall be limited to equipment less than 20 horsepower or 1,000 pounds. Grout shall be placed and cured in accordance with manufacturer's instructions.

3.05 EPOXY GROUT FOR EQUIPMENT MOUNTING

Prepare concrete surfaces of equipment pads as indicated in details on the Drawings and as required by the epoxy grout manufacturer. Epoxy grout for equipment mounting shall be placed and cured in accordance with the requirements of Section 11002, details on the Drawings, and in strict conformance with manufacturer’s recommendations.

GROUT 03600-14 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014

3.06 EPOXY GROUT FOR CRACK REPAIR AND DOWEL ANCHORAGE

Epoxy grout shall be used for repairing cracks by pressure grouting or gravity flow, repairing structural concrete, and may be used for setting reinforcing dowels or anchor bolts into holes for grouting. Concrete shall be primed in accordance with the grout manufacturer's instructions.

Use of epoxy grout for anchorage of bolts or reinforcing dowels shall be subject to the following conditions:

1. Use shall be limited to locations where exposure, on an intermittent or continuous basis, to acid concentrations higher than 10 percent, to chlorine gas, or to machine or diesel oils, is extremely unlikely.

2. Use shall be limited to applications where exposure to fire or exposure to concrete or rod temperature above the product's heat deflection temperature or 120 degrees F (whichever is less) is extremely unlikely. Overhead applications (such as pipe supports) because of the above concerns, shall be disallowed.

3. Approval from Construction Manager for specific application and from supplier of equipment to be anchored, if applicable.

4. Anchor diameter and grade of steel shall be per contract documents or per equipment supplier specifications. Anchor shall be threaded or deformed full length of embedment and shall be free of rust, scale, grease, and oils.

5. Embedment depth and hole diameter shall be as specified.

6. Holes shall have rough surfaces, such as can be achieved using a rotary percussion drill.

7. Holes shall be blown clean with compressed air and be free of dust or standing water prior to application of grout.

8. Anchor shall be left undisturbed and unloaded for full curing period.

9. Anchors shall not be placed in concrete below 25 degrees F.

3.07 ADHESIVE CAPSULES

Adhesive resin capsules may be used for setting and anchoring reinforcing dowels or anchor bolts into predrilled holes in concrete. Use of the adhesive resin capsules for anchorage of reinforcing dowels or bolts shall be as specified in paragraph 05501-3.03.

GROUT DECEMBER 2014 PWS CONTRACT NO. 13-40UTIL 03600-15 3.08 PRESSURE GROUTING

Prior to grouting, systems and holes to be grouted shall be washed clean. Washing is not required for grouting soil voids outside pipe cylinders or casing pipes. Grouting, once commenced, shall be completed without stoppage. In case of breakdown of equipment, the Contractor shall wash out the grouting system sufficiently to ensure fresh grout and adequate bond and penetration will occur upon restarting the grouting operation. Grout pressure shall be maintained until grout has set.

3.09 CONSOLIDATION

Grout shall be placed in such a manner, for the consistency necessary for each application, so as to assure that the space to be grouted is completely filled.

** END OF SECTION **

GROUT 03600-16 PWS CONTRACT NO. 13-40UTIL DECEMBER 2014