Section 031000 - Concrete Formwork
PART 1 GENERAL
1.01 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to work of this Section.
1.02 SUMMARY
A. Section includes concrete formwork, shoring and accessories as shown on the drawings and as herein specified, for the following:
1. Footings. 2. Foundation walls. 3. Slabs-on-grade. 4. Elevated slabs. 5. Concrete toppings. 6. Building frame members. 7. Building walls. 8. Concrete sidewalks. 9. Entrance slabs. 10. Miscellaneous items requiring forms. B. Related Sections:
1. Section 0133000 – Submittal Procedures 2. Section 032000 – Concrete Reinforcement 3. Section 033000 – Cast-In-Place Concrete 4. Division 05 – Metals 5. Division 23 – Mechanical 6. Division 26 – Electrical C. Reference to Standards:
1. ACI 117-10 – Specification for Tolerances for Concrete Construction and Materials. 2. ACI 301-10 – Specifications for Structural Concrete. 3. ASTM D4397 – Standard Specification for Polyethylene Sheeting for Construction, Industrial, and Agricultural Applications. 4. ASTM E1643 – Standard Practice for Selection, Design, Installation, and Inspection of Water Vapor Retarders Used in Contact with Earth or Granular Fill Under Concrete Slabs. 5. COE CRD-C 572 – Specification for Polyvinyl Chloride Waterstop.
031000 – Concrete Formwork 031000-1 1.03 DEFINITIONS
A. (RESERVED)
1.04 SUBMITTALS
A. Submit under the provisions of Division 1 - Section 013300 – Submittal Procedures.
B. Product Data: For each type of product indicated.
C. Formwork shop drawings: Prepared by or under the supervision of a licensed professional engineer detailing fabrication, assembly, and support of formwork.
1. Shoring and Reshoring: Indicate proposed schedule and sequence of stripping formwork, shoring removal, and reshoring installation and removal.
D. Construction Joint Layout: Indicate proposed construction joints required to construct the structures if different than that shown on plans.
1. Location of construction joints is subject to approval of the Engineer. E. Samples: For all waterstops to be used, vapor retarder. F. Qualification Data: For installer and manufacturer of forms.
1.05 QUALITY ASSURANCE A. Construct and erect concrete formwork in accordance with ACI 301.
1.06 DELIVERY, STORAGE AND HANDLING A. Deliver form materials in manufacturer's packaging with installation instructions. B. Store off ground in ventilated and protected area to prevent deterioration from moisture or damage.
C. Waterstops: Store waterstops under cover to protect from moisture, sunlight, dirt, oil, and other contaminants.
1.07 SYSTEM DESCRIPTION
A. Design and construct formwork, shoring and bracing such that resultant concrete conforms to shapes, lines and dimensions shown in the contract documents.
PART 2 PRODUCTS
1.08 FORM-FACING MATERIALS A. Smooth-Formed Finished Concrete: Form-facing panels that will provide continuous, true, and smooth concrete surfaces. Furnish in largest practicable sizes to minimize number of joints in formwork.
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1. Plywood, metal, or other approved panel materials. 2. Exterior-grade plywood panels, suitable for concrete forms, complying with DOC PS 1, and as follows:
a. Structural 1, B-B or better; mill oiled and edge sealed.
B. Rough-Formed Finished Concrete: Plywood, lumber, metal, or another approved material. Provide lumber dressed on at least two edges and one side for tight fit.
C. Forms for Cylindrical Columns, Pedestals, and Supports: Metal, glass-fiber-reinforced plastic, paper, or fiber tubes that will produce surfaces with gradual or abrupt irregularities not exceeding specified formwork surface class. Provide units with sufficient wall thickness to resist plastic concrete loads without detrimental deformation.
D. Pan-Type Forms: Glass-fiber-reinforced plastic or formed steel, stiffened to resist plastic concrete loads without detrimental deformation.
E. Chamfer Strips: Wood, metal, PVC, or rubber strips, 3/4 by 3/4 inch, minimum. F. Rustication Strips: Wood, metal, PVC, or rubber strips, kerfed for ease of form removal.
1.09 FORM RELEASE AGENT A. Commercially formulated form-release agent that will not bond with, stain, or adversely affect concrete surfaces and will not impair subsequent treatments of concrete surfaces.
B. Contractor shall verify compatibility of form release agent selected with coating specified here-in.
C. Formulate form-release agent with rust inhibitor for steel form-facing materials. D. Products: Subject to compliance with requirements, provide one of the products specified.
1. Dayton Superior Conctruction Chemicals - Magic Kote 2. Lambert Corporation – Form Release Gold 3. Euclid Chemical Co. – Formshield Pure 4. Or Engineer approved equal.
1.10 FORM TIES
A. Factory-fabricated, removable or snap-off metal or glass-fiber-reinforced plastic form ties designed to resist lateral pressure of fresh concrete on forms and to prevent spalling of concrete on removal.
B. Furnish units that will leave no corrodible metal closer than 1 inch to the plane of exposed concrete surface.
C. Furnish ties that, when removed, will leave holes no larger than 1 inch in diameter in concrete surface.
D. Ties shall be removed after forms are removed and holes shall then be filled with mortar that matches adjacent surface.
031000 – Concrete Formwork 031000-3 E. Provide stainless steel form ties for exterior surfaces exposed to view.
F. Furnish ties with integral water-barrier plates to walls indicated to receive dampproofing or waterproofing.
1.11 WATERSTOPS (RESERVED)
1.12 VAPOR RETARDERS (RESERVED)
1.13 METAL FORMS
A. Centering shall be as manufactured by U.S. Steel Deck; Wheeling Corrugating Co.; Vulcraft or Engineer approved equal. Metal forms shall be minimum 9/16" deep, 26 gauge galvanized. Metal forms shall be installed in strict accordance with manufacturer's directions and specifications.
B. Metal forms shall be capable of safely supporting dead and live loads as shown on drawings.
1.14 ANCHORS AND DOVETAIL ANCHOR SLOTS (RESERVED)
PART 3 EXECUTION
1.15 INSPECTION A. Verify lines, levels and measurements before proceeding with formwork.
1.16 FORMWORK A. Design, erect, shore, brace, and maintain formwork, according to ACI 301, to support vertical, lateral, static and dynamic loads, and construction loads that might be applied, until structure can support such loads. Load supporting formwork shall remain in place until concrete has reached 75% of specified minimum 28-day compressive strength.
B. Construct formwork so concrete members and structures are of size, shape, alignment, elevation, and position indicated, within tolerance limits of ACI 117.
C. Concrete surfaces exposed to view shall conform to Surface Finish 3.0. All other as-cast finishes shall conform to Surface Finish-2.0 as specified in ACI 301.
D. Construct forms tight enough to prevent loss of concrete mortar.
E. Fabricate forms for easy removal without hammering or prying against concrete surfaces. Provide crush or wrecking plates where stripping may damage cast concrete surfaces. Provide top forms for inclined surfaces steeper than 1.5 horizontal to 1 vertical. 1. Install keyway, reglet, recesses, formwork, and the like, for easy removal. 2. Do not use rust-stained steel form-facing material. F. Set edge forms, bulkheads, and intermediate screed strips for slabs to achieve required elevations and slopes in finished concrete surfaces. Provide and secure units to support screed strips; use strike-off templates or compacting-type screeds.
031000 – Concrete Formwork 031000-4 G. Chamfer exterior corners and edges of beams, joists, and columns. Chamfer exterior corners and edges of permanently exposed concrete as indicated on drawings.
H. Form openings, chases, offsets, sinkages, keyways, reglets, blocking, screeds, and bulkheads required in the Work. Determine sizes and locations from trades providing such items.
I. Clean forms and adjacent surfaces to receive concrete. Remove chips, wood, sawdust, dirt, and other debris just before placing concrete.
J. Retighten forms and bracing before placing concrete, as required, to prevent mortar leaks and maintain proper alignment.
K. Coat contact surfaces of forms with form-release agent, according to manufacturer's written instructions, before placing reinforcement, anchoring devices and embedded items. Do not apply form release agent where concrete surfaces are scheduled to receive special finishes, which may be affected by agent. Soak contact surfaces of untreated forms with clean water. Keep surfaces wet prior to placing concrete.
L. Earth forms, except for footings, not permitted. M. Minimize form joints. Symmetrically align joints. N. Provide temporary ports in formwork to facilitate cleaning and inspection. Locate openings at bottom of forms to allow flushing water to drain. Close ports with tight fitting panels, flush with inside face of forms, neatly fitted so that joints will not be apparent in exposed concrete surfaces.
O. Steel centering shall be placed with corrugation edges up and with corrugations perpendicular to supports. Sheets shall be placed end to end along one side of building. Adjacent rows are to be placed in like manner, side lapping one corrugation with previously placed row. End laps shall always occur over supporting joists, beams or purlins and should be centered over support. Minimum end lap is 2" for welded attachment. Bottom sheet shall not extend beyond edge at support flange. Sheets shall be attached to supports by plug welding through curved washers to supporting top chords. Centering attached by welding shall have following minimum welding requirements:
1. End Laps - each lap is to be fastened using a weld washer at each side lap plus one intermediate weld (3 welds per sheet). 2. Intermediate Supports - weld sheet at side laps at each intermediate support plus one intermediate weld (3 welds per sheet). 3. Spacing between deck attachments to top chord shall not exceed 36".
1.17 INSERTS, EMBEDDED PARTS AND OPENINGS
A. Provide formed openings where required for work embedded in or passing through concrete.
B. Coordinate work of other sections in forming and setting openings, slots, recesses, chases, sleeves, bolts, anchors and other inserts.
C. Install accessories in accordance with manufacturer's instructions, level and plumb. Ensure items are not disturbed during concrete placement.
031000 – Concrete Formwork 031000-5 D. Place and secure anchorage devices and other embedded items required for adjoining work that is attached to or supported by cast-in-place concrete. Use setting drawings, templates, diagrams, instructions, and directions furnished with items to be embedded.
1.18 REMOVING AND REUSING FORMS
A. General: Formwork for sides of beams, walls, columns, and similar parts of the Work that does not support weight of concrete may be removed after cumulatively curing at not less than 50 deg F for 24 hours after placing concrete. Concrete has to be hard enough to not be damaged by form-removal operations and curing and protection operations need to be maintained.
1. Leave formwork for beam soffits, joists, slabs, and other structural elements that supports weight of concrete in place until concrete has achieved at least 75 percent of its 28-day design compressive strength. 2. Remove forms only if shores have been arranged to permit removal of forms without loosening or disturbing shores.
B. Clean and repair surfaces of forms to be reused in the Work. Split, frayed, delaminated, or otherwise damaged form-facing material will not be acceptable for exposed surfaces. Apply new form-release agent.
C. When forms are reused, clean surfaces, remove fins and laitance, and tighten to close joints. Align and secure joints to avoid offsets. Do not use patched forms for exposed concrete surfaces unless approved by Engineer.
D. During cold weather, remove ice and snow from forms. Do not use deicing salts. Do not use water to clean out completed forms, unless formwork and construction proceed within heated enclosure. Use compressed air to remove foreign matter.
1.19 SHORES AND RESHORES A. Comply with ACI 301 for design, installation, and removal of shoring and reshoring.
1. Do not remove shoring or reshoring until measurement of slab tolerances is complete. B. In multistory construction, extend shoring or reshoring over a sufficient number of stories to distribute loads in such a manner that no floor or member will be excessively loaded or will induce tensile stress in concrete members without sufficient steel reinforcement. C. Plan sequence of removal of shores and reshore to avoid damage to concrete. Locate and provide adequate reshoring to support construction without excessive stress or deflection.
1.20 VAPOR RETARDERS
A. Sheet Vapor Retarders: Place, protect, and repair sheet vapor retarder according to ASTM E 1643 and manufacturer's written instructions.
1.21 JOINTS A. General: Construct joints true to line with faces perpendicular to surface plane of concrete.
031000 – Concrete Formwork 031000-6 B. Construction Joints: Install so strength and appearance of concrete are not impaired, at locations indicated or as approved by Engineer.
1. Place joints perpendicular to main reinforcement. Continue reinforcement across construction joints unless otherwise indicated. Do not continue reinforcement through sides of strip placements of floors and slabs. 2. Form keyed joints as indicated. Embed keys at least 2 inches into concrete. 3. Unless indicated differently on the Drawings, locate joints for beams, slabs, joists, and girders in the middle third of spans. Offset joints in girders a minimum distance of twice the beam width from a beam-girder intersection. 4. Unless indicated differently on the Drawings, locate horizontal joints in walls and columns at underside of floors, slabs, beams, and girders and at the top of footings or floor slabs. 5. Space vertical joints in walls such that the ratio of the dimensions of the pour does not exceed 2:1, or as indicated on the Drawings. Locate joints beside piers integral with walls, near corners, and in concealed locations where possible.
C. Contraction Joints in Slabs-on-Grade: Form weakened-plane contraction joints, sectioning concrete into areas with a ratio of plan dimensions not greater than 2:1, or as indicated on the Drawings. Construct contraction joints for a depth equal to at least one-fourth of concrete thickness as follows:
1. Grooved Joints: Form contraction joints after initial floating by grooving and finishing each edge of joint to a radius of 1/8 inch. Repeat grooving of contraction joints after applying surface finishes. Eliminate groover tool marks on concrete surfaces. 2. Sawed Joints: Form contraction joints with power saws equipped with shatterproof abrasive or diamond-rimmed blades. Cut 1/8-inch-wide joints into concrete when cutting action will not tear, abrade, or otherwise damage surface and before concrete develops random contraction cracks.
D. Isolation Joints in Slabs-on-Grade: After removing formwork, install joint-filler strips at slab junctions with vertical surfaces, such as column pedestals, foundation walls, grade beams, and other locations, as indicated.
1. Extend joint-filler strips full width and depth of joint, terminating flush with finished concrete surface unless otherwise indicated. 2. Terminate full-width joint-filler strips not less than 1/2 inch or more than 1 inch below finished concrete surface where joint sealants, specified in Division 07 Section "Joint Sealants," are indicated. 3. Install joint-filler strips in lengths as long as practicable. Where more than one length is required, lace or clip sections together.
E. Doweled Joints: Install dowel bars and support assemblies at joints where indicated. Lubricate or asphalt coat one-half of dowel length to prevent concrete bonding to one side of joint.
1.22 WATERSTOPS (RESERVED)
END OF SECTION 031000
031000 – Concrete Formwork 031000-7 Section 032000 – Concrete Reinforcement
PART 1 - GENERAL
1.01 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to work of this Section.
B. Section includes reinforcing steel bars, welded wire fabric and accessories for cast-in-place concrete.
C. Related Sections
1. Section 013300 – Submittal Procedures. 2. Section 031000 – Concrete Formwork. 3. Section 033000 – Cast-in-Place Concrete. 4. Section 042000 – Unit Masonry. D. Reference to Standards
1. ACI 117-10 – Specifications for Tolerances for Concrete Construction and Materials. 2. ACI 301-10 – Specifications for Structural Concrete. 3. ACI 315-99 - Details and Detailing of Concrete Reinforcement. 4. ACI SP-66 - Detailing Manual. 5. ANSI/ASTM A82 – Standard Specification for Steel Wire, Plain, for Concrete Reinforcement. 6. ANSI/ASTM A185 – Standard Specification for Steel Welded Wire Reinforcement, Plain, for Concrete. 7. ASTM A615 – Standard Specification for Deformed and Plain Carbon Steel Bars for Concrete Reinforcement. 8. ASTM A706 – Standard Specification for Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement. 9. ASTM A775 – Standard Specification for Epoxy Coated Steel Reinforcing Bars. 10. ASTM A884 – Standard Specification for Epoxy Coated Steel Wire and Welded Wire Reinforcement. 11. ASTM C1116 – Standard Specification for Fiber Reinforced Concrete. 12. ASTM D3963 – Standard Specification for Fabrication and Jobsite Handling of Epoxy Coated Steel Reinforcing Bars. 13. AWS D1.4 – Structural Welding Code – Reinforcing Steel. 14. CRSI - Concrete Reinforcing Steel Institute - Manual of Standard Practice.
1.02 DEFINITIONS (RESERVED)
1.03 SUBMITTALS
A. Submit under the provisions of Division 1 - Section 013300 – Submittal Procedures. B. Steel Reinforcement Shop Drawings: Placing drawings that detail fabrication, bending, and placement. Include bar sizes, lengths, material, grade, bar schedules, stirrup spacing, bent bar
032000 Concrete Reinforcement 032000-1
diagrams, bar arrangement, splices and laps, mechanical connections, tie spacing, hoop spacing, and supports for concrete reinforcement.
C. Qualification Data: For installer and manufacturer of reinforcement.
D. Material Certificates: For each of the following, signed by manufacturers:
1. Steel reinforcement and accessories. 2. Fiber reinforcement.
E. Welder’s Certificates: Submit under provisions Division 1 – General Requirements, Manufacturer’s Certificates, certifying welders employed on the Work, verifying AWS qualifications within the previous 12 months.
1.04 QUALITY ASSURANCE
A. Perform Work in accordance with CRSI Manual of Standard Practice, ACI 117, ACI 301, and ACI 315.
B. Welding Qualifications: Qualify procedures and personnel according to AWS D1.4, "Structural Welding Code - Reinforcing Steel."
C. Maintain one copy of each document on site.
1.05 DELIVERY, STORAGE, AND HANDLING A. Steel Reinforcement: Deliver, store, and handle steel reinforcement to prevent bending and damage. Avoid damaging coatings on steel reinforcement.
1.06 COORDINATION A. Coordinate work under provisions of Division 1 – General Requirements. B. Coordinate with placement of formwork, formed openings and other Work.
PART 2 PRODUCTS
1.07 STEEL REINFORCEMENT
A. Recycled Content of Steel Products: Provide products with an average recycled content of steel products so postconsumer recycled content plus one-half of preconsumer recycled content is not less than 60 percent.
B. Reinforcing Bars: ASTM A 615, Grade 60, deformed.
C. Epoxy-Coated Reinforcing Bars: ASTM A 615, Grade 60, deformed bars, ASTM A 775, epoxy coated, with less than 2 percent damaged coating in each 12-inch bar length.
D. Plain-Steel Welded Wire Reinforcement: ASTM A 185, plain, fabricated from as-drawn steel wire into flat sheets.
E. Epoxy-Coated Welded Wire Reinforcement: ASTM A 884, Class A coated, Type 1, plain steel.
032000 Concrete Reinforcement 032000-2
1.08 REINFORCEMENT ACCESSORIES
A. Tie Wire: Minimum 16 gage annealed type.
B. Joint Dowel Bars: ASTM A 615, Grade 60, plain-steel bars, cut true to length with ends square and free of burrs.
C. Epoxy-Coated Joint Dowel Bars: ASTM A 615, Grade 60, plain-steel bars, ASTM A 775 epoxy coated.
D. Epoxy Repair Coating: Liquid, two-part, epoxy repair coating; compatible with epoxy coating on reinforcement and complying with ASTM D 3963.
E. Bar Supports: Bolsters, chairs, spacers, and other devices for spacing, supporting, and fastening reinforcing bars and welded wire reinforcement in place. Manufacture bar supports from steel wire, plastic, or precast concrete according to CRSI's "Manual of Standard Practice," of greater compressive strength than concrete and as follows:
1. For concrete surfaces exposed to view where legs of wire bar supports contact forms, use CRSI Class 1 plastic-protected steel wire or CRSI Class 2 stainless-steel bar supports. 2. For epoxy-coated reinforcement, use epoxy-coated or other dielectric-polymer-coated wire bar supports.
1.09 FABRICATION A. Fabricate concrete reinforcing in accordance with CRSI Manual of Standard Practice, ACI 117, and ACI 315.
B. Locate reinforcing splices not indicated on drawings at point of minimum stress.
1.10 FIBER REINFORCEMENT (RESERVED)
PART 3 EXECUTION
1.11 PLACEMENT
A. General: Comply with CRSI's "Manual of Standard Practice" for placing reinforcement.
1. Do not cut or puncture vapor retarder. Repair damage and reseal vapor retarder before placing concrete.
B. Clean reinforcement of loose rust and mill scale, earth, ice, and other foreign materials that would reduce bond to concrete.
C. Accurately position, support, and secure reinforcement against displacement. Reinforcement shall be tied at a minimum of 50 percent of the bar intersections. Locate and support reinforcement with bar supports to maintain minimum concrete cover. Do not tack weld crossing reinforcing bars.
D. Set wire ties with ends directed into concrete, not toward exposed concrete surfaces.
032000 Concrete Reinforcement 032000-3
E. Install welded wire reinforcement in longest practicable lengths on bar supports spaced to minimize sagging. Lap edges and ends of adjoining sheets at least one mesh spacing. Offset laps of adjoining sheet widths to prevent continuous laps in either direction. Lace overlaps with wire.
F. Epoxy-Coated Reinforcement: Repair cut and damaged epoxy coatings with epoxy repair coating according to ASTM D 3963. Use epoxy-coated steel wire ties to fasten epoxy-coated steel reinforcement.
G. Accommodate placement of formed openings.
H. Wall reinforcement shall not be placed in the work until one side of the wall forms has been erected, aligned and braced. As the wall reinforcement is placed, it shall be secured to the wall form with the proper clearance between the steel and forms.
I. Slab reinforcement shall be supported by manufactured steel bolsters only. Concrete half- bricks may be permitted only in slab on grade or footing construction.
J. Where walls or other items are shown as built integrally with other sections, but are placed as separate pours, keys and dowels shall be provided. Dowels shall be same size and at same spacing as reinforcing, unless noted otherwise.
K. Provide 4 x 4 - W 4.0 x W 4.0 electrically welded wire fabric, ASTM A185 reinforcing in all concrete slabs on ground unless shown otherwise.
L. Provide corner bars of same size and spacing as main reinforcement at all intersections and corners, unless noted otherwise.
M. Where openings occur in walls or slabs, and unless otherwise noted on the plans, provide two (2) #5 bars at all sides and extending at least 2 feet beyond corners and two (2) #5 bars at least 4 feet long diagonally across each re-entrant corner.
N. The Contractor shall give 24 hour notice to the Engineer for inspection of the reinforcing prior to the placement of the concrete.
O. The reinforcing for the concrete placement shall be completed and inspected before ordering concrete.
1.12 FIELD QUALITY CONTROL
A. Field inspection will be performed under provisions of Division 1 – General Requirements.
END OF SECTION 032000
032000 Concrete Reinforcement 032000-4
Section 033000 – Cast-In-Place Concrete
PART 1 GENERAL
1.01 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to work of this Section.
1.02 SUMMARY
A. Section Includes:
1. Cast-in-place concrete floors, foundation walls, supported slabs, beams and columns. 2. Floors and slabs on grade. 3. Control, expansion and contraction joint devices associated with concrete work, including joint sealants. 4. Equipment pads and manhole slabs. 5. Non-Shrink grout for concrete installation and/or repair.
B. Related Sections:
1. Section 02317 – Backfilling and Compacting 2. Section 031000 – Concrete Formwork 3. Section 032000 – Concrete Reinforcement 4. Section 033900 – Concrete Curing 5. Section 055000 – Metal Fabrications 6. Section 079200 – Joint Sealants 7. Section 260533– Conduit and Raceway: Electrical items for casting into concrete
C. Reference to Standards
1. ACI 117-10 – Specification for Tolerances for Concrete Construction and Materials. 2. ACI 301-10 – Specifications for Structural Concrete. 3. ACI 305.1-06 – Specification for Hot Weather Concreting. 4. ACI 306.1-02 – Standard Specification for Cold Weather Concreting. 5. ASTM C31 – Standard Practice for Making and Curing Concrete Test Specimens in the Field. 6. ASTM C33 – Standard Specification for Concrete Aggregates. 7. ASTM C39 – Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens. 8. ASTM C40 – Standard Test Method for Organic Impurities in Fine Aggregates for Concrete. 9. ASTM C42 – Standard Test Method of Obtaining and Testing Drilled Cores and Sawed Beams of Concrete. 10. ASTM C94 – Standard Specification for Ready Mixed Concrete. 11. ASTM C143 – Standard Test Method for Slump of Hydraulic Cement Concrete. 12. ASTM C150 – Standard Specification for Portland Cement.
033000 Cast-In-Place Concrete 033000-1
13. ASTM C157 – Standard Test Method for Length Change of Hardened Hydraulic- Cement Mortar and Concrete. 14. ASTM C172 – Standard Practice of Sampling Freshly Mixed Concrete. 15. ASTM C219 – Standard Terminology Relating to Hydraulic Cement. 16. ASTM C231 – Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method. 17. ASTM C260 – Standard Specification for Air Entraining Admixtures for Concrete. 18. ASTM C494 – Standard Specification for Chemical Admixtures for Concrete. 19. ASTM C618 – Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete. 20. ASTM C881 – Standard Specification for Epoxy Resin Base Bonding Systems for Concrete. 21. ASTM C989 – Standard Specification for Slag Cement for Use in Concrete and Mortars. 22. ASTM C1017 – Standard Specification for Chemical Admixtures for Use in Producing Flowing Concrete. 23. ASTM C1059 – Standard Specification for Latex Agents for Bonding Fresh To Hardened Concrete. 24. ASTM C1064 – Standard Test Method for Temperature of Freshly Mixed Hydraulic-Cement Concrete. 25. ASTM C1077 – Standard Practice for Agencies Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Testing Agency Evaluation. 26. ASTM C1116 – Standard Specification for Fiber Reinforced Concrete. 27. ASTM C1240 – Standard Specification for Silica Fume Used in Cementitious Mixtures. 28. ASTM D1751 – Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types). 29. ASTM D2240 – Standard Test Method for Rubber Property – Durometer Hardness. 30. ASTM E329 – Standard Specification for Agencies Engaged in Construction Inspection, Special Inspection, or Testing Materials Used in Construction. 31. ASTM E1155 – Standard Test Method for Determining FF Floor Flatness and FL Floor Levelness Numbers.
1.03 DEFINITIONS A. Cementitious Materials: Portland cement alone or in combination with one or more of the following: blended hydraulic cement, fly ash and other pozzolans, ground granulated blast- furnace slag, and silica fume; subject to compliance with project specifications.
1.04 SUBMITTALS A. Submit under the provisions of Division 1 - Section 013300 – Submittal Procedures. B. Product Data: Submit data on joint devices, attachment accessories, admixtures, form release agents and bonding agent.
C. Material Certifications: For each item listed, submit information indicated.
1. Coarse and Fine Aggregate
a. Producer Name.
033000 Cast-In-Place Concrete 033000-2
b. Quarry Location. c. Contact Person and Phone Number. d. Material Test Reports: From a qualified testing agency, indicating compliance with requirements.
2. Cement
a. Mill Test Report. b. Producer Name and Location.
3. Water
a. Specify Potable Water Source. D. Design Mixtures: For each concrete mixture. Submit alternate design mixtures when characteristics of materials, use of additional admixtures, Project conditions, weather, test results, or other circumstances warrant adjustments. Design Mixtures shall be reviewed according to the provisions of ACI 301.
1. Indicate amounts of mixing water to be withheld for later addition at Project site. E. Concrete Mix Properties:
1. Mix Design
a. Cementitious Materials (Lbs./C.Y.) b. Fine Aggregate (Lbs./C.Y.) c. Coarse Aggregate (Lbs./C.Y.) d. Water (Lbs./C.Y.) e. Admixtures.
2. Slump. 3. Air Content. F. Floor surface flatness and levelness measurements indicating compliance with specified tolerances. G. Field quality-control reports.
1.05 QUALITY ASSURANCE A. Perform work in accordance with ACI 301.
1. Maintain one copy of document on site. B. Installer Qualifications: A qualified installer who employs on Project personnel qualified as ACI-certified Flatwork Technician and Finisher and a supervisor who is an ACI-certified Concrete Flatwork Technician.
C. Manufacturer Qualifications: A firm experienced in manufacturing ready-mixed concrete products and that complies with ASTM C 94 requirements for production facilities and equipment.
033000 Cast-In-Place Concrete 033000-3
1. Manufacturer certified according to NRMCA's "Certification of Ready Mixed Concrete Production Facilities." 2. Engineer reserves the right to reject Manufacturer at any time and to require Contractor to obtain different supplier.
D. Testing Agency Qualifications: An independent agency, qualified according to ASTM C 1077 and ASTM E 329 for testing indicated. E. Source Limitations: Obtain each type or class of cementitious material of the same brand from the same manufacturer's plant, obtain aggregate from single source, and obtain admixtures from single source from single manufacturer.
F. Concrete Testing Service: Engage a qualified independent testing agency to perform material evaluation tests and to design concrete mixtures.
1.06 PROJECT RECORD DOCUMENTS A. Contractor shall accurately record actual locations of embedded utilities and components which are concealed from view.
1.07 COORDINATION A. Coordinate Work under provisions of Division 1 – General Requirements.
PART 2 PRODUCTS
2.01 CONCRETE MATERIALS A. Cementitious Material: Use the following cementitious materials, of the same type, brand, and source, throughout Project:
1. Portland Cement: ASTM C 150, Type I. Supplement with the following:
a. Fly Ash: ASTM C 618, Class F or C. b. Ground Granulated Blast-Furnace Slag: ASTM C 989, Grade 100 or 120. B. Silica Fume: ASTM C 1240, amorphous silica. C. Normal-Weight Aggregates: ASTM C 33, Class 3S coarse aggregate or better, graded. Provide aggregates from a single source.
1. Maximum size of coarse aggregate shall be in accordance with guidelines listed below:
033000 Cast-In-Place Concrete 033000-4
Max. Aggregate Size Type of Structure ½-inch Concrete Toppings and Concrete Repair Mud Slabs, Stairs and Steps, Columns, Beams, ¾-inch Elevated Slabs, Flowable Fill Grade Beams, Equipment Pads, Slabs on Grade, 1-inch Interior and Exterior Tank Walls, All Other Structures 1½-inch Caissons, Piles and Piers, Footings
D. Fine Aggregate: ASTM C 33, Free of materials with deleterious reactivity to alkali in cement. E. Water: ASTM C 94 and potable.
2.02 ADMIXTURES A. When required or permitted, admixtures shall conform to requirements specified below. Use of one or more admixtures in concrete shall be approved by Engineer prior to its use at job site. B. Air-Entraining Admixture: ASTM C 260. C. Chemical Admixtures: Provide admixtures certified by manufacturer to be compatible with other admixtures and that will not contribute water-soluble chloride ions exceeding those permitted in hardened concrete. Do not use calcium chloride or admixtures containing calcium chloride.
1. Water-Reducing Admixture: ASTM C 494, Type A. 2. Retarding Admixture: ASTM C 494, Type B. 3. Accelerating Admixture: ASTM C 494, Type C. 4. Water-Reducing and Retarding Admixture: ASTM C 494, Type D. 5. High-Range, Water-Reducing Admixture: ASTM C 494, Type F. 6. High-Range, Water-Reducing and Retarding Admixture: ASTM C 494, Type G. 7. Plasticizing and Retarding Admixture: ASTM C 1017, Type II. 8. Shrinkage Reducing Admixture: ASTM C 494, Type S; Maximum Length Change, tested in accordance with ASTM C 157, of 0.030%.
D. Field Service: When requested, the Contractor shall arrange to have a qualified concrete technician employed by manufacturer be available to assist in proportioning concrete materials for optimum use, to advise on proper use of admixture and adjustment of concrete mix proportions to meet job site and climatic conditions.
2.03 FLOOR AND SLAB TREATMENTS (RESERVED)
2.04 LIQUID FLOOR TREATMENTS (RESERVED)
2.05 RELATED MATERIALS A. Expansion- and Isolation-Joint-Filler Strips: ASTM D 1751, asphalt-saturated cellulosic fiber, ½-inch thick (unless shown otherwise). B. Semirigid Joint Filler: Two-component, semirigid, 100 percent solids, epoxy resin with a Type A shore durometer hardness of 80 per ASTM D 2240.
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C. Latex Bonding Agent: ASTM C 1059, Type II, non-redispersible, acrylic emulsion or styrene butadiene.
D. Epoxy Bonding Adhesive: ASTM C 881, two-component epoxy resin, capable of humid curing and bonding to damp surfaces, of class suitable for application temperature and of grade to suit requirements, and as follows:
1. Types IV and V, load bearing, for bonding hardened or freshly mixed concrete to hardened concrete. E. Sealant and Primer: As specified in Section 07920 – Joint Sealants.
2.06 REPAIR MATERIALS A. Repair Underlayment: Cement-based, polymer-modified, self-leveling product that can be applied in thicknesses from ⅛-inch and that can be feathered at edges to match adjacent floor elevations.
1. Cement Binder: ASTM C 150, portland cement or hydraulic or blended hydraulic cement as defined in ASTM C 219. 2. Primer: Product of underlayment manufacturer recommended for substrate, conditions, and application. 3. Aggregate: Well-graded, washed gravel, ⅛-inch to ¼-inch or coarse sand as recommended by underlayment manufacturer. 4. Compressive Strength: Not less than 4000 psi at 28 days when tested according to ASTM C 109. B. Repair Overlayment: Cement-based, polymer-modified, self-leveling product that can be applied in thicknesses from ¼-inch and that can be filled in over a scarified surface to match adjacent floor elevations.
1. Cement Binder: ASTM C 150, Portland Cement or hydraulic or blended hydraulic cement as defined in ASTM C 219. 2. Primer: Product of topping manufacturer recommended for substrate, conditions, and application. 3. Aggregate: Well-graded, washed gravel, ⅛-inch to ¼-inch or coarse sand as recommended by topping manufacturer. 4. Compressive Strength: Not less than 5000 psi at 28 days when tested according to ASTM C 109.
2.07 CONCRETE MIXTURES, GENERAL A. Prepare design mixtures for each type and strength of concrete, proportioned on the basis of laboratory trial mixture or field test data, or both, according to ACI 301.
1. Use a qualified independent testing agency for preparing and reporting proposed mixture designs based on laboratory trial mixtures. B. Cementitious Materials: Limit percentage, by weight, of cementitious materials other than portland cement in concrete as follows:
1. Fly Ash: 25 percent. 2. Combined Fly Ash and Pozzolan: 25 percent.
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3. Ground Granulated Blast-Furnace Slag: 50 percent. 4. Combined Fly Ash or Pozzolan and Ground Granulated Blast-Furnace Slag: 50 percent portland cement minimum, with fly ash or pozzolan not exceeding 25 percent. 5. Silica Fume: 10 percent. 6. Combined Fly Ash, Pozzolans, and Silica Fume: 35 percent with fly ash or pozzolans not exceeding 25 percent and silica fume not exceeding 10 percent. 7. Combined Fly Ash or Pozzolans, Ground Granulated Blast-Furnace Slag, and Silica Fume: 50 percent with fly ash or pozzolans not exceeding 25 percent and silica fume not exceeding 10 percent.
C. Limit water-soluble, chloride-ion content in hardened concrete to 0.30 percent by weight of cement.
D. Admixtures: Use admixtures according to manufacturer's written instructions.
1. Use water-reducing, high-range water-reducing, or plasticizing admixture in concrete, as required, for placement and workability. 2. Use water-reducing and retarding admixture when required by high temperatures, low humidity, or other adverse placement conditions. 3. Use water-reducing admixture in pumped concrete, concrete for heavy-use industrial slabs and parking structure slabs, concrete required to be watertight, and concrete with a water-cementitious materials ratio below 0.50. 4. Use corrosion-inhibiting admixture in concrete mixtures where indicated.
2.08 CONCRETE MIXTURES FOR BUILDING ELEMENTS B. Mix Design A: Proportion normal-weight concrete mixture for all parts of Work as follows: 1. Minimum Compressive Strength: 2500 psi at 7 days, 4000 psi at 28 days. 2. Maximum Water-Cementitious Materials Ratio: 0.45. 3. Slump: 4 inches; 8 inches for concrete with verified slump of 2 to 4-inches before adding high-range water-reducing admixture or plasticizing admixture. 4. Air Content:
Max. Aggregate Size Air Content (percent) ½-inch 7 ± 1.5 ¾-inch 6 ± 1.5 1 inch 6 ± 1.5 1½- inch 5.5 ± 1.5
a. Interior floor slabs located indoors not subjected to exposure conditions shall not contain entrained air.
2.09 CONCRETE MIXING B. Ready-Mixed Concrete: Measure, batch, mix, and deliver concrete according to ASTM C 94.
1. When air temperature is between 85 and 90 deg F, reduce mixing and delivery time from 1½ hours to 75 minutes; when air temperature is above 90 deg F, reduce mixing and delivery time to 60 minutes.
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2. In addition to batch ticket information required by ASTM C 94, the following shall be provided:
a. Concrete Design Strength. b. Type and amount of cement. c. Class and amount of coal fly ash, or raw or calcined natural pozzolans, if present. d. Class and amount of ground granulated blast furnace slag, if present. e. Type and amount of silica fume, if present. f. Type and amount of admixtures. g. Type and amount of fiber reinforcement, if present. h. Maximum size of aggregate. i. Amount of water added at job site shall be noted on ticket. No water is to be added at job site unless acceptable to Engineer.
3. One copy of delivery ticket shall be furnished to Engineer at time truck arrives at job site.
PART 3 EXECUTION
3.01 INSPECTION A. Verify site conditions under provisions of Division 1 - General Requirements. B. Verify requirements for concrete cover over reinforcement have been met. C. Verify that anchors, seats, plates, reinforcement and other items to be cast into concrete are accurately placed and positioned securely. D. Verify that installation of formwork, reinforcement, and embedded items is complete and that required inspections have been performed.
3.02 PREPARATION A. Prepare previously placed concrete by cleaning with steel brush and applying bonding agent in accordance with manufacturer's instructions.
B. In locations where new concrete is dowelled to existing work, drill holes in existing concrete, insert steel dowels and pack solid with non-shrink or epoxy grout, unless noted otherwise. C. Contractor shall inform Engineer 24 hours in advance of any concrete pours, indicating location and size of pour by submitting completed pre-pour checklist.
3.03 CONCRETE PLACEMENT A. Concrete shall be conveyed and placed in conformance with ACI 301. Contractor shall instruct laborers on proper vibration techniques required for each situation.
B. Before test sampling and placing concrete, water may be added at Project site, subject to limitations of ACI 301.
1. Do not add water to concrete after adding high-range water-reducing admixtures to mixture.
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C. Delivery of mixed concrete shall be regulated so that there will not be an interruption of more than 20-minutes duration in placement of concrete. Engineer may waive these requirements if slump and temperature requirements are met without adding water. D. At beginning of concrete placement, a spare vibrator shall be on job site in addition to vibrators to be used during placement. E. If electrical power for equipment used in the concrete placement is provided by a portable electric generator, an additional back-up portable electric generator or an alternate reliable electrical source shall be available prior to and during the concrete placement. F. Deposit concrete continuously in one layer or in horizontal layers of such thickness that no new concrete will be placed on concrete that has hardened enough to cause seams or planes of weakness. If a section cannot be placed continuously, provide construction joints in accordance with Contract Documents. Deposit concrete to avoid segregation.
1. Deposit concrete in horizontal layers of depth to not exceed formwork design pressures and in a manner to avoid inclined construction joints. Concrete placed in vertical forms shall be placed in lifts of not more than 2 feet which shall be kept practically level. 2. Chutes shall extend as nearly as practicable to point of deposit. Concrete shall not be dropped more than 6 feet. For walls or column placements in excess of 6 feet vertical height, tremie shall be used in placing concrete. If reinforcing steel or formwork is such that tremie cannot be used, method of placement shall be approved by Engineer. 3. Consolidate placed concrete with mechanical vibrating equipment according to ACI 301. 4. Do not use vibrators to transport concrete inside forms. Insert and withdraw vibrators vertically at uniformly spaced locations to rapidly penetrate placed layer and at least 6 inches into preceding layer. Do not insert vibrators into lower layers of concrete that have begun to lose plasticity. At each insertion, limit duration of vibration to time necessary to consolidate concrete and complete embedment of reinforcement and other embedded items without causing mixture constituents to segregate.
G. Deposit and consolidate concrete for floors and slabs in a continuous operation, within limits of construction joints, until placement of a panel or section is complete.
1. Consolidate concrete during placement operations so concrete is thoroughly worked around reinforcement and other embedded items and into corners. 2. Maintain reinforcement in position on chairs during concrete placement. 3. Screed slab surfaces with a straightedge and strike off to correct elevations. 4. Slope surfaces uniformly to drains where required. 5. Begin initial floating using bull floats or darbies to form a uniform and open- textured surface plane, before excess bleedwater appears on the surface. Do not further disturb slab surfaces before starting finishing operations. H. Pumping Concrete: Comply with ACI 301 and as follows.
1. Selection of pipe diameter for pumping shall be such that smallest inside diameter is no less than 4 inches or 3 times nominal maximum size coarse aggregate, whichever is greater.
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2. Pumping lines shall be lubricated with minimum of 1 cubic yard of grout prior to pumping regular mix through lines. 3. Contractor shall show sufficient evidence prior to use of pump that mix is pumpable. This shall be accomplished by submittal, in accordance with Specification Section 01330, of a certification from supplier that mix has performed satisfactorily on previous jobs of similar nature or by performing full scale field test for pumpability with line height and other variables being identical (or nearly so) to that of actual placing conditions. I. Cold-Weather Placement: Comply with ACI 306.1 and as follows. Protect concrete work from physical damage or reduced strength that could be caused by frost, freezing actions, or low temperatures. 1. When average high and low temperature is expected to fall below 40 deg. F for three successive days, maintain delivered concrete mixture temperature within the temperature range required by ACI 301. 2. Do not use frozen materials or materials containing ice or snow. Do not place concrete on frozen subgrade or on subgrade containing frozen materials. 3. Do not use calcium chloride, salt, or other materials containing antifreeze agents or chemical accelerators unless otherwise specified and approved in mixture designs. J. Hot-Weather Placement: Comply with ACI 305.1 and as follows:
1. Maintain concrete temperature below 90 deg. F at time of placement. Chilled mixing water or chopped ice may be used to control temperature, provided water equivalent of ice is calculated to total amount of mixing water. Using liquid nitrogen to cool concrete is Contractor's option. 2. Fog-spray forms, steel reinforcement, and subgrade just before placing concrete. Keep subgrade uniformly moist without standing water, soft spots, or dry areas.
3.04 FINISHING FORMED SURFACES A. Defects in new concrete such as rock pockets and tie holes shall be repaired when forms are removed. Grout used for repair shall contain a bonding admixture conforming to ASTM C1059, Type II. Use admixture according to manufacturer's written instructions. This shall be done for all surface finishes of formed concrete surfaces.
1. Snap-off form ties shall be removed to a point 1-inch beneath surface of concrete and resulting depression shall be carefully pointed with grout. 2. Removable form tie holes shall be plugged with X-Plug by Greenstreak, or Engineer approved equal, and packed with grout. B. Rough-Formed Finish: As-cast concrete texture imparted by form-facing material with tie holes and defects repaired and patched.
1. Apply to concrete surfaces to be covered by earth fill. C. Smooth-Formed Finish: As-cast concrete texture imparted by form-facing material, arranged in an orderly and symmetrical manner with a minimum of seams. Repair and patch tie holes and defects. Remove fins and other projections that exceed specified limits on formed- surface irregularities.
1. Apply to exposed concrete surfaces and submerged surfaces.
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D. Scrubbed Finish: Apply the following to smooth-formed finished as-cast concrete surfaces indicated on plans:
1. Wet down the entire area and fill all air pockets, voids and other depressions with grout to produce a smooth dense surface free from pits and other irregularities. Thoroughly scrub into the wetted surface a mortar mixture consisting of 1 part well graded sand passing the No. 30 sieve, 1 part portland cement and a sufficient quantity of a bonding admixture (described previously) to produce a workable mixture. Scrubbing shall be accomplished by use of a rubber or wood float following by finishing with a cork float or a light brush. The resulting surface shall be true and uniform, with no discernible thickness of mortar on the surface. 2. Finish shall extend a minimum of one foot below final grade. E. Related Unformed Surfaces: At tops of walls, horizontal offsets, and similar unformed surfaces adjacent to formed surfaces, strike off smooth and finish with a texture matching adjacent formed surfaces. Continue final surface treatment of formed surfaces uniformly across adjacent unformed surfaces unless otherwise indicated.
F. Edges and corners of structures, which are exposed in the completed structures, shall be chamfered ¾-inch, unless noted otherwise.
3.05 FINISHING FLOORS AND SLABS A. General: Comply with ACI 301 recommendations for screeding, restraightening, and finishing operations for concrete surfaces. Do not wet concrete surfaces. B. Scratch Finish: While still plastic, texture concrete surface that has been screeded and bull- floated or darbied. Use stiff brushes, brooms, or rakes to produce a profile amplitude of ¼- inch in one direction. C. Apply scratch finish to surfaces to be covered with fill material and surfaces to receive concrete toppings. D. Float Finish: Consolidate surface with power-driven floats or by hand floating if area is small or inaccessible to power driven floats. Restraighten, cut down high spots, and fill low spots. Repeat float passes and restraightening until surface is left with a uniform, smooth, granular texture.
1. Apply float finish to surfaces to receive trowel finish and to be covered with built-up or membrane roofing.
E. Trowel Finish: After applying float finish, apply first troweling and consolidate concrete by hand or power-driven trowel. Continue troweling passes and restraighten until surface is free of trowel marks and uniform in texture and appearance. Grind smooth any surface defects that would telegraph through applied coatings or floor coverings.
1. Apply a trowel finish to surfaces exposed to view and to clarifier floor grout. F. Broom Finish: In lieu of final troweling, apply a broom finish to exterior concrete slabs, sidewalks, platforms, steps, ramps, and elsewhere as indicated.
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1. Immediately after float finishing, slightly roughen trafficked surface by brooming with fiber-bristle broom perpendicular to main traffic route. Coordinate required final finish with Engineer before application. G. Edges and corners of structures, which are exposed in the completed structures, shall be chamfered ¾-inch, unless noted otherwise. Edges of walks and slabs on grade shall be finished with an edging tool. H. Walks and slabs on grade shall have contraction joints scored in the concrete to control cracking. The spacing of the scored joints shall be equal to the width of the walk or slab unless otherwise specified or noted on the plans.
3.06 MISCELLANEOUS CONCRETE ITEMS A. Filling In: Fill in holes and openings left in concrete structures after work of other trades is in place unless otherwise indicated. Mix, place, and cure concrete, as specified, to blend with in-place construction. Provide other miscellaneous concrete filling indicated or required to complete the Work. B. Equipment Bases and Foundations: Provide machine and equipment bases and foundations as shown on Drawings. Set anchor bolts for machines and equipment at correct elevations, complying with diagrams or templates from manufacturer furnishing machines and equipment.
C. Steel Pan Stairs: Provide concrete fill for steel pan stair treads, landings, and associated items. Cast-in inserts and accessories as shown on Drawings. Screed, tamp, and trowel finish concrete surfaces.
3.07 SCHEDULE - JOINT FILLERS Sealants: As specified in 079200 – Joint Sealants.
3.08 CONCRETE SURFACE REPAIRS A. Defective Concrete: Repair and patch defective areas when directed by Engineer. Remove and replace concrete that cannot be repaired and patched to Engineer's approval.
B. Patching Mortar: Mix dry-pack patching mortar, consisting of one part portland cement to two and one-half parts fine aggregate passing a No. 16 sieve, using only enough water and/or bonding agent for handling and placing. C. Repairing Formed Surfaces: Surface defects include color and texture irregularities, cracks, spalls, air bubbles, honeycombs, rock pockets, fins and other projections on the surface, and stains and other discolorations that cannot be removed by cleaning.
1. Immediately after form removal, cut out honeycombs, rock pockets, and voids more than ½-inch in any dimension to solid concrete. Limit cut depth to ¾-inch. Make edges of cuts perpendicular to concrete surface. Clean, dampen with water, and brush-coat holes and voids with bonding agent. Fill and compact with patching mortar before bonding agent has dried. Fill form-tie voids with patching mortar or cone plugs secured in place with bonding agent. 2. Repair defects on surfaces exposed to view by blending white portland cement and standard portland cement so that, when dry, patching mortar will match surrounding
033000 Cast-In-Place Concrete 033000-12
color. Patch a test area at inconspicuous locations to verify mixture and color match before proceeding with patching. Compact mortar in place and strike off slightly higher than surrounding surface. 3. Repair defects on concealed formed surfaces that affect concrete's durability and structural performance as determined by Engineer. D. Repairing Unformed Surfaces: Test unformed surfaces, such as floors and slabs, for finish and verify surface tolerances specified for each surface. Correct low and high areas. Test surfaces sloped to drain for trueness of slope and smoothness; use a sloped template.
1. Repair finished surfaces containing defects. Surface defects include spalls, popouts, honeycombs, rock pockets, crazing and cracks in excess of 0.01-inch wide or that penetrate to reinforcement or completely through unreinforced sections regardless of width, and other objectionable conditions. 2. After concrete has cured at least 14 days, correct high areas by grinding. 3. Correct localized low areas during or immediately after completing surface finishing operations by cutting out low areas and replacing with patching mortar. Finish repaired areas to blend into adjacent concrete. 4. Repair defective areas, except random cracks and single holes 1 inch or less in diameter, by cutting out and replacing with fresh concrete. Remove defective areas with clean, square cuts and expose steel reinforcement with at least a ¾-inch clearance all around. Dampen concrete surfaces in contact with patching concrete and apply bonding agent. Mix patching concrete of same materials and mixture as original concrete except without coarse aggregate. Place, compact, and finish to blend with adjacent finished concrete. Cure in same manner as adjacent concrete. 5. Repair random cracks and single holes 1-inch or less in diameter with patching mortar. Groove top of cracks and cut out holes to sound concrete and clean off dust, dirt, and loose particles. Dampen cleaned concrete surfaces and apply bonding agent. Place patching mortar before bonding agent has dried. Compact patching mortar and finish to match adjacent concrete. Keep patched area continuously moist for at least 72 hours. E. Perform structural repairs of concrete, subject to Engineer's approval, using epoxy adhesive and patching mortar. F. Repair materials and installation not specified above may be used, subject to Engineer's approval.
3.09 PLANT QUALITY CONTROL A. Sufficient testing shall be done by the supplier to assure the quality and consistency of the mix produced. The field tests are not to be used as a gauge of this quality.
3.10 FIELD QUALITY CONTROL A. Provide under provisions of Division 1 - General Requirements. B. Concrete Tests: Testing of composite samples of fresh concrete obtained according to ASTM C 172 shall be performed according to the following requirements: 1. Testing Frequency: Obtain one composite sample for each day's pour of each concrete mixture exceeding 5 cu. yd., but less than 25 cu. yd., plus one set for each additional 50 cu. yd. or fraction thereof.
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a. When frequency of testing will provide fewer than five compressive- strength tests for each concrete mixture, testing shall be conducted from at least five randomly selected batches or from each batch if fewer than five are used. 2. Slump: ASTM C 143; one test at point of delivery for each composite sample, but not less than one test for each day's pour of each concrete mixture. Perform additional tests when concrete consistency appears to change. 3. Air Content: ASTM C 231, pressure method, for normal-weight concrete; one test for each composite sample, but not less than one test for each day's pour of each concrete mixture. 4. Concrete Temperature: ASTM C 1064; one test hourly when air temperature is 40 deg. F and below and when 80 deg. F and above, and one test for each composite sample. 5. Compression Test Specimens: ASTM C 31.
a. Cast and laboratory cure one set of four standard cylinder specimens for each composite sample. b. Where the Contractor intends to remove load supporting forms (when conditions permit), cast and field cure one set of four standard cylinder specimens for each composite sample. Field curing shall continue up to within four hours prior to laboratory testing. The Contractor shall be responsible for the safe field storage of the concrete cylinders during the field curing process.
6. Compressive-Strength Tests: ASTM C 39; test one laboratory-cured specimen at 7 days and two specimens at 28 days. The fourth cylinder shall be held for testing as a check cylinder.
a. A 28 day compressive-strength test shall be the average compressive strength of two specimens obtained from same composite sample.
7. Test results shall be submitted in writing to Engineer, concrete manufacturer, and Contractor within 48 hours of testing. Reports of compressive-strength tests shall contain:
a. Project identification name and number b. Name of concrete testing and inspecting agency c. Date of concrete placement d. Date of compressive strength test e. Location of concrete batch in Work f. Design compressive strength at 28 days g. Mix design designation h. Slump of concrete i. Temperature of concrete at placement j. Percent air entrained k. Number of specimens tested l. Compressive breaking strength m. Type of break for both 7- and 28-day tests
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8. Strength of each concrete mixture will be satisfactory if every average of any three consecutive compressive-strength tests equals or exceeds specified compressive strength and no compressive-strength test value falls below specified compressive strength by more than 500 psi.
9. Additional Tests: Testing and inspecting agency shall make additional tests of concrete when test results indicate that slump, air entrainment, compressive strengths, or other requirements have not been met, as directed by Engineer. a. If compressive strength requirements are not met, steps shall be taken to increase average of subsequent strength test results. Engineer shall have right to order a change in proportions of mix for remaining work. Engineer shall also have right to require conditions of temperature and moisture necessary to secure required strength. b. If any strength test of laboratory-cured cylinders falls below specified compressive strength by more than 500 psi or if tests of field-cured cylinders indicate deficiencies in protection or curing, steps shall be taken to assure that the load-carrying capacity of structure is not jeopardized. c. If likelihood of low-strength concrete is confirmed and computations indicate that load-carrying capacity may have been significantly reduced, tests of cores drilled from area in question may be required in accordance with ASTM C 42. In such cases, three cores shall be taken for each strength test more than 500 psi below specified compressive strength. If concrete in structure will be dry under service condition, cores shall be air dried (temperature 60° to 80° F., relative humidity less than 60%) for 7 days before test and shall be tested dry. If concrete in structure will be more than superficially wet under service conditions, cores shall be immersed in water for at least 40 hours and be tested wet. d. Concrete in an area represented by core tests shall be considered structurally adequate if average of three cores is equal to at least 85% of specified compressive strength and if no single core is less than 75% of specified compressive strength. To check testing accuracy, locations represented by erratic core strengths may be retested. e. If criteria of paragraph (d) are not met, and if structural adequacy remains in doubt, the Engineer may order load tests as outlined in ACI 318 for questionable portion of structure or require other appropriate action. f. All costs associated with performing analytical investigations, core testing and load testing shall be paid for by Contractor.
10. Nondestructive Testing: Impact hammer, sonoscope, or other nondestructive device may be permitted by Engineer but will not be used as sole basis for approval or rejection of concrete. 11. Additional testing and inspecting, at Contractor's expense, will be performed to determine compliance of replaced or additional work with specified requirements. 12. Correct deficiencies in the Work that test reports and inspections indicate do not comply with the Contract Documents. C. Measure floor and slab flatness and levelness according to ASTM E 1155 within 48 hours of finishing. 3.11 WATERTIGHTNESS (RESERVED)
END OF SECTION 033000
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Section 033900 - Concrete Curing
PART 1 GENERAL
1.01 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to work of this Section.
1.02 SUMMARY
A. Section includes initial and final curing, sealing of vertical foundation wall surfaces and exterior concrete flat work and curing, sealing and dust proofing of interior concrete floor slab surfaces.
B. Related Sections:
1. Section 013300 – Submittal Procedures 2. Section 033000 - Cast-In-Place Concrete C. Reference to standards
1. AASHTO M182 – Standard Specification for Burlap Cloth Made from Jute or Kenaf and Cotton Mats. 2. ACI 301-10 – Specifications for Structural Concrete. 3. ACI 305.1-06 – Specification for Hot Weather Concreting. 4. ACI 306.1-02 – Standard Specification for Cold Weather Concreting. 5. ACI 308.1-11 – Standard Specification for Curing Concrete. 6. ASTM C171 – Standard Specification for Sheet Materials for Curing Concrete. 7. ASTM C309 – Standard Specification for Liquid Membrane-Forming Compounds for Curing Concrete. 8. ASTM C1315 – Standard Specification for Liquid Membrane Forming Compounds Having Special Properties for Curing and Sealing Concrete. 9. ASTM D2103 – Standard Specification for Polyethylene Film and Sheeting.
1.03 DEFINITIONS
A. (RESERVED)
1.04 SUBMITTALS
A. Submit under the provisions of Division 1 - Section 013300 – Submittal Procedures.
B. Product Data: Provide data on curing compounds, including compatibilities and limitations.
1.05 QUALITY ASSURANCE A. Perform work in accordance with ACI 301, ACI 305.1, ACI 306.1 and ACI 308.1. 1. Maintain one copy of each document on site.
1.06 DELIVERY, STORAGE, AND HANDLING
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A. Deliver, store, protect, and handle products under provisions of Division 1 - General Requirements.
B. Deliver curing materials in manufacturer's packaging including application instructions.
PART 2 PRODUCTS
2.01 EVAPORATION RETARDER:
A. Waterborne, monomolecular film forming, manufactured for application to fresh concrete.
B. Products: Subject to compliance with requirements, provide one of the products specified:
1. Axim Italcementi Group, Inc.; CATEXOL CimFilm. 2. BASF Construction Chemicals - Building Systems; Confilm. 3. ChemMasters; SprayFilm. 4. Conspec by Dayton Superior; Aquafilm. 5. Dayton Superior Corporation; Sure Film (J-74). 6. Edoco by Dayton Superior; BurkeFilm. 7. Euclid Chemical Company (The), an RPM company; Eucobar. 8. Kaufman Products, Inc.; Vapor-Aid. 9. Lambert Corporation; LAMBCO Skin. 10. L&M Construction Chemicals, Inc.; E-CON. 11. Meadows, W. R., Inc.; EVAPRE. 12. Metalcrete Industries; Waterhold. 13. Nox-Crete Products Group; MONOFILM. 14. Sika Corporation; SikaFilm. 15. SpecChem, LLC; Spec Film. 16. Symons by Dayton Superior; Finishing Aid. 17. TK Products, Division of Sierra Corporation; TK-2120 TRI-FILM. 18. Unitex; PRO-FILM. 19. Vexcon Chemicals, Inc.; Certi-Vex Envio Set. 20. Or Engineer approved equal.
2.02 ABSORPTIVE COVER:
A. AASHTO M 182, Class 2, burlap cloth made from jute or kenaf, weighing approximately 9 oz./sq. yd. when dry.
2.03 MOISTURE-RETAINING COVER:
A. ASTM C 171, polyethylene film or white burlap-polyethylene sheet.
033900 Concrete Curing 033900-2
2.04 WATER:
A. ASTM C 94 and potable.
B. Engineer approved equal.
2.05 CLEAR, WATERBORNE, MEMBRANE-FORMING CURING COMPOUND
A. ASTM C 309, Type 1, Class B, dissipating
1. Euclid Chemical Company – Kurez DR-100 2. Dayton Superior – Clear Resin Cure J11W 3. BASF – MasterKure 181
2.06 CLEAR, SOLVENT-BORNE, MEMBRANE-FORMING CURING AND SEALING COMPOUND:
A. ASTM C 1315, Type 1, Class A. B. Products: Subject to compliance with requirements, provide one of the products specified.
1. BASF Construction Chemicals - Building Systems; Kure-N-Seal 25 LV. 2. ChemMasters; Spray-Cure & Seal Plus. 3. Conspec by Dayton Superior; Sealcure 1315. 4. Dayton Superior Corporation; Day-Chem Cure and Seal (J-22UV). 5. Edoco by Dayton Superior; Cureseal 1315. 6. Euclid Chemical Company (The), an RPM company; Super Diamond Clear; LusterSeal 300. 7. Kaufman Products, Inc.; Sure Cure 25. 8. Lambert Corporation; UV Super Seal. 9. L&M Construction Chemicals, Inc.; Lumiseal Plus. 10. Meadows, W. R., Inc.; CS-309/30. 11. Metalcrete Industries; Seal N Kure 30. 12. Right Pointe; Right Sheen 30. 13. Vexcon Chemicals, Inc.; Certi-Vex AC 1315. 14. Or Engineer approved equal.
C. COATING SCHEDULE
1. Exterior & Interior Concrete Foundation Walls: One coat application 2. Exterior Concrete Flatwork: One coat application 3. Interior Concrete Floor Slabs: Two coat application
PART 3 EXECUTION
3.01 INSPECTION A. Verify substrate conditions under provisions of Division 1 - General Requirements. B. Verify that substrate surfaces are ready to be cured.
033900 Concrete Curing 033900-3
3.02 CURING AND PROTECTION
A. General: Protect freshly placed concrete from premature drying and excessive cold or hot temperatures. Comply with ACI 306.1 for cold-weather protection and ACI 305.1 for hot- weather protection during curing.
B. Evaporation Retarder: Apply evaporation retarder to unformed concrete surfaces if hot, dry, or windy conditions cause moisture loss approaching 0.2 lb/sq. ft./hour before and during finishing operations. Apply according to manufacturer's written instructions after placing, screeding, and bull floating or darbying concrete, but before float finishing.
C. Formed Surfaces: Cure formed concrete surfaces, including underside of beams, supported slabs, and other similar surfaces. If forms remain during curing period, moist cure after loosening forms. If removing forms before end of curing period, continue curing for the remainder of the curing period.
D. Unformed Surfaces: Begin curing immediately after finishing concrete. Cure unformed surfaces, including floors and slabs, concrete floor toppings, and other surfaces.
E. Cure concrete according to ACI 308.1, by one or a combination of the following methods:
1. Moisture Curing: Keep surfaces continuously moist for not less than seven days with the following materials:
a. Water. b. Continuous water-fog spray. c. Absorptive cover, water saturated, and kept continuously wet. Cover concrete surfaces and edges with 12-inch lap over adjacent absorptive covers.
2. Moisture-Retaining-Cover Curing: Cover concrete surfaces with moisture-retaining cover for curing concrete, placed in widest practicable width, with sides and ends lapped at least 12-inches, and sealed by waterproof tape or adhesive. Cure for not less than seven days. Immediately repair any holes or tears during curing period using cover material and waterproof tape.
a. Moisture cure or use moisture-retaining covers to cure concrete surfaces to receive floor coverings. b. Moisture cure or use moisture-retaining covers to cure concrete surfaces to receive penetrating liquid floor treatments. c. Cure concrete surfaces to receive floor coverings with either a moisture- retaining cover or a curing compound that the manufacturer certifies will not interfere with bonding of floor covering used on Project.
3. Curing and Sealing Compound: Apply uniformly to surfaces indicated in a continuous operation by power spray or roller according to manufacturer's written instructions. Recoat areas subjected to heavy rainfall within three hours after initial application. Repeat process 24-hours later and apply a second coat where indicated. Maintain continuity of coating and repair damage during curing period.
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F. Cold Weather Concreting and Curing: Placing and protection of concrete shall be in conformance with ACI 306.1 and shall meet approval of Engineer prior to its use.
1. Contractor shall maintain temperature records of concrete. When concrete is placed, the time, date, weather conditions, outside air temperature and temperature of concrete shall be recorded. Temperatures shall be recorded at several locations (or as directed by Engineer) within enclosures and on concrete surfaces, edges and corners to obtain the range of temperatures. The maximum and minimum temperatures in each 24-hour period shall be recorded using measuring devices embedded in concrete surface or by placing thermometer against surface under temporary cover of thick insulation until a constant temperature is registered.
G. Hot Weather Concreting and Curing: Placing and protection of concrete shall be in conformance with ACI 305.1 and shall meet approval of Engineer prior to its use.
1. Contractor shall conform to ACI 305.1 when following conditions exist:
a. Any combination of high air temperature, low relative humidity and high wind velocity. b. Any combination of rising air temperature and falling relative humidity.
2. Under hot weather conditions, Contractor shall be responsible for making arrangements for installation of windbreaks, shading, fog spraying, sprinkling, ponding or wet covering of light color. Arrangements shall be made in advance of placement and such protective measures shall be taken as quickly as concrete hardening and finishing operations will allow.
3.03 PROTECTION OF FINISHED WORK A. Protect finished work under provisions Division 1 - General Requirements. B. Do not permit traffic over unprotected floor surface.
3.04 FINAL ACCEPTANCE OF COMPLETE WORK A. The work shall be complete in every detail and the finished work approved by the Engineer and Owner before final acceptance.
END OF SECTION 033900
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