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DIVISION 3 CONCRETE SECTION 03 30 00 CAST-IN-PLACE CONCRETE 1.0 GENERAL 1.1 DESCRIPTION A. Work included: Provide all cast-in-place concrete as indicated on the Drawings, specified herein, and needed for a complete and proper installation. 1. B. Related work described elsewhere: 1. 2. 3. 4. 1.2 A. Standards: Comply with standards specified in this Section and as listed in Section 01 08 50. In case of conflict between the referenced standards, the more stringent requirements shall govern. B. Qualifications of installers: 1. Throughout the progress of installation of the work of this Section, provide at least one person who shall be thoroughly familiar with the specified requirements, completely trained and experienced in the necessary skills, and who shall be present at the site and shall direct all work performed under this Section. 2. In actual installation of the work of this Section, use adequate numbers of skilled workmen to insure installation in strict accordance with the approved design. 3. In acceptance or rejection of work performed under this Section, the Architect/Engineer will make no allowance for lack of skill on the part of workmen. Quality control: 1. In lieu of taking test cylinders of new cast in place concrete, the contractor shall guarantee that the specified cast in place concrete shall be free from defects of materials and workmanship for two (2) years from the date of final certificates. Repair and or replace the defective work and materials and other associated work required to repair or replace concrete, which becomes defective during the guarantee period, without additional costs to the Owner. This guarantee will not apply to defects caused by the failure of work by others, if such defects were impossible to detect at the time of examination of the other work. SUBMITTALS A. 1.4 Alternates: Section 01 11 00 Excavating, Filling, and Grading: Section 02 22 00 Concrete Form-work: Section 03 10 00 Concrete Reinforcement: Section 03 20 00 QUALITY ASSURANCE C. 1.3 Coordinate placement of concrete pads required in Division 16. General: Comply with pertinent provisions of Section 01 33 00. PRODUCT HANDLING A. 13-173B Protection: Use all means necessary to protect the materials of this Section before, during, and after installation and to protect the work and materials of all other trades. 03 30 00 - 1 SECTION 03 30 00 CAST-IN-PLACE CONCRETE B. 1.5 Replacements: In the event of damage, immediately make all repairs and replacements necessary to the approval of the Architect/Engineer and at no additional cost to the Owner. ALTERNATES A. The emergency generator pad has been designed to accommodate the larger fuel tank that is requested in Alternate E-1. 2.0 PRODUCT 2.1 MATERIALS A. Portland Cement: Cement used for General Construction unless otherwise indicated, shall conform to ASTM C150 Type I. All cement used shall be from the same mill and manufacturer and shall be of uniform color and shade. B. Aggregate: The analysis of aggregate shall be submitted with mix information report as previously specified. The same aggregate shall be used throughout the job. 1. Coarse aggregate; hard, clean, durable, uncoated crushed stone conforming to ASTM C33. Maximum size aggregate allowed is 1/5 of the narrowest dimension between forms, not larger than 3/4 the minimum clear spacing between reinforcing bars and not larger than 1/4 the thickness of the slabs. Percentages by weight passing: a. b. c. d. 2. 2.2 1-1/2" Sieve 3/4" Sieve 3/8" Sieve No. 4 Sieve - 95 to 100 - 35 to 70 - 10 to 30 - Not More Than 5 Fine aggregate; hard, clean, durable natural sand, manufactured sand free from silt, loam, and clay conforming to ASTM C33. C. Mixing water: Clean, potable and free from oil, acid, vegetable matter, alkalies, and other salts. D. Admixtures: 1. Air entraining admixture, ASTM C-260. 2. Water reducing admixture: ASTM C-494, Type A, D. 3. High range water reducing admixture (superplasticizer): "Eucon 37" by The Euclid Chemical Company or "Sikament" by Sika Chemical Corporation. The admixture shall conform to ASTM C 494, Type F or G. 4. Non-corrosive, non-chloride accelerator: "Accelguard 80" by The Euclid Chemical Company or approved equal. The admixture shall conform to ASTM C 494, Type C or E. 5. Prohibited admixtures: Calcium chloride. All admixtures shall not contain more chloride ions than are present in municipal drinking water. CONCRETE PROPERTIES A. Proportions strength and consistency of concrete: 1. 03 30 00 - 2 Proportions: Concrete shall be homogeneous, readily placeable, uniformly workable, and proportioned in accordance with ACI 318. Proposed mix design shall be submitted to Architect-Engineer for approval. The approved mix shall not be changed without approval of Architect-Engineer. 13-173B SECTION 03 30 00 CAST-IN-PLACE CONCRETE 2. Strength: Concrete shall have a minimum compressive strength at 28 days of 3000 psi. Maximum slump shall be 4 inches. The method for determining the cement/water ratio for each batch shall be one which is closely controlled and easily checked at any time. All concrete shall contain the specified waterreducing or water-reducing-retarding admixture and/or high-range water-reducing admixture (superplasticizer). All concrete slabs, placed at air temperature below 50oF shall contain the specified non-corrosive non-chloride accelerator. All concrete required to be air-entrained shall contain an approved air-entraining admixture. All pumped concrete, concrete for industrial slabs, architectural concrete, concrete required to be water-tight and concrete with a water-cement ratio below 0.50 shall contain the specified high-range water reducing admixture (superplasticizer). 3. Consistency: Concrete exposed to the weather shall contain 6% plus or minus one entrained air with use of admixtures. All concrete containing the high-range water-reducing admixture (superplasticizer) shall have a maximum slump of 8" unless otherwise approved by the Architect/Engineer. The concrete shall arrive at the job site at a slump of 2" to 3", be verified, then the high-range water-reducing admixture added to increase the slump to the approved level. All other concrete shall have a maximum slump of 3" for slabs and 4" for other members. 2.3 CURING MATERIALS A. Liquid curing and sealing compounds: Conform to ASTM C309 Type 1 and be equal to the following acceptable products: 1. 2. 3. Sonneborn; Kure-N-Seal Symons; Cure & Seal Euclid Chemical Company; Rez-Seal This material shall not be used on any surface against which additional concrete is to be placed. Curing compound may only be used on floors receiving additional finishes as approved by subcontractor responsible for such finishes. Calcium Chloride is not permitted refer to Article 2.1.D.5. 2.4 B. Sheet material: Conform to ASTM C171, lap and tape joints. C. Absorptive mat or fabric: Jute or burlap cloth weighing approximately 9 oz. per sq. yd. shall conform to AASHTO M182. Use two layers. OTHER MATERIALS A. Expansion and control joint filler material: 1. Premolded expansion joint filler; conforming to ASTM D1752 3/8" thick x depth of slab. 2. Bond breaker: 15# roofing felt or 6 mil. polyethylene film x depth of slab. Provide in all locations where concrete would otherwise bond to wall material. 3. Control joint filler; self leveling horizontal joint filler conforming to Fed. Spec. TTS-0022/e Type 1 Class A and be equal to the following acceptable products. a. b. c. B. 13-173B Sonneborn; Sonolastic Paving Joint Sealant A. C. Horn; Hornflex Euclid Chemical Company; Thiokol Sealant Vapor barrier under interior building slabs: 03 30 00 - 3 SECTION 03 30 00 CAST-IN-PLACE CONCRETE 1. 10 mil polyethylene film in compliance with ASTM E1745, or equal. 2. Provide Vapor Seal with Plasmatic Core as Manufactured by W.R. Meadows. a. C. Install using the “Butt Joint” method and as per manufacturer’s recommendations. Bonding compound: The compound shall be a polyvinyl acetate, rewettable type, "Euco Weld" by The Euclid Chemical Company or "Weldcrete" by The Larson Company. Structural bonding epoxy adhesive: The compound shall be a two (2) component, 100% solids, 100% reactive compound suitable for use on dry or damp surfaces, "Euco Epoxy" #463 or #620 by The Euclid Chemical Company or "Sikadur Hi-Mod" by Sika Chemical Corporation. Patching compound: "Euco Epoxy #460 Mortar" by the Euclid Chemical Company or "Sikadur Lo-Mod" by Sika Chemical Corporation. The compound shall be epoxy type, 100% solids, suitable for use on dry or damp surfaces. Patching compound (cementitious type): "Thin Coat" by The Euclid Chemical Company or "Sikatop 122" by Sika Chemical Company. Abrasive aggregate for nonslip aggregate finish: "Non-Slip" by The Euclid Chemical Company, "Alundum" by North Company or approved equal. D. Non-shrink grout: The grout shall conform to CRD-C-621-80, "Corps of Engineers specification for Non-Shrink Grout", "Euco NS" by The Euclid Chemical Company or "Masterflow 713" by Master Builders or an approved equal. E. Aggregate/granular base: Section 02 22 00 3.0 EXECUTION 3.1 INSPECTION A. Examine the areas and conditions under which work of this Section will be performed. Correct conditions detrimental to the proper and timely completion of the work. Do not proceed until unsatisfactory conditions have been corrected. 1. 3.2 Coordinate placement of concrete pads required in Division 16. CONCRETE PLACEMENT A. General: Place concrete in compliance with the practices and recommendations of ACI 304, and as herein specified. B. Procedures: 03 30 00 - 4 1. The Contractor shall notify the Architect-Engineer's representative and testing laboratory at least one day prior to making any pour. 2. Install the provided items of other trades, which require being cast-in-place. Properly locate in cooperation with other trades and secure in position before concrete is poured. See the Drawings and other Divisions of these Specifications for the extent, location and details of items to be embedded or placed in concrete. 3. Concrete shall be placed in forms as nearly as practical in final position, and worked around reinforcing and into corners of forms with an internal vibrator. Care shall be taken not to over-vibrate concrete and to keep vibrator off the reinforcing steel and off the forms. 13-173B SECTION 03 30 00 CAST-IN-PLACE CONCRETE 3.3 4. Runways shall be provided for wheeled concrete and handling equipment. Such equipment shall not be wheeled over reinforcing nor shall runways be supported on the reinforcing. 5. Vibration shall not be used to move concrete in a horizontal direction after initial placement. 6. Concrete shall not be placed on muddy or frozen ground. 7. The rate and method of placing concrete and arrangement of construction joint bulkheads shall be such that the concrete between construction joints shall be placed in one continuous operation. 8. Use chutes or tremies for placing concrete where a drop of more than 6 feet is required. 9. Do not use concrete which becomes non-plastic and unworkable, or does not meet the required quality control units, or which has been contaminated by foreign materials. 10. Concrete shall have a temperature not below 50oF and not above 85oF during depositing. Suitable means shall be provided during freezing conditions for maintaining concrete at a temperature not lower than 70oF for 3 days or 50oF for 5 days after placing. Methods and recommended practice shall be in accordance with ACI 306 R-78, winter concreting, and ACI 305 R-77 (1982), hot weather concreting. Admixtures shall not be used without prior approval of the ArchitectEngineer. 11. Slabs on grade shall be placed on 4 inches compacted thickness of #467 washed gravel or limestone with a vapor barrier and isolation joints as specified. Install vapor barrier in accordance with manufacturer's printed directions. 12. All exposed corners of concrete shall have ¾” X ¾” chamfer. See Section 03 10 00, Item 3.2.E. 13. Concrete pour stops are to be placed at systematic locations to minimize cracking. JOINTS A. 13-173B Construction and contraction joints: 1. Construction joints shall be located in accordance with ACI 301 as directed and approved by the Architect-Engineer. 2. If construction joints necessary for the progress of the work are not indicated on the Drawings, show them in complete detail on the shop drawings. 3. All reinforcing steel and welded wire fabric shall be continuous across joints, except for slabs on grade. 4. Provide keyways at least 1-1/2" deep in all construction joints, in walls, slabs, and between footing and walls. 03 30 00 - 5 SECTION 03 30 00 CAST-IN-PLACE CONCRETE B. 5. For slabs on grade, locate the unindicated joints in a manner to divide the slab into areas not in excess of 225 SF with one dimension being not greater than 120% of the other dimension. 6. Prior to resumption of concreting, the surfaces of previously placed concrete shall be roughened, cleaned and wetted immediately before additional concrete is placed. Isolation joints in slabs on grade: Provide isolation joints at points of contact between slabs on grade and vertical surfaces where indicated and specified herein: 1. Premolded expansion joint filler a. b. 2. C. 3.4 All exterior slabs where indicated or required Interior slabs which received floor finish and base Bond breaker; All interior slabs. Control joints: Provide control joints on slabs on grade to form panels, patterns or as indicated on the Drawings and specified herein: 1. Control joints shall be maximum of 1/4" wide by 1/3" of slab thickness. 2. Form joint by sawing as soon as concrete has hardened sufficiently to permit sawing without excessive raveling. Clean each joint thoroughly and cover with masking tape until concrete is cured. 3. Fill control joints with self-leveling horizontal joint filler in accordance with manufacturer's directions. CONCRETE FINISHING A. Finish of formed surfaces: 1. Rough form finish: Provide as-cast rough form finish to formed concrete surfaces that are to be concealed in the finish work or by any other construction. a. 2. 3. 03 30 00 - 6 Standard rough form finish shall be the concrete surface having the texture imparted by the form facing material used, with tie holes and defective areas repaired and patched. Smooth form finish: Provide as-cast smooth form finish for formed concrete surfaces that are to be exposed to view, or that are to be covered with a coating material other than cement plaster applied directly to the concrete. a. Produce smooth form finish by selecting form material to impart a smooth, hard, uniform texture and arranging them orderly and symmetrically with a minimum of seams. Patch defective areas with cement mortar immediately after removal of forms. b. Provide ¾” X ¾” chamfer on all exposed corners unless indicated on the Drawings. See Section 03 10 00, Item 3.2.E. c. Repair and patch defective areas with all fins and other projections completely removed and smoothed. Related unformed surfaces: At tops of walls, horizontal offsets, and similar unformed surfaces occurring adjacent to formed surfaces, strike off smooth and finish with a smooth troweled finish. 13-173B SECTION 03 30 00 CAST-IN-PLACE CONCRETE 3.5 CURING A. 3.6 General: All concrete shall be cured for a period of not less than 7 days. Freshly placed concrete shall be protected from premature drying by one of the following methods: 1. Ponding or continuous sprinkling; provide one person on the job at all times for this purpose. 2. Absorptive mat or fabric kept continuously wet. 3. Sheet material; lap and tape or cement joints and free edges weighted down to prevent moisture loss. 4. Liquid curing and sealing compound: Apply in accordance with manufacturer's directions at a rate of 200 SF/Gal. in a uniform spray. This material shall not be used on any surface against which additional concrete is to be placed. Curing compound may only be used on floors receiving additional finishes as approved by subcontractor responsible for such finishes. PATCHING A. B. General: After the forms have been removed, all exposed concrete surfaces shall be inspected. All defective areas, as required by the Architect-Engineer, shall be patched as herein specified. 1. Do not fill or patch construction joints unless specifically authorized by the Architect-Engineer. 2. Do not patch any concrete in freezing weather. 3. Chip away defective area to a depth of not less than one inch, with edges perpendicular to the surface. 4. Thoroughly apply bonding agent to area to be patched. 5. A grout, of equal parts of Portland Cement and sand with sufficient water to allow brushing, shall be brushed into area; followed immediately with patching mix. 6. The patch shall be of same material as the concrete except the course aggregate shall be omitted. 7. The patch mix shall be thoroughly compacted into place and screeded off and finished to match surrounding surfaces. Remedial work: Reinforce or replace deficient work as directed by the ArchitectEngineer and at no additional cost to the Owner. END OF SECTION 03 30 00 13-173B 03 30 00 - 7