Cast-In Place ConcreteME- Building Group

SECTION 033000 - CAST-IN-PLACE CONCRETE

PART 1 - GENERAL

1.1RELATED DOCUMENTS

  1. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section.

1.2SUMMARY

  1. This Section specifies cast-in place concrete, including formwork, reinforcing, mix design, placement procedures, and finishes.
  2. Cast-in-place concrete includes the following:
  3. Grade walls and footings as detailed.
  4. Pits and trenches as detailed.
  5. Elevated floor slabs.
  6. Related Sections:
  7. Division 32 Section “Concrete Paving” for exterior paving slab work.
  8. Division 03 Sections “Industrial and Polished Concrete Floor Slabs” and “Elevated Industrial and Polished Concrete Floor Slabs” for polished concrete finishes.
  9. Division 07 Section “Bentonite Waterproofing” for water stops and waterproofing

1.3SUBMITTALS

  1. Product data for proprietary materials and items, including reinforcement and forming accessories, admixtures, patching compounds, water stops, joint systems, curing compounds, dry-shake finish materials, and others if requested by Owner’s Representative.
  2. Abrasive nosings.
  1. Concrete Mix Design: Submit concrete supplier's concrete mix design information based on requirements specified in "PROPORTIONING AND DESIGNING MIXES".
  2. Submit a concrete mix design prepared by either the “laboratory trial batch” or the field experience” method as specified in the latest issue of ACI 318, Section 5.3 or CSA A 23.1 for approval. Provide proportions of cement, fine aggregate, coarse aggregate, and water.
  1. LEED Submittals:
  2. Product Data for Credit MR4: For products having recycled content, documentation indicating percentages by weight of postconsumer and preconsumer recycled content.
  3. Include documentation from product manufacturer indicating cost for each product having recycled content.
  4. Product Certificates for CreditMR5: For products and materials required to comply with requirements for regional materials, certificates indicating location of material manufacturer and point of extraction, harvest, or recovery for each raw material.
  5. Include documentation indicating distance to Project for harvest and manufacturing location, cost for each regional material, and fraction by weight that is considered regional.
  6. Product Data for CreditIEQ4.3: For curing and sealing compounds, documentation including printed statement of VOC content from product manufacturer.
  7. Design Mixtures for CreditID1.1: For each concrete mixture containing fly ash as a replacement for portland cement or other portland cement replacements, and for equivalent concrete mixtures that do not contain portland cement replacements.
  8. Shop drawings for reinforcement detailing fabricating, bending, and placing concrete reinforcement. Comply with ACI 315 "Manual of Standard Practice for Detailing Reinforced Concrete Structures" showing bar schedules, stirrup spacing, bent bar diagrams, and arrangement of concrete reinforcement. Include special reinforcing required for openings through concrete structures.
  9. Laboratory test reports for concrete materials and mix design test.

1.4QUALITY ASSURANCE

  1. Codes and Standards: Comply with provisions of the following codes, specifications, and standards, except where more stringent requirements are shown or specified:
  2. American Concrete Institute (ACI) 301, "Specifications for Structural Concrete for Buildings."
  3. ACI 318, "Building Code Requirements for Reinforced Concrete."
  4. Concrete Reinforcing Steel Institute (CRSI) "Manual of Standard Practice."
  5. Concrete Testing Service: Engage a testing agency acceptable to Owner’s Representative to perform material evaluation tests and to design concrete mixes.
  6. Materials and installed work may require testing and retesting at any time during progress of Work. Tests, including retesting of rejected materials for installed Work, shall be done at Contractor's expense.

PART 2 - PRODUCTS

2.1FORM MATERIALS

  1. Forms for Exposed Finish Concrete: Plywood, metal, metal-framed plywood faced, or other acceptable panel-type materials to provide continuous, straight, smooth, exposed surfaces. Furnish in largest practicable sizes to minimize number of joints and to conform to joint system indicated on the Drawings.
  2. Use overlaid plywood complying with U.S. Product Standard PS-1 "A-C or B-B High Density Overlaid Concrete Form," Class I.
  3. Forms for Unexposed Finish Concrete: Plywood, lumber, metal, or another acceptable material. Provide lumber dressed on at least two edges and one side for tight fit.
  4. Form Release Agent: Provide commercial formulation form release agent with a maximum of 350 g/l volatile organic compounds (VOCs) that will not bond with, stain, or adversely affect concrete surfaces and will not impair subsequent treatments of concrete surfaces.
  5. Form Ties: Factory-fabricated, adjustable-length, removable or snap-off metal form ties designed to prevent form deflection and to prevent spalling of concrete upon removal. Provide units that will leave no metal closer than 1-1/2 inches to the plane of the exposed concrete surface.
  6. Provide ties that, when removed, will leave holes not larger than 1 inch in diameter in the concrete surface.

2.2REINFORCING MATERIALS

  1. Recycled Content of Steel Products: Postconsumer recycled content plus one-half of preconsumer recycled content not less than 60 percent.
  1. Reinforcing Bars: ASTMA615 Grade 60, deformed.
  2. Supports for Reinforcement: Bolsters, chairs, spacers, and other devices for spacing, supporting, and fastening reinforcing bars and welded wire fabric in place. Use wire bar-type supports complying with CRSI specifications.
  3. For pits, use supports with sand plates or horizontal runners where base material will not support chair legs.
  4. For exposed-to-view concrete surfaces where legs of supports are in contact with forms, provide supports with legs that are protected by plastic (CRSI, Class 1) or stainless steel (CRSI, Class 2).
  5. The use of bricks, stones, etc. as supports for reinforcements will not be allowed.

2.3CONCRETE MATERIALS

  1. Portland Cement: ASTMC 150, Type I. Use one brand of cement throughout Project unless otherwise acceptable to Owner’s Representative.
  2. Regional Materials: Concrete products shall be manufactured within 500 miles of Project site from materials that have been extracted, harvested, or recovered, as well as manufactured, within 500 miles of Project site.
  3. Cementitious Materials:Use fly ash, pozzolan, ground granulated blast-furnace slag, and silica fume as needed to reduce the total amount of portland cement, which would otherwise be used, by not less than 40 percent.
  4. Fly Ash: 25 percent.
  5. Combined Fly Ash and Pozzolan: 25 percent.
  6. Ground Granulated Blast-Furnace Slag: 50 percent.
  7. 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.
  8. Fly ash: ASTM C618, Type F with maximum loss on ignition (L.O.I.) of 6%.
  9. Ground Granulated Blast-Furnace Slag: ASTMC989, Grade100 or 120.
  10. Normal-Weight Aggregates: ASTMC 33 and as specified. Provide aggregates from a single source for exposed concrete.
  11. For exposed exterior surfaces, do not use fine or coarse aggregates that contain substances that cause spalling.
  12. Local aggregates not complying with ASTMC 33 that have been shown to produce concrete of adequate strength and durability by special tests or actual service may be used when acceptable to Owner’s Representative.
  13. Water: ASTMC94/C94M Potable.

2.4ADMIXTURES

  1. General: Provide concrete admixtures that contain not more than 0.1 percent chloride ions.
  2. Air-Entraining Admixture: ASTMC 260, certified by manufacturer to be compatible with other required admixtures.
  3. Products: Unless otherwise directed by the Owner, provide products by one of the following:
  4. Air-Mix or AEA 92; Euclid Chemical Co.
  5. Darex AEA or Daravair, W.R. Grace & Co.
  6. MB-VR or Micro-Air; Master Builders, Inc.
  7. Sika AEA; Sika Corp.
  8. Sika Air 260 or 360, Sika Corp.
  9. Mid-Range Water-Reducing Admixture: ASTMC 494, Type A.
  10. Products: Unless otherwise directed by the Owner, provide products by one of the following:
  11. Eucon WR-75; Euclid Chemical Co.
  12. WRDA 20 or Hycol; W.R. Grace & Co.
  13. Pozzolith 220N, 200N or MasterPolyheed; BASF
  14. Sikaplast Series or Sikament Series; Sika Corp.
  15. Water-Reducing, Accelerating Admixture: ASTMC 494, Type E.
  16. Products: Unless otherwise directed by the Owner, provide products by one of the following:
  17. Accelguard 80; Euclid Chemical Co.
  18. MasterSet FP 20; BASF
  19. SikaSet RHE, Sika Corp.
  20. Water-Reducing, Retarding Admixture: ASTMC 494, Type D.
  21. Products: Unless otherwise directed by the Owner, provide products by one of the following:
  22. Eucon Retarder 75; Euclid Chemical Co.
  23. Daratard-17; W.R. Grace & Co.
  24. MasterSet R100; BASF
  25. Plastiment; Sika Corporation.

2.5RELATED MATERIALS

  1. Joint-Filler Strips: ASTMD1751, asphalt-saturated cellulosic fiber.
  2. Absorptive Cover: Burlap cloth made from jute or kenaf, weighing approximately 9 oz./sq. yd., complying with AASHTO M 182, Class 2.
  3. Moisture-Retaining Cover: One of the following, complying with ASTMC171.
  4. Waterproof paper.
  5. Polyethylene film.
  6. Polyethylene-coated burlap.
  7. Plastic sheet bonded to water absorbent fabric.
  8. Liquid Membrane-Forming Curing Compound: Liquid-type membrane-forming curing compound complying with ASTMC 309, Type I, Class A. Moisture loss not more than 0.55 kg/sq. m when applied at 200 sq. ft./gal. Do not use for slab on grade.
  9. Products: Unless otherwise directed by the Owner, provide products by one of the following:
  10. A-H 3 Way Sealer; Anti-Hydro Co., Inc.
  11. Spartan-Cote, Conspec #1 or Day-Chem Cure and Seal; DaytonSuperior
  12. Sealco 309; Cormix International LTD.
  13. Eucocure VOX; Euclid Chemical Co.
  14. Masterkure 106 or Kure N Seal 25 LV; BASF
  15. 1100 Clear; W.R. Meadows, Inc.
  16. Seal N Kure; Metalcrete Industries.
  17. Evaporation Control: Monomolecular film-forming compound applied to exposed concrete surfaces for temporary protection from rapid moisture loss. Do not use on slab on grade.
  18. Products: Unless otherwise directed by the Owner, provide products by one of the following:
  19. Aquafilm; Dayton Superior Corp.
  20. Eucobar; Euclid Chemical Co.
  21. E-Con; L&M Construction Chemicals, Inc.
  22. Confilm; BASF
  23. Waterhold; Metalcrete Industries.
  24. Sikafilm, Sika Corp.
  25. Bonding Agent: Bonding agent bonding freshly mixed concrete to hardened or existing concrete shall be either Sika Chemical Corp. "Armatec 110" EpoCem or as directed by the Owner.
  26. Epoxy grout for anchor bolts and dowels shall be Sika AnchorFix-3001 or as directed by the Owner.
  27. Epoxy Adhesive: ASTMC 881, two-component material suitable for use on dry or damp surfaces. Provide material type, grade, and class to suit Project requirements.
  28. Products: Unless otherwise directed by the Owner, provide products by one of the following:
  29. Euco Epoxy System #452 or #620; Euclid Chemical Co.
  30. Concresive Standard Liquid; Master Builders, Inc.
  31. Sikadur 32 Hi-Mod; Sika Corp.
  32. Self-Expanding Butyl Strip Waterstops: Manufactured rectangular or trapezoidal strip, butyl rubber with sodium bentonite or other hydrophilic polymers, for adhesive bonding to concrete. Dumbbell waterstops are not acceptable.
  33. Products: Unless otherwise directed by the Owner, provide products by one of the following:
  34. Swellstop, Sika Greenstreak.
  35. Bluestop, Vinylex.
  36. Water-tite, Southern Metala and Plastic Products.
  37. Parged Coatings:
  38. Above Grade: Thorocoat by BASF or as directed by Owner.
  39. Smooth, Fine or Coarse Texture to be selected by Owner.
  40. Standard or custom color to be selected by Owner.
  41. Below Grade: Thoroseal with ACRYL 60 by BASF or as directed by Owner.
  42. Abrasive Nosings:
  43. Cast-Metal Units: Cast iron, with an integral abrasive, as-cast finish consisting of aluminum oxide, silicon carbide, or a combination of both. Fabricate units in lengths necessary to accurately fit openings or conditions.
  44. Configuration: Cross-hatched angle-shaped units, 1-1/2 to 2 inches wide.

2.6PROPORTIONING AND DESIGNING MIXES

  1. Prepare design mixes for each type and strength of concrete by either laboratory trial batch or field experience methods as specified in ACI 301. For the trial batch method, use an independent testing agency acceptable to Owner’s Representative for preparing and reporting proposed mix designs.
  2. Limit the use of fly ash to not exceed 25 percent of cement content by weight.
  3. Fly ash permitted in grade beams and walls, drilled piers, footings, piers, and pile caps.
  4. Submit written reports to Owner’s Representative of each proposed mix for each class of concrete at least 15 days prior to start of Work. Do not begin concrete production until proposed mix designs have been reviewed by Owner’s Representative.
  5. Design mixes to provide normal weight concrete with the following properties as indicated on drawings and schedules:
  6. 4000 psi, 28-day compressive strength; water-cement ratio, 0.55 maximum (non-air-entrained), 0.50 maximum (air-entrained). Required for machine foundations.
  7. 3000 psi, 28-day compressive strength; water-cement ratio, 0.62 maximum (non-air-entrained).
  8. Water-Cement Ratio: Provide concrete for following conditions with maximum water-cement (W/C) ratios as follows:
  9. Subjected to freezing and thawing: W/C 0.45.
  10. Subjected to deicers/watertight: W/C 0.40.
  11. Subjected to brackish water, salt spray, or deicers: W/C 0.40.
  12. Slump Limits: Proportion and design mixes to result in concrete slump at point of placement as follows:
  13. Ramps, slabs, and sloping surfaces: Not more than 3 inches.
  14. Reinforced foundation systems: Not less than 1 inch and not more than 3 inches.
  15. Concrete containing high-range water-reducing admixture (super plasticizer): Not more than 8 inches after adding admixture to site-verified 2 - 3 inch slump concrete.
  16. Other concrete: Not more than 4 inches.
  17. Adjustment to Concrete Mixes: Mix design adjustments may be requested by Contractor when characteristics of materials, job conditions, weather, test results, or other circumstances warrant, as accepted by Owner’s Representative. Laboratory test data for revised mix design and strength results must be submitted to and accepted by Owner’s Representative before using in Work.
  18. Use water-reducing admixture or high-range water-reducing admixture (super plasticizer) in concrete, as required, for placement and workability.
  19. Use mid-range water-reducing admixture in pumped concrete, concrete for heavy-use industrial slabs, architectural concrete, parking structure slabs, concrete required to be watertight, and concrete with water-cement ratios below 0.50. Incorporate admixtures w/Section 2.4.f for watertight applications per manufacturer.
  20. Use air-entraining admixture in exterior exposed concrete unless otherwise indicated. Add air-entraining admixture at manufacturer's prescribed rate to result in concrete at point of placement having total air content with a tolerance of plus or minus 1-1/2 percent within the following limits:
  21. Concrete structures and slabs exposed to freezing and thawing, deicer chemicals, or hydraulic pressure:
  22. 4.5 percent (moderate exposure) for 1-1/2 inch maximum aggregate.
  23. 4.5 percent (moderate exposure) for 1 inch maximum aggregate.
  24. 5.0 percent (moderate exposure) for 3/4 inch maximum aggregate.
  25. 5.5 percent (moderate exposure) for 1/2 inch maximum aggregate.
  26. Other concrete not exposed to freezing, thawing, or hydraulic pressure, or to receive a surface hardener: 2 to 4 percent air.
  27. Use admixtures for water reduction and set accelerating or retarding in strict compliance with manufacturer's directions.

2.7CONCRETE MIXING

  1. Job-Site Mixing: Measure, batch, and mix concrete materials and concrete according to ASTMC94. Mix concrete materials in appropriate drum-type batch machine mixer. For mixers of 1 cu. yd. or smaller capacity, continue mixing at least 1-1/2 minutes, but not more than 5 minutes after ingredients are in mixer, before any part of batch is released. For mixers of capacity larger than 1 cu. yd., increase minimum 1-1/2 minutes of mixing time by 15 seconds for each additional 1 cu. yd.
  2. Provide batch ticket for each batch discharged and used in the Work, indicating Project identification name and number, date, mix type, mix time, quantity, and amount of water introduced.
  3. Ready-Mixed Concrete: Comply with requirements of ASTMC 94, and as specified.
  4. When air temperature is between 85 deg F and 90 deg F, reduce mixing and delivery time from 1-1/2 hours to 75 minutes, and when air temperature is above 90 deg F, reduce mixing and delivery time to 60 minutes.

PART 3 - EXECUTION

3.1GENERAL

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

3.2FORMS

  1. General: Design, erect, support, brace, and maintain formwork to support vertical, lateral, static, and dynamic loads that might be applied until concrete structure can support such loads. Construct formwork so concrete members and structures are of correct size, shape, alignment, elevation, and position. Maintain formwork construction tolerances and surface irregularities complying with the following ACI 347 limits:
  2. Provide Class A tolerances for concrete surfaces exposed to view.
  3. Provide Class C tolerances for other concrete surfaces.
  4. Construct forms to sizes, shapes, lines, and dimensions shown and to obtain accurate alignment, location, grades, level, and plumb work in finished structures. Provide for openings, offsets, sinkages, keyways, recesses, moldings, rustications, reglets, chamfers, blocking, screeds, bulkheads, anchorages and inserts, and other features required in the Work. Use selected materials to obtain required finishes. Solidly butt joints and provide backup at joints to prevent cement paste from leaking.
  5. Fabricate forms for easy removal without hammering or prying against concrete surfaces. Provide crush plates or wrecking plates where stripping may damage cast concrete surfaces. Provide top forms for inclined surfaces where slope is too steep to place concrete with bottom forms only. Kerf wood inserts for forming keyways, reglets, recesses, and the like for easy removal.
  6. Provide temporary openings for clean-outs and inspections where interior area of formwork is inaccessible before and during concrete placement. Securely brace temporary openings and set tightly to forms to prevent losing concrete mortar. Locate temporary openings in forms at inconspicuous locations.
  7. Chamfer exposed corners and edges as indicated, using wood, metal, PVC, or rubber chamfer strips fabricated to produce uniform smooth lines and tight edge joints.
  8. Provisions for Other Trades: Provide openings in concrete formwork to accommodate work of other trades. Determine size and location of openings, recesses, and chases from trades providing such items. Accurately place and securely support items built into forms.
  9. Cleaning and Tightening: Thoroughly clean forms and adjacent surfaces to receive concrete. Remove chips, wood, sawdust, dirt, or other debris just before placing concrete. Retighten forms and bracing before placing concrete, as required, to prevent mortar leaks and maintain proper alignment.

3.3PLACING REINFORCEMENT

  1. General: Comply with Concrete Reinforcing Steel Institute's recommended practice for "Placing Reinforcing Bars," for details and methods of reinforcement placement and supports and as specified.
  2. Clean reinforcement of loose rust and mill scale, earth, ice, and other materials that reduce or destroy bond with concrete.
  3. Accurately position, support, and secure reinforcement against displacement. Locate and support reinforcing by metal chairs, runners, bolsters, spacers, and hangers, as approved by Owner’s Representative.

1. The use of bricks, stones, etc. for the support of reinforcing will not be allowed.