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SECTION 03001

CONCRETE

PART 1 GENERAL

1.1 SECTION INCLUDES

A. Cast-in-place concrete

B. Reinforcing steel

C. Forms

D. Concrete accessories

1.2 REFERENCES

A. ACI 214 Recommended Practice for Evaluating Compression Test Results of

Field Concrete

B. ACI 301 Structural Concrete for Buildings

C. ACI 302 Recommended Practice for Concrete Floor and Slab Construction

D. ACI 304 Recommended Practice for Measuring, Mixing, Transporting and

Placing Concrete

E. ACI 305/305R Hot Weather Concreting

F. ACI 306/306R Cold Weather Concreting

G. ACI 308 Standard Practice for Curing Concrete

H. ACI 309 Standard Practice for Consolidation of Concrete

I. ACI 318 Building Code Requirements for Reinforced Concrete

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J. ACI 347 Recommended Practice for Concrete Formwork

K. ASTM A82 Cold Drawn Steel Wire for Concrete Reinforcement

L. ASTM A185 Welded Steel Wire Fabric for Concrete Reinforcement

M. ASTM C31 Making and Curing Concrete Test Specimens in the Field

N. ASTM C39 Test Method for Compressive Strength of Cylindrical Concrete

Specimens

O. ASTM C143 Test Method of Slump of Hydraulic Cement Concrete

P. ASTM A615 Deformed and Plain Billet Steel Bars for Concrete

Reinforcement

Q. ASTM C33 Concrete Aggregates

R. ASTM C94 Ready-Mixed Concrete

S. ASTM C150 Portland Cement

T. ASTM C171 Sheet Materials for Curing Concrete

U. ASTM C260 Air Entraining Admixtures for Concrete

V. ASTM C309 Liquid Membrane-Forming Compounds for Curing Concrete

W. ASTM C494 Chemical Admixtures for Concrete

X. ASTM C618 Fly Ash and Raw or Calcinated Natural Pozzolan for Use as a

Mineral Admixture in Portland Cement Concrete

Y. ASTM D994 Preformed Expansion Joint Filler for Concrete (Bituminous

Type)

Z. ASTM D1190 Concrete Joint Sealer, Hot-Poured Elastic Type

AA. ASTM D1751 Preformed Expansion Joint Fillers for Concrete Paving and

Structural Construction (Non-extruding and Resilient Bituminous Types)

BB. ASTM D1752 Preformed Sponge Rubber and Cork Expansion Joint Fillers

for Concrete Paving and Structural Construction

CC. ASTM D2103 Polyethylene Film and Sheeting

DD. CRSI Concrete Reinforcing Steel Institute -Manual of Practice

EE. CRSI 63 Recommended Practice for Placing Reinforcing Bars

FF. CRSI 65 Recommended Practice for Placing Bar Supports, Specifications

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and Nomenclature

GG. PS 1 Construction and Industrial Plywood

1.3 PERFORMANCE TOLERANCES

A. Confirm to ACI 301 and ACI 347, as modified herein. In case of conflict,

ACI 347 governs over ACI 301

1.4 SUBMITTALS

A. Submit under provisions of Section 01340

B. Shop Drawings: Reinforcing bar lists, fabrication and placement drawings

C. Product Data: Provide sufficient information on mix design and products

specified to verify compliance with specifications:

1. Existing data on proposed design mixes, certified and complete

2. Submit reports of field quality control testing

1.5 QUALITY ASSURANCE

A. Perform work in accordance with ACI 301

B Acquire cement and aggregate from same source for all work

1.6 DELIVERY, STORAGE, AND HANDLING

A. Reinforcing steel: Store on supports which will keep it from contact with the

ground and cover

B. Rubber and plastic materials: Store in a cool place, do not expose to direct

sunlight

C. Prepare a delivery ticket for each load of ready-mixed concrete

D. Truck operator shall hand ticket to Engineer at the time of delivery with ticket

to show:

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1. Quantity delivered

2. Actual quantity of each material in batch

3. Outdoor temp in the shade

4. Time at which cement was added

5. Numerical sequence of the delivery

6. Quantity of water that can be added in the field based on mix design

7. Free moisture in fine and coarse aggregate in percent by weight

8. Temperature of batch

PART 2 PRODUCTS

2.1 PRECAST CONCRETE VAULT

A. GENERAL

1 DESCRIPTION

This section includes materials, design, and installation of precast concrete vaults with factory applied waterproofing.

2. RELATED WORK SPECIFIED ELSEWHERE

a. Record Drawings Submittals: STD SPEC 01340. b. Earthwork: STD SPEC 02200. c. General Concrete Construction: STD SPEC 03001. .

B. SUBMITTALS

1. Submit submittal packages in accordance with Standard Specification Section 01340.

2. Submit manufacturer's catalog data on precast concrete items. Show

dimensions of vault and location of openings including thicknesses of walls, floor and top slab. Show reinforcing wire and steel. Show materials of construction by ASTM reference and grade.

3. Submit manufacturer's design calculations and certification signed and

sealed by a professional civil or structural engineer registered in the State of California that vault design and construction comply with the specified design load conditions and the referenced ASTM specification (e.g.,

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ASTM C 857 and C 858).

4. Submit manufacturer's catalog data, descriptive literature, and installation instructions for the waterproofing material.

C INSPECTION

1. The District=s Representative or his authorized representative may conduct

an inspection of the vault fabrication process at the manufacturer=s plant prior to the placement of the concrete into the formwork. The inspection will review the quality of materials, the formwork, placement of reinforcing steel, location of openings in the vault, and other construction details as shown in the approved fabrication drawings in the submittal package. If the concrete is placed into the formwork without this prior inspection, the vault will be rejected.

2. The District=s Representative or his authorized representative will conduct

a second inspection of the vault upon its arrival at the jobsite. The inspection will review the quality of the concrete surfaces, defects that indicate any imperfect concrete mixing and molding, surface deflects indicated by honey-combed or open texture and damaged areas, any exposed or bare reinforcing steel, and waterproofing that is missing from indicated surfaces or poorly applied. If any of these items are present or exist, the vault will be rejected.

D. MATERIALS

1. MANUFACTURERS

a. Precast concrete vaults shall be manufactured by Brooks Products Inc., Utility Vault, or District approved equal.

E. PRECAST CONCRETE VAULTS

1.. Precast concrete vaults shall comply with ASTM C 858 except as

modified herein.

2. Design Requirements

a. Precast concrete vaults and access doors shall be designed for H-20 wheel loading.

b. Design live and dead loads shall be in accordance with ASTM C

857. Design precast concrete vaults to withstand site soil

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conditions and traffic loading of A-16 per Table 1 of ASTM C 857 with a 30% increase due to impact. Soil lateral loads shall be as determined by ASTM C 857. Alternate design by the strength design method shall include a load factor of 1.7 times the lateral earth or hydrostatic pressures.

c. Design shall also comply with the following restrictions: 1). The maximum reinforcement ratio allowed is one-half the

reinforcement ratio that would produce a balanced strain condition.

2). Earth pressure shall be converted to a horizontal pressure using a coefficient of earth pressure at rest of 0.5 and not a coefficient of active earth pressure.

3). Include a live load surcharge of 2 feet of soil in the design of the walls.

d. Precast vault construction shall be in the form of monolithic walls or horizontal wall sections; do not use panel walls.

e. Minimum wall thickness shall be 6 inches. Design knockout wall

panels to accommodate loading pressures defined above.

f. Design and construct vaults to be watertight when subjected to groundwater over the entire height of the vault.

g. Provide openings in precast vaults for piping and access. Provide

cast in place inserts in the roof slab and end walls at the locations as shown on the Drawings. No field coring of openings is allowed.

F PRECAST CONCRETE RISERS

1. Precast concrete grade rings and cones shall comply with ASTM C 478,

except that the wall thickness shall be 6 inches minimum. Provide interlocking keyways on rings and cones. Provide cones with cast in place inserts for the manhole frame.

G. SEALANTS AND MORTAR

1. Fill joints between precast sections with a double layer of plastic sealing

compound and make watertight. Plastic sealing compound shall comply with Federal Specification SS-S00210. Fill with mortar all recesses, lifting inserts, or other cavities not filled with plastic sealing compound. Mortar shall comply with ASTM C 387, Type S.

H. CEMENT

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1. Cement shall be ASTM C 150, Type II.

I ADMIXTURES

1. Provide concrete admixtures as specified in Standard Specification Section

03000.

J. WATERPROOFING

1. The waterproofing material shall be Horn Dehydratine 4, Select Shield 301-A, or District approved equal. The material is a black bituminous compound of brush or spray consistency for application on below grade concrete surfaces.

K. VAULT APPURTENANCES

1. Provide ladders, covers and frames, vents, supports, inserts, eyebolts, and

other miscellaneous metalwork. See Standard Specification Section 05120 for a description of the vault appurtenances.

L. EXECUTION

1 EXCAVATING AND BACKFILLING FOR VAULTS

Perform earthwork as specified in Standard Specification Section 02200. Provide 6-inch minimum thickness 3/4-inch crushed rock over the full width of the vault base and extend 12 inches beyond the edges of the vault. After repairing the waterproofing, backfill and compact around the vault with structural backfill material. Excavated material may be used for structural backfill provided it conforms to the Standard Specifications for structural backfill material.

2 INSTALLING VAULTS AND RISERS

Set each precast concrete vault section or riser plumb on a double layer bed of sealant at least 1/2-inch thick to make a watertight joint with the preceding unit. Point the inside joint and wipe off the excess sealant.

3 WATERPROOFING

Waterproofing shall be factory applied to all exterior surfaces of vaults and risers. This includes the bottom of the vault to be coated as an exterior surface. Apply two coats at a rate of 65 square feet per gallon per coat.

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Prior to backfilling, field apply waterproofing material on joints and damaged surfaces. Protect coating from damage during backfilling and compacting.

PART 3 FORMS

3.1. Plywood: PS 1, waterproof resin-bonded, exterior type Douglas Fir; face adjacent to

concrete Grade B or better

3.2. Lumber: Straight, uniform width and thickness and free from knots, offsets, holes,

dents, and other surface defects

3.3. Chamfer strips: Clear, white pine, surface against concrete planed

3.4. Form coating: The Burke Company "Burke Release #1," Industrial lubricants

"Nox-Crete Form Coating", L & M "Debond", Protex "Pro-Cote", Richmond "Rich

Cote", or equal

3.5. Form ties: Removable end, permanently embedded body types with waterstops not

requiring auxiliary spreaders, with cones on both ends, embedded portion 1 inch

minimum back from concrete face. If not provided with threaded ends, constructed

for breaking off ends without damage to concrete. The Burke Company "Burke

Penta-Tie System" or equal

PART 4 REINFORCING STEEL

4.1. Bars: ASTM A615, Grade 60

4.2. Welded wire fabric: ASTM A185 or A497

4.3. Bar supports: PS 7; CRSI Class B or E, fabricated from galvanized wire having

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PVC coated legs

4.4. Tie Wire: 16-1/2 gage or heavier, black annealed wire

PART 5 CONCRETE

5.1. Cement: ASTM C150, Type II

5.2. Fly ash: ASTM C618, Class C or Class F, except loss on ignition not more than 5

percent

5.3. Fine aggregate: Clean, natural sand, ASTM C33; no manufactured or artificial sand

5.4. Coarse aggregate: Crushed rock, natural gravel, or other inert granular material,

ASTM C33 except clay and shale particles no more than 1 percent. Free of all

material deleteriously reactive with alkalies in the cement in an amount to cause

excessive expansion of concrete

5.5. Water: Clean and free from injurious amount of oils, acids, alkalis, salts, organic

materials, or other substances that may be deleterious to concrete or steel. Provide

missing water free from deleterious amounts of chloride ion for prestressed concrete

or for concrete which will contain aluminum embedments including that portion of

the mixing water contributed in the form of free moisture on the aggregates

5.6. Admixtures:

A. Air entraining agent: ASTM C260; Grace "Darex AEA", Master Builders

"MB-VR", Protex "AES", Sika Chemical "AEK", or equal

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PART 6 ACCESSORIES

6.1. Polyethylene film: ASTM C171, ASTM D2103 6 mil

6.2. Expansion Joint Filler: ASTM D1751, asphalt impregnated fiber board, 1/2 inch

thickness unless indicated otherwise

6.3. Expansion and contraction joint shear bar grease: No-Ox-Id "A Special," axle

grease, or equal

6.4. Membrane curing compound and floor sealer: ASTM C309, Sonneborn "Sonosil"

curing compound or Sonneborn "Lapiolith" concrete hardener and dust proofer, or

equal E. Vapor barrier: Polyethylene-coated reinforced paper, Sisalkraft "Mois-top",

or equal F. Bonding Admixture and Bonding Agent: Sika "Sikalatex" bonding

admixture and agent or Tamms "Akkro-7T" bonding admixture and Tamms

"Tamms Bond" bonding agent, or equal

PART 7 MIX

7.1. Comply with ASTM C94

7.2. Maximum Aggregate Size: 3/4 inch

7.3. Water/Cementitious Material (Cement and Fly Ash) Ratio: 1. Less than or equal to

0.41

7.4. Slump: 4 inch maximum:

A. As low as possible consistent with proper handling and thorough compaction

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7.5. Volumetric Air Content: 6 percent ∀. 1 percent after placement:

A. Maximum 6 percent ∀. 1 percent after placement

B. Vary air content with maximum size aggregate, ASTMC94, Table 3

C. Air may be omitted from interior slabs to be trowel finished

7.6. Strength: Compressive strength as determined by ASTM C39: 3,000 psi minimum

at 28 days

7.7. Consistency: Uniform slump, suitable for the placement conditions with aggregate

floating uniformly throughout the concrete mass, flowing sluggishly when vibrated or

spaded

7.8. Adjust mix as required to meet specifications

7.9. Contractor may substitute fly ash for up to 22 percent of cement at a ratio of the

specific gravity of cement divided by specific gravity of fly ash

PART 8 EXECUTION

8.1 EXAMINATION

A. Verify site conditions under provisions of Section 01010

B. Verify requirements for concrete cover over reinforcement

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C. Verify that anchors, seats, plates, reinforcement and other items to be

encased into concrete are accurately placed, positioned securely, and will not

cause hardship in placing concrete

8.2 FORMS

A. Design to produce hardened concrete to the shape, lines, and dimensions

indicated on the Drawings

B. Conform to ACI 347 as modified herein

C. Plywood or lined forms are not required for surface normally submerged or

not normally exposed to view

D. Other type of forms may be used for surfaces not restricted to plywood or

lined forms as backing for form lining

E. Provide forms above all extended footings; flat segmental forms, 2 foot

maximum width, may be used for curved surfaces 25 feet minimum diameter

F. Provide polyethylene film to protect concrete from water loss when placing

concrete against gravel or crushed rock not containing 25 percent minimum

material passing a No. 4 sieve, lap joint 4 inches

G. When placing concrete against rock, remove all loose pieces of rock and

clean exposed surface with high pressure hose

H. Provide substantial forms sufficiently tight to prevent leakage of concrete

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I. Brace or tie forms to maintain desired position, shape, and alignment during

and after concrete placement

J. Size and space wailers, studs, internal ties and other form supports so

proper working stresses are not exceeded

K. Install form ties on exposed surfaces in uniformly spaced vertical and

horizontal rows

L. Provide chamfer strips to bevel salient edges and corners. Do not provide for

top edges of walls and slabs to be tooled or for edges to be buried

M. Do not remove or disturb until concrete has attained sufficient strength to

safely support all dead and live loads

N. Maintain forms in place for a minimum of 40 hours or for length of curing

time in accordance with ACI 306/306R when temperature is 45 degrees F

and below

O. Remove forms carefully to prevent surface gouging, corner or edge breakage

and other damage

8.3 REINFORCING STEEL

A. Accurately position reinforcing steel on supports, spacers, hangers, or other

reinforcing steel at maximum intervals of 4 feet on centers

B. Secure with wire ties or suitable clips. Tie 50 percent of all reinforcement

and reinforcement at intersections for wall and floor construction

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C. Where reinforcement is placed in 2 layers, place bars in upper layer directly

above bars in lower layer

8.4 TRANSPORTING MIXED CONCRETE

A. Transporting of mixed concrete shall conform to ACI 305R

B.. Do not exceed manufacturer's guaranteed capacity of truck agitators.

Maintain the mixed concrete in a thoroughly mixed and uniform mass during

hauling

C. Do not incorporate additional mixing water into the concrete during hauling or

after arrival at the delivery point, unless ordered by the Engineer. If

additional water is to be incorporated into the concrete, revolve the drum not

less than 30 revolutions at mixing speed after the water is added and before

placing concrete

D. Furnish a water measuring device in good working condition, mounted on

each transit mix truck, for measuring the water added to the mix on the site

by the Engineer

E. Provide delivery ticket and comply with delivery requirements of this section

8.5 PLACING CONCRETE

A. Place concrete in accordance with ACI 301

B. Notify Engineer not less than 24 hrs in advance of the times and places at

which contractor intends to place concrete

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C. Predetermine limits at each pour and place all concrete within limits of pour

in one continuous operation

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D. Rigidly secure forms, reinforcing steel in proper position

E. Remove all mud, water, ice, snow, frozen material, and debris from space to

be occupied by concrete

F. Clean surfaces encrusted with dried concrete from previous concrete

operations

G. Convey to the point of final deposit by methods which will prevent separation

or loss of ingredients

H. Place concrete in final position without being moved laterally more than 5

feet

I. Place concrete in approximately horizontal layers of proper depth for proper

compaction, not more than 2 feet

J. Place subsequent layer while the preceding layer is still plastic

K. Top finish concrete when thoroughly settled

L. Remove all laitance, debris, and surplus water from the tops of the forms by

screeding, scraping or other effective means

M. Overfill the forms for walls whose tops will be exposed to the weather and

screed off the excess after the concrete has settled

N. Provide vertical construction joints as required to comply with these

requirements

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8.6 COMPACTION

A. Thoroughly compact concrete during and immediately after placement

B. Work concrete around all reinforcements and embedments and into the

corners of the forms

C. Use mechanical vibrators which will maintain 9,000 cycles per minutes when

immersed in the concrete, 1-1/2 hp motor minimum

8.7 COLD WEATHER CONCRETING

A. Conform to ACI 306/306R, except as modified herein

B. Minimum concrete temp at the time of mixing

Outdoor Temp at Placement (in shade) Concrete Temp at Mixing

Below 30 degrees F 70 degrees F

Between 30 degrees F and 45 degrees F 60 degrees F

Above 45 degrees F 45 degrees F

C. Do not place heated concrete which is warmer than 80 degrees F

D. If freezing temp are expected during curing, maintain the concrete temp at or

above 50 degrees F for 5 days or 70 degrees F for 3 days with forms in

place

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E. Do not allow concrete to cool suddenly

8.8 HOT WEATHER CONCRETING

A. Conform to ACI 305/305R, except as modified herein

B. At air temp of 90 degrees F and above keep concrete as cool as possible

during placement and curing

C. Do not allow concrete temperature to exceed 70 degrees F at placement

D. Prevent plastic shrinkage cracking due to rapid evaporation of moisture

E. Do not place concrete when the actual or anticipated evaporation rate equals

or exceeds 0.2 lbs per sq ft per hr as determined from ACI 305, Fig 2.1.4

8.9 FINISHING UNFORMED SURFACES

A. Float finish buried or permanently submerged concrete not forming an

integral part of a structure except as required to attain surface elevations,

contours and freedom from laitance

8.10 CURING AND PROTECTION

A. Protect concrete from moisture loss at relatively constant temperature for at

least 7 days after placement except that the time period for curing by

saturation for concrete being protected from low temp shall be 1 day less

than the duration of low temp protection

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B. Cure concrete by methods which will keep concrete surfaces adequately wet

during curing, in accordance with ACI 308

C. Maintain rate of temperature change less than 5 degrees F in any one (1)

hour period

D. Water curing:

1. Begin water saturation as quickly as possible after initial set

2. Regulate water application to provide complete surface coverage with

a minimum of runoff

3. Interrupt the application of water to walls for grout cleaning only over

the area being cleaned at the time and do not permit the surface to

become dry during such an interruption

E. Membrane curing:

1. Membrane curing compound may be used in lieu of water curing on

concrete which will not be covered later with mortar or concrete

2. Spray apply membrane curing compound at not more than:

a. General use: 300 sf per gal recommended

3. Cover unformed surfaces within 30 minutes of final finishing

4. If forms are removed before the end of the curing period, immediately

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apply curing compound to the formed surface before they dry out

5. Protect curing compound against abrasion during the curing period

F. Film curing:

1. Polyethylene sheeting may be used in lieu of water curing on

concrete which will be covered or hidden from view

2. Begin film curing as quickly after initial set of the concrete as possible

3. Completely cover the surfaces with polyethylene sheeting

4. Overlap the sheeting edges for sealing and anchorage

5. Seal joints between sheets

6. Promptly repair tears, holes, and other damage

7. Anchor covering continuously at edges and on the surfaces as

required to prevent billowing

8.11 DEFECTIVE CONCRETE

A. Defective Concrete: Concrete not conforming to required lines, details,

dimensions, tolerances or specified requirements

B. Repair or replacement of defective concrete will be determined by the

Engineer

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C. Repair defects in formed concrete surfaces within 24 hours of removing

forms

D. Replace defective concrete within 48 hrs

E. Cut out and remove to sound concrete honeycombed or otherwise defective

concrete

F. Cut edges square to avoid feathering

G. Comply with Chapter 9, ACI 301

H. Perform repair work so as not to interfere with thorough curing of adjacent

concrete

I. Adequately cure repair work

8.12 FIELD QUALITY CONTROL

A. Field inspection and testing will be performed in accordance with ACI 301

under provisions of Sections 01010 and 01400

B. Slump: Test a sample from each truck load in accordance with ASTM C143

if requested by Engineer and when making test cylinders

C. Air Content: Test a sample from each truck load if requested by Engineer