Sp Ci Cc 001 Concrete Work Specification

DOCUMENT NO. REV.

PT Caltex Pacific Indonesia SP-CI-CC-001 1

DATE: June 27, 02 SHEET: 1 OF 30

PREPARED BY Darmawan B DBS

CHECKED BY Darmawan B DBS SPECIFICATION

APPROVED BY Shawn SPD

CONCRETE WORK SPECIFICATION

PT. CALTEX PACIFIC INDONESIA

REV DATE PAGES DESCRIPTION PREP’D CHK’D APP’D

0 9/17/01 ALL ISSUED FOR IMPLEMENTATION DBS DBS SPD

1 15/5/02 ALL CPI SPEC REVIEW TEAM FIB

TABLE OF CONTENT

1. GENERAL .......................................................................................................................... 2

1.1. Scope........................................................................................................................ 2

1.2. References................................................................................................................. 2

1.3. Terminology.............................................................................................................. 6

1.4. Conflicting Requirements ........................................................................................... 6

1.5. Submittals................................................................................................................. 6

1.6. Delivery.................................................................................................................... 8

2. PRODUCTS ........................................................................................................................ 8

2.1. General..................................................................................................................... 8

2.2. Materials .................................................................................................................. 8

2.3. Design Criteria ....................................................................................................... 14

2.4. Mixing Procedure.................................................................................................... 15

3. EXECUTION .................................................................................................................... 16

3.1. Preparation............................................................................................................. 17

3.2. Installation.............................................................................................................. 18

3.3. Curing and Protection ............................................................................................. 26 3.4. Testing.................................................................................................................... 27

3.5. Field Quality Control............................................................................................... 29

OPTIONAL ATTACHEMENTS FOR THIS SPECIFICATION:

ADDENDUM 1: “Project Specific Clarifications & Requirements”

PT. CALTEX PACIFIC INDONESIA Concrete Work SP-CI-CC-001 Rev. 1

September 17, 2001 Page 2 of 29

1. GENERAL

1.1. Scope

This specification prescribes the requirements for cast-in-place and precast concrete construction. The scope of this specification consists as follows:

?? Construction of plain and reinforced concrete work.

?? Sampling, testing, and inspecting concrete and concrete construction.

?? Placing anchor bolts and embedments for structural items.

?? Detailing, providing fabrication, and placing steel bar reinforcing, including reinforcing supports and accessories.

1.2. References

1.2.1. Related Specifications

Work prescribed by this specification is to be coordinated with Work, which is prescribed in other specification.

These following specifications prescribe items of related work:

?? SP-CI-CI-001 Earthwork

?? SP-CI-GG-002 General Specification for Civil and Structural

?? PP-CI-CC-001 Construction Procedure for Concrete Formwork

?? PP-CI-CC-002 Construction Procedure for Concrete Work

?? PP-CI-CC-003 Construction Procedure for Reinforcing Bar Work

?? PP-CI-CC-004 Concrete Mix Design

?? PP-CI-CC-005 Construction Procedure for Foundation and Anchor Bolt Setting Work

?? PP-CI-GG-005 Inspection and Testing Services

1.2.2. Code and Standard

The publications listed below form of this specification. Each publication shall be latest revision and addendum in affect at the time of the project’s execution unless noted otherwise. Except as modified by the requirements specified herein or the details of the drawings, all Works included in this specification shall conform to the applicable provisions of these publications.

ACI (American Concrete Institute) ACI 207R Mass Concrete ACI 211.1 Standard Practice for Selecting Proportions for Normal,

Heavyweight, and Mass Concrete ACI 211.2 Standard Practice for Selecting Proportions for Structural

Lightweight Concrete ACI 214 Recommended Practice for Evaluation of Strength Test

Results of Concrete



Results of Concrete ACI 301 Standard Specifications for Structural Concrete for Buildings ACI 302.1R Guide for Concrete Floor and Slab Construction ACI 304R Guide for Measuring, Mixing, Transporting, and Placing

Concrete ACI 304.2R Placing Concrete by Pumping Methods ACI 305R Hot Weather Concreting ACI 306R Cold Weather Concreting ACI 308 Standard Practice for Curing Concrete ACI 309 Standard Practice for Consolidation of Concrete ACI 315 Standard Practice for Details and Detailing of Concrete

Reinforcement ACI 318/318R Building Code Requirements for Structural Concrete (ACI

318) and Commentary (ACI 318R) ACI 347R Guide to Form work for Concrete ACI 504R Guide to Sealing Joints in Concrete Structures ACI SP-15 Standard Specification for Structural Concrete for ACI 301-

96 with selected ACI and ASTM References ACI SP-66 ACI Detailing Manual

AISC (American Institute for Steel Construction) Code of Standard Practice for Buildings and Bridges

ASTM (American Society for Testing and Materials)

The standards of the American Society for Testing and Materials are listed under Section 1.4 of ACI 301 and are declared to be a part of this specification. In addition, the following form a part of this specification to the extent referenced: ASTM A82 Standard Specification for Steel Wire, Plain, for Concrete

Reinforcement ASTM A184 Standard Specification for Fabricated Deformed Steel Bar

Mats for Concrete Reinforcement ASTM A185 Standard Specification for Steel Welded Wire Fabric, Plain,

for Concrete Reinforcement ASTM A370 Standard Test Methods and Definitions for Mechanical

Testing of Steel Products ASTM A497 Standard Specification for Steel Welded Wire Fabric,

Deformed, for Concrete Reinforcement ASTM A615 Standard Specification for Deformed and Plain Billet-Steel

Bars for Concrete Reinforcement ASTM A767 Standard Specification for Zinc-Coated (Galvanized) Steel

Bars for Concrete Reinforcement ASTM A775 Standard Specification for Epoxy-Coated Reinforcing Steel

Bars ASTM A820 Standard Specification for Steel Fibers for Fiber-Reinforced

Concrete ASTM C29 Standard Test Method for Bulk Density (Unit Weight) and

Voids in Aggregate ASTM C31 Standard Test Method for Making and Curing Concrete Test

Specimens in the Field



ASTM C33 Standard Specification for Concrete Aggregates ASTM C39 Standard Test Method for Compressive Strength of

Cylindrical Concrete Specimens ASTM C40 Standard Test Method for Organic Impurities in Fine

Aggregates for Concrete ASTM C88 Standard Test Method for Soundness of Aggregates by Use

of Sodium Sulfate or Magnesium Sulfate ASTM C91 Standard Specification for Masonry Cement ASTM C94 Standard Specification for Ready-Mixed Concrete ASTM C109 Standard Test Method for Compressive Strength of

Hydraulic Cement Mortars (Using 2-in. or 50-mm Cube Specimens)

ASTM C117 Standard Test Method for Materials Finer than 75-micrometer (Number 200) Sieve in Mineral Aggregates by Washing

ASTM C123 Standard Test Method for Lightweight Particles in Aggregate

ASTM C127 Standard Test Method for Specific Gravity and Absorption of Coarse Aggregate

ASTM C128 Standard Test Method for Specific Gravity and Absorption of Fine Aggregate

ASTM C131 Standard Test Method for Resistance to Degradation of Small Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

ASTM C136 Standard Method for Sieve Analysis of Fine and Coarse Aggregates

ASTM C138 Standard Test Method for Density (Unit Weight), Yield, and Air Content (Gravimetric) of Concrete

ASTM C142 Standard Test Method for Clay Lumps and Friable Particles in Aggregates

ASTM C143 Standard Test Method for Slump of Hydraulic Cement Concrete

ASTM C144 Standard Specification for Aggregate for Masonry Mortar ASTM C150 Standard Specification for Portland Cement ASTM C171 Standard Specification for Sheet Materials for Curing

Concrete ASTM C172 Standard Practice for Sampling Freshly Mixed Concrete ASTM C207 Standard Specification for Hydrated Lime for Masonry

Purposes ASTM C227 Standard Test Method for Potential Alkali Reactivity of

Cement-Aggregate Combinations (Mortar-Bar Method) ASTM C260 Standard Specification for Air-Entraining Admixtures for

Concrete ASTM C270 Standard Specification for Mortar for Unit Masonry ASTM C289 Standard Test Method for Potential Alkali-Silica Reactivity

of Aggregates (Chemical Method) ASTM C295 Standard Guide for Petrographic Examination of Aggregates

for Concrete ASTM C309 Standard Specification for Liquid Membrane-Forming

Compounds for Curing Concrete



Compounds for Curing Concrete ASTM C330 Standard Specification for Lightweight Aggregates for

Structural Concrete ASTM C404 Standard Specification for Aggregates for Masonry Grout ASTM C494 Standard Specification for Chemical Admixtures for

Concrete ASTM C531 Standard Test Method for Linear Shrinkage and Coefficient

of Thermal Expansion of Chemical-Resistant Mortars, Grouts, and Monolithic Surfacing

ASTM C579 Standard Test Method for Compressive Strength of Chemical-Resistant Mortars, Grouts, and Monolithic Surfacing and Polymer Concrete

ASTM C595 Standard Specification for Blended Hydraulic Cements ASTM C618 Standard Specification for Coal Fly Ash and Raw or

Calcined Natural Pozzolan for Use as a Mineral Admixture in Concrete

ASTM C827 Standard Test Method for Change in Height at Early Ages of Cylindrical Specimens from Cementitious Mixtures

ASTM C882 Standard Test Method for Bond Strength of Epoxy-Resin Systems used with Concrete by Slant Shear

ASTM C1017 Standard Specification for Chemical Admixtures for Use in Producing Flowing Concrete

ASTM C1064 Standard Test Methods for Temperature of Freshly-Mixed Portland Cement Concrete

ASTM C1157 Standard Performance Specification for Blended Hydraulic Cement

ASTM D412 Standard Test Methods for Rubber Properties in Tension ASTM D512 Standard Test Method for Chloride Ion in Water ASTM D516 Standard Test Methods for Sulfate Ion in Water ASTM D994 Standard Specification for Preformed Expansion Joint Filler

for Concrete (Bituminous Type) ASTM D1056 Standard Specification for Flexible Cellular Materials-

Sponge or Expanded Rubber ASTM D1751 Standard Specification for Preformed Expansion Joint Filler

for Concrete Paving and Structural Construction (Non-extruding and Resilient Bituminous Types)

CRD (Corps of Engineer) CRD C611 Method of Test for Flow of Grout Mixtures (Flow Cone Method) CRD C621 Corps of Engineers Specification for Non-shr ink Grout

NRMCA (National Ready Mixed Concrete Association) Checklist for Ready Mixed Concrete Production Facilities

AWS (American Welding Society) D14 Structural Welding Code ---Reinforcing Steel

OSHA (Occupational Safety and Health Administration)

JIS (Japanese Industrial Standards) G3112 Steel Bars for Concrete Reinforcement



1.3. Terminology

In this specification, the following words and terms shall have the meanings hereby assigned to them, unless noted otherwise.

1.3.1. COMPANY

Refers to PT. CALTEX PACIFIC INDONESIA, as the ultimate user and owner, the authorized representative of COMPANY or COMPANY third party inspection.

1.3.2. CONTRACTOR

Refers to company selected by COMPANY, which may be responsible for the detailed engineering design, material and equipment procurement, and construction as specified in Contract, Scope of Work, or Work Order.

1.3.3. Vendor

Refers to the company selected by COMPANY or CONTRACTOR, which is responsible for the purchase agreement or purchase order of the goods/services specified in this specification.

Note: ?? For EPC (Engineering, Procurement and Construction) project purposes:

The terminology shall have the meanings as above.

?? For “ Direct Procurement “ by COMPANY purposes: Vendor shall also be responsible as CONTRACTOR.

1.4. Conflicting Requirements

1.4.1. In case of conflict between this Specification and its associated Specifications and the above Codes and Standards, the Vendor shall bring the matter to the COMPANY’s attention for resolution and approval in writing. However, the most stringent requirement shall apply.

1.4.2. Should conflicts exist between this specification and other documents, the following order of precedence shall govern: ?? Scope of Work ?? Data Sheets. ?? This Specification ?? Other COMPANY Specifications ?? Other Referenced Publications ?? Approved for Construction Drawings

?? Vendor’s Code

1.5. Submittals

1.5.1. CONTRACTOR shall submit one (1) copy of the following documentation for review and approval as required by Project Requirements, not less than 14-days prior to placing any concrete:



?? Mix designs for each combination of ingredients on each class of concrete for review. Mix designs shall be proportioned in accordance with Chapter 3 of ACI 301.

?? Trial batch qualification test results, or completes standard deviation analysis based on previous field experience.

?? Ingredients test results or certifications.

?? Compressive strength for 7-days, 14-days, and 28-days results.

?? Material suppliers, sources, properties, and certifications.

?? The current National Ready Mixed Concrete Association Certificate of Conformance for Concrete Production Facilities for Vendor’s Plants, if concrete is provided by a Ready Mixed Concrete Vendor.

1.5.2. Prior to the production of concrete, CONTRACTOR shall submit:

?? One (1) copy of Manufacturer’s specifications with application and installation instructions for proprietary materials and items.

?? A complete description of proposed curing methods.

1.5.3. A delivery ticket for each batch, conforming to Section 16 of ASTM C94. Breaks of 500 psi below the specified design strength at 28-days shall be submitted on the same day. Reports shall contain the project identification name and number, date of concrete placement, name of CONTRACTOR, name of concrete supplier and truck number, name of concrete testing service, concrete type and class, location of concrete in structure, design compressive strength at 28-days, compressive break strength, and type of break.

1.5.4. Prior to placing reinforcing steel, CONTRACTOR shall submit the following:

?? Bar lists for fabrication of reinforcing steel.

?? Field placing drawings.

?? Certified mill test reports for each bar size for each heat of delivered reinforcing steel.

1.5.5. Manufacturer of grout shall submit the following data for approval not less than 14-days prior to placing any grout:

?? Compressive strength at 12-hours, 7-days, and 28-days.

?? Shrinkage or expansion factors.

?? Coefficient of linear thermal expansion.

?? Water absorption.

?? Specific Gravity.

?? Pot life at 70?F (21?C) and 95?F (35?C).

?? Recommended optimum pour depth range.

?? Complete instructions for surface preparation, forming, mixing, pouring, and curing.



1.5.6. CONTRACTOR shall submit the following data of mortar for review:

?? Manufacturer’s published data for each type mortar furnished, including mixing, handling, and storage instructions.

?? Cured (28-days) sample of color pigmented mortar.

?? Certification of the percentage of free alkali in Portland cement to be used.

1.6. Delivery

1.6.1. Concrete

1.6.1.1 Deliver ready mixed concrete in truck mixer, meeting the requirements of ASTM C94.

1.6.1.2 Water reducing, accelerating, and air entraining admixtures are to be added at the batch plant, while accelerators and retarders may be added at the batch plant or job Site. Refer to ACI 304R, Section 4.5, for requirements for charging of ingredients into the mixer.

1.6.1.3 Add high range water reducing admixtures to the concrete at the project Site, after verification of the initial slump.

1.6.2. Reinforcing Steel

1.6.2.1 Reinforcing steel shall be prepared for shipment in such a manner that quality and cleanliness shall be maintained during shipment. Materials shall be adequately protected against damage during shipment.

1.6.2.2 Shipments shall be by structure to the maximum extent possible.

1.6.2.3 Store reinforcement above ground and protect from dirt, oil, and grease.

1.6.3. Grout and Mortar

1.6.3.1 Deliver material and products in Manufacturer’s original, unopened packages. Identify clearly each package with contents, and Manufacturer’s name and address.

1.6.3.2 Store and handle materials and products in Manufacturer’s original, unopened packages to prevent damage caused by vandalism, weather, or work performed under this specification or by other trades.

2. PRODUCTS

2.1. General

All products listed under the following Materials section shall be submitted to COMPANY for review and approval. A product that is not listed will not be used without written approval of COMPANY. All products shall meet applicable local VOC (Volatile Organic Compounds) regulations.

2.2. Materials

2.2.1. Concrete Materials



2.2.1.1 Cement

ASTM C150 Type I.

2.2.1.2 Fly ash

ASTM C618, Class F.

2.2.1.3 Fine and coarse aggregates

ASTM C33 for normal weight concrete; ASTM C330 for lightweight concrete. All aggregates shall be composed of inert materials that are durable, strong, and reasonably free of dust and organic matter. Dune sand, bank run sand, and manufactured sand are not acceptable.

2.2.1.4 Water

Mixing water for concrete shall meet the requirements of ASTM C94. Water shall be potable unless otherwise approved by COMPANY. When unpotable water is used, mortar test cubes shall be made in accordance with ASTM C109. Tested cubes shall have at least 90% of the 28-days strength of cubes made with potable water and shall not be less than the minimum specified.

2.2.2. Admixtures

Admixtures containing calcium chloride, thiocyanates, or any admixture shall not contribute more than 0.005 percent.

2.2.2.1 Air entrainment

ASTM C260, liquid air-entraining admixture

2.2.2.2 Water reducing

ASTM C494, Type A

2.2.2.3 Water reducing and retarding

ASTM C494, Type D

2.2.2.4 High range water reducer

ASTM C494, Type F or G (superplasticizer)

2.2.2.5 Noncorrosive, nonchloride accelerator (if specified)

ASTM C494, Type C or E and not contain more chloride ions than are present in municipal drinking water.

2.2.3. Concrete Accessories

2.2.3.1 Bonding compounds

The compound shall be a polyvinyl acetate type and rewettable on areas not exposed to moisture. Obtain COMPANY’s approval prior to use.

2.2.3.2 Epoxy adhesive

The compound shall be 2-components; 100 percent solids and 100 percent reactive compound suitable for use on dry or damp surfaces.



2.2.3.3 Repair topping

Latex and microsilica modified cementitious mortar designed for use as a floor or deck topping.

2.2.3.4 Underlayment Compound

Free-flowing, self-leveling, and pumpable cementitious base compound.

2.2.3.5 Vapor barrier

10-mil thick clear polyethylene film or fabric reinforced plastic film; recommended for below grade applications.

2.2.3.6 Synthetic fibers

Monofilament or Fibrillated polypropylene fibers for secondary reinforcing of concrete members.

2.2.3.7 Patching mortar

Free-flowing polymer-modified cementitious coating.

2.2.3.8 Liquid Densifier

Siliconate compound that reacts with the concrete constituents to harden the surface.

2.2.3.9 Anti-corrosion Epoxy/Cementitious Adhesive

Water-based epoxy resin for adhesion and corrosion protection of reinforcing members.

2.2.4. Curing Compounds and Accessories

In areas that require VOC (Volatile Organic Compounds) compliance for curing compounds, CONTRACTOR shall select a product and submit for COMPANY’s approval.

2.2.4.1 Liquid membrane curing compounds

ASTM C309, Type I, ID, Class A and B; shall be water clear, styrene acrylate type, and minimum solid content 30 percent. Maximum moisture loss shall not exceed 5.5x10-4 pounds/inch2 when applied at a coverage rate of 300 ft2 per gallon. Application rate shall not exceed that as stated by the manufacturer, which shall meet the moisture retention requirements.

2.2.4.2 Liquid chemical curing compounds

ASTM C309, Type I, ID, Class A and B, have minimum solid content of 14 percent.

2.2.4.3 Polyethylene film

ASTM C171, 4-mil thick, clear, white opaque color or black.

2.2.4.4 Absorptive mats

ASTM C171, cotton fabric or burlap-polyethylene, minimum 8-ounces per square yard, bonded to prevent separation during handling and



placing.

2.2.5. Products for Joints in Concrete

2.2.5.1 Joint Primer

A 2-components penetrating liquid urethane based primer, for use with urethane and epoxy sealant.

2.2.5.2 Backup material

ASTM D1056, round closed cell foam rod, oversized 30 to 50 percent larger than joint width.

2.2.5.3 Waterstop

Waterstops shall be heavy-duty dumbbell or centerbulb type in accordance with ASTM D412 and shall be made for extruded PVC (polyvinyl chloride) with a minimum width of 6-inches, unless noted otherwise.

2.2.5.4 Joint Filler

?? ASTM D994, bituminous impregnated fiberboard, ½-inch and 1-inch thickness.

?? ASTM D1751, asphalt impregnated cork, with asphalt saturated glass-fiber felt liners, ½ -inch thickness.

2.2.5.5 Joint Sealant

?? Joint sealant shall conform to the provisions of ACI 504R.

?? Expansion and isolation joints: Self-leveling, 2-components polyurethane sealant.

?? Control and construction joints: Corrosion resistant, 2-components resin hardener for joints cut with Soft-Cut saws.

2.2.6. Reinforcing Steel

2.2.6.1 Fabrication

?? Reinforcing bars: ASTM A615, Grade 60, deformed billet-steel bars, plain finish unless noted otherwise herein.

?? Reinforcing bar mat: ASTM A184, deformed billet-steel bars, plain finish.

?? Spiral reinforcing: ASTM A82, cold-drawn plain steel wire, plain finish; for spiral reinforcing in columns, cast-in-place piles, drilled piers, and caissons.

?? Welded wire fabric: ASTM A185, cold-drawn plain steel; ASTM A497, cold-worked deformed steel; in flat sheets, plain finish.

?? Coatings: ASTM A767 for galvanized coating or ASTM A775 for epoxy coating.

?? Bar bends and fabrication tolerances shall be in accordance with ACI



315.

?? Bar supports shall be in accordance with Chapter 5 of ACI 301.

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

?? Reinforcement bars/steel shall be free from mud, oil, and other nonmetallic coatings that decrease bond.

?? Reinforcing steel shall be bent cold. Rebending of hooks shall not be permitted. Bars may be straightened provided the bend is more than or equal to 2 times the recommended minimum diameter of bends.

?? Materials shall be new and in accordance with the ASTM specification or other recognized standards specified. Certificates of compliance of reinforcing steel with applicable ASTM standards and mechanical test reports of the tensile and bend tests shall be submitted to COMPANY for approval.

2.2.6.2 Placing Drawings and Bending Schedules

?? Placing drawings and bending schedules showing the number, grade, size, length, mark, location, and bending diagrams for reinforcing steel shall be prepared in accordance with ACI 315.

?? Lap splices shall be as indicated on the design drawings.

?? Each structure and foundation shall have a different identity number.

2.2.6.3 Identification and Tagging

?? Tag reinforcing in accordance with this specification using embossed metal tags.

?? Tag each bundle of bars, straight or bent, showing drawing number, structure, mark number, bar quantity, and size. Any bundle of reinforcing steel not so tagged or not readily identifiable will be subject to rejection.

?? Tag stock length straight bars showing number of bars, grade, size, and length.

2.2.7. Products for Concrete Formwork

Design and installation of formwork, tolerances, preparation of form surfaces, removal of forms, and reshoring is to be in strict accordance with Chapter 4 of ACI 301 and applicable section of ACI 347. Form may be constructed of lumber, steel, plywood, wood fiberboard, or a combination of these materia ls. Form materials shall be free of surface defects that would adversely affect the concrete finish.

2.2.8. Grout Materials

Grout shall be used for supporting structures and equipment on foundations. Grout to be used for equipment shall follow Table 1 below. Miscellaneous consists of non-structural columns like ladder, stair, instrumentation support, electrical support, etc. Static equipment consists of vessels, towers, structural



columns, heat exchangers, etc. The type of grouts shall be approved by COMPANY. Additive of prone for oxidation shall not be used.

Table 1

GROUT TYPES Pumps, Fans & Drivers

Miscellaneous Static Equipment < 500 hp > 500 hp

Compressors

Cement Mortar Non-shrinking grout

Non-shrinking grout

Epoxy grout Epoxy grout

2.2.8.1 Cement Mortar

Cement Mortar shall be mixed in volumetric proportions of one part cement and two parts clean sand, preferably having sharp-angled grains, using a minimum amount of water. Water shall be potable.

2.2.8.2 Non-shrinking or Expanding Grout

The non-shrinking or expanding grout shall be cement based, pre-measured, pre-packaged materials supplied by the manufacturer with the exception of water. Minimum the non-shrinking or expanding grout shall be 10,000 PSI. Metallic fillers shall not be acceptable as non-shrink or expansive additive. Grout containing calcium chloride additive is not acceptable. The grout shall be of good flowable consistency without setting accelerators in accordance with CRD C611. Expanding grout shall have a maximum expansion factor of 1.5 percent. Grout expansion shall not continue after seven days in accordance with ASTM C531 and ASTM C827.

2.2.8.3 Epoxy Grout

The epoxy grout shall be nonmetallic and formulated with thermosetting resins and inert fillers. The cured grout shall be unaffected by oils, synthetic lubricants, water, or chemicals. The epoxy grout shall be supplied in premeasured packages to facilitate accurate field mixing. The mixed consistency shall be pourable and self-leveling to ensure simple, accurate placement. The peak exothermic temperature rise from ambient at maximum recommended pour depth shall not exceed 120?F (49?C). The direct contact temperature limit of grout to be used shall exceed the calculated temperatures of machinery by at least 10 percent.

2.2.9. Mortar Materials (ASTM C270)

2.2.9.1 Portland Cement

Portland Cement to be used shall conform to ASTM C150 Type I. In addition, Portland Cement is used for exterior mortar shall contain not more than 0.1 % free-alkali water in accordance with ASTM C114.

2.2.9.2 Masonry Cement (ASTM C91)

?? Lime Putty



a. Hydrated Lime: ASTM C207, Type S. b. Lime Paste: Made from hydrated lime.

?? Sand (ASTM C144) Sand for mortar shall also pass No. 16 sieve, with 10 percent passing a No. 100 sieve. Use one source for all sand.

?? Water Clean and potable, free of deleterious amounts of acids, salts, or organic materials.

?? Antifreeze or Accelerating Compounds Do not add antifreeze compounds to the mortar.

2.3. Design Criteria

2.3.1. Concrete Strength

Unless noted otherwise, minimum 28-days compressive strength (fc’) shall be as follows:

2.3.1.1 Structural Foundations: fc’ = 3000 psi

2.3.1.2 Slabs on grade: fc’ = 3000 psi

2.3.1.3 Structures, columns, beams, slabs: fc’ = 3000 psi

2.3.1.4 Underground ducts, lean concrete, and other non-structural foundations: fc’ = 2000 psi

2.3.1.5 Fireproofing: fc’ = 3000 psi

If high early strength concrete is specified, compressive strength shall be 7-days strength.

2.3.2. Slump

The specimens for slump test are taken out prior to placement of concrete at the job site location and at the batching plant in accordance with ASTM C143.

The consistency of the concrete mix shall be such that it is plastic and workable by having a slump in accordance with the requirements below, if consolidation is to be by vibration method. The maximum slump values may be increased by 1-inch if consolidation is to be by methods other than vibration.

2.3.2.1 Footings, piers, piling, and walls: 2-inches to 4-inches

2.3.2.2 Beams, reinforced slabs, and columns: 1-inch to 4-inches

2.3.2.3 Fireproofing, side walks, slabs on ground, and underground ducts: 2-inches to 6-inches

2.3.2.4 Pours over 2.5 feet thick: 1-inch to 2½-inches

2.3.2.5 Bridge decks: 2-inch to 3-inches

2.3.2.6 Concrete containing high range water reducer:

?? When high range water reducer is added to maintain slump with lower water/cement ratio, slump shall be as specified above, after



addition of the reducer.

?? When high range water reducers is added to increase slump without changing water/cement ratio, slump before addition of reducer shall be as specified above and shall not exceed 8-inches after addition of reducer.

2.3.3. Water-Cement Ratio

Maximum 0.40 for water retaining (hydraulic) structures and concrete subject to, brackish water, or salt spray; 0.45 for other structures.

2.3.4. Formwork

Design and construction shall comply with Chapter 4 of ACI 301, applicable sections of ACI 347, and the building code of the local jurisdiction.

2.3.5. Grout strength

?? Non-shrinking or Expanding Grout: fc’ = 10,000 psi ?? Epoxy Grout: fc’ = 14,000 psi

2.4. Mixing Procedure

2.4.1. Concrete

2.4.1.1 Proportion normal weight concrete mixes in accordance with Chapter 3 of ACI 301, mass concrete mixes in accordance with Appendix 5 of ACI 211.1, and lightweight concrete mixes in accordance with ACI 211.2 on the basis of either previous field experience or trial mixes. Do not proportion concrete mixes based on empirical data. Refer to Appendix A of ACI 301 for flow chart on proportioning normal weight concrete mixes. Mixing and transportation of concrete shall be in accordance with Chapter 4 of ACI 304R.

2.4.1.2 Include proposed chemical admixtures in mix design in same proportions and batching sequence as shall be used in production concrete.

2.4.1.3 The proposed mix designs shall be accompanied by complete standard deviation analysis or trial mix test data.

2.4.1.4 Determine standard deviation and required average compressive strength in accordance with the requirements of ACI 301.

2.4.1.5 Under no circumstances shall the concrete contain more than 2% calcium chloride by weight of cement.

2.4.1.6 Give particular attention to aggregate gradation for pumpable concrete mixes.

2.4.1.7 Concrete shall be air entrained according to Table 3.4.1 of ACI 301. Interior floor slabs preferably shall have no air entrainment, with no more than 3 percent entrapped air.



2.4.1.8 Fly ash may be used as a cementitious material, with the fly ash replacing a maximum of 20 percent of the cement (by weight). The fly ash shall be used in calculating the water-cement ratio and shall come from the same source.

2.4.2. Grout

Grout shall be mixed in strict accordance with the grout Manufacturer’s procedures and limitations. For mixing cement grout, a “paddle” mixer shall be used to minimize air entrapment. Water shall be placed in the mixer first and the cement shall be added slowly. Total mixing time shall not exceed 5-minutes, including a minimum of 2-minutes after adding the last bag. The time from start of mixing until placement shall not exceed 10-minutes. Ambient temperature during mixing, placing, and curing for all grout types shall normally be within the range of 40?F to 90?F (4?C to 32?C), unless otherwise accepted by the Manufacturer’s specification. If grouting is to be done when ambient temperatures are not between 40?F and 90?F, then hot or cold weather procedures as specified in ACI 305 or ACI 306 must be followed.

2.4.3. Mortar

Parts by volume as follows:

2.4.3.1 Cement Lime Mortars (Use where work is exposed to weather) Mortar Type

Portland Cement

Lime Putty

Sand

M 1 ¼ S 1 Over ¼ to ½ N 1 Over ½ to 1 ¼

No less than 2 ¼ or more than 3 times the sum of separate volumes of cementitious materials

2.4.3.2 Masonry Cement Mortars (Use for fire rated assemblies and where work is not exposed to weather)

Mortar Type

Portland Cement

Masonry Cement

Sand

M 1 1 4 ½ to 6 S ½ 1 3 ½ to 4 ½ N 0 1 2 ¼ to 3

2.4.3.3 Mix color pigmented mortar according with Manufacturer’s instruction

to produce color as selected by COMPANY.

2.4.3.4 Mix materials in mechanical batch mixer with water quantity consistent with workability to provide maximum bond strength and impermeability to moisture. Measure material by volume in accurately calibrated containers. Measurement by shovel count is prohibited.

3. EXECUTION



3.1. Preparation

3.1.1. Anchor Bolts and Embedments

3.1.1.1 Steel, ironwork, pipe sleeves, inserts, wood blocking, nailer strips, isolation joint material, construction joint dowels, and other fixtures as shown, specified or required to be built into concrete shall be placed accurately and secured against displacement during concreting. Sufficient time between erection of forms and placing concrete shall be given to the various trades to permit proper installation of their work. The installation of anchors, inserts, and sleeves for electrical, mechanical, plumbing, heating, and ventilation work shall be subjected to the inspection and approval of the supervisor of the particular trade or trades involved before concrete is placed.

3.1.1.2 The installation of and tolerances for anchor bolts and embedded items shall comply with paragraph 7.5 of the AISC Code of Standard Practice.

3.1.1.3 Protect bolt threads against damage and concrete cap or plug sleeves to keep out water, concrete, and debris.

3.1.1.4 Tack welding of anchor bolts, reinforcing steel, and embedments is not permitted unless note otherwise.

3.1.2. Concrete

3.1.2.1 Preparation before placement and conveying of concrete shall be in accordance with Chapter 8, Section 8.1 and 8.2 respectively of ACI 301.

3.1.2.2 Before placing concrete, surfaces of form and/or concrete shall be sufficiently cleaned and water sprayed. Ponding on any surfaces will not be permitted. Form surfaces should be waxed or greased, if required.

3.1.2.3 Any laitance on the surface of construction joints shall be removed. The surface of hardened concrete against which fresh concrete is to be placed shall first be roughened by an approved method.

3.1.2.4 Anchor bolts and other items to be embedded in concrete (water stop, anchor boxes, insert plates, pipe sleeves, etc.) shall be placed and secured in position. All such items shall be held in position rigidly to prevent displacement while concrete is being placed. Anchor bolts shall be set by using templates and shall be carefully plumbed and checked for location and elevation.

3.1.3. Grout

Surfaces contacting grout shall be cleaned free of all oil, grease, paint, or loose material. Laitance shall be removed from new concrete surfaces to be covered with grout. The laitance can be removed by chipping following set, or by painting the wet concrete surface with retarder and flushing and brushing following set. Surfaces shall be thoroughly flushed with clean fresh water. Excess water shall be removed by air blowing or with clean rags. Surfaces shall be wet when the cementitious grout is placed. When epoxy grout is used, all surfaces meeting the epoxy grout shall be kept dry before application.



3.2. Installation

3.2.1. Formwork

3.2.1.1 The design, installation, and removal of formwork shall be in accordance with ACI 347 except as modified herein. Wall and soil supported member forms may be removed after 48 hours provided the concrete is sufficiently hard not to be damaged by form removal, and provided curing operations start immediately. Self-supporting member forms may be removed after 7-days provided the concrete strength is 80 percent of the 28-days strength. No superimposed load shall be applied before the 28-days strength has been verified by field-cured cylinders. Formwork tolerances shall meet ACI 301 Table 4.3.1.

3.2.1.2 Unless otherwise shown on the concrete drawings, exposed edges shall have a 1-inch chamfer. They shall be 1-inch x 1-inch (25 mm x 25 mm) triangular section. Unexposed corners may be either square or chamfered. Chamfer Strips shall be used on top edges and inner corners of forms to produce straight and uniform chamfers.

3.2.1.3 Obtain approval before framing openings in structural members.

3.2.1.4 Do not apply form release agent wherever concrete surfaces shall receive special finishes or wherever applied coverings are affected by agent; soak inside surfaces of untreated forms with clean water; keep surfaces coated before placing concrete.

3.2.1.5 Coordinate work of other specifications in forming and placing openings, slots, reglets, recesses, chases, sleeves, bolts, anchors, and other inserts.

3.2.1.6 Forms shall result in a final structure that conforms to shapes, lines, and dimensions of the members as required by the design drawings and specifications.

3.2.1.7 Formwork shall be substantial and sufficiently tight to prevent leakage of mortar or concrete.

3.2.1.8 Forms shall be properly shored, braced and tied together to maintain position and shape.

3.2.1.9 Forms and their supports shall be designed so as not to damage previously placed structures and easy for removal.

3.2.1.10 Wet all formwork for surface that will not be exposed before placing concrete, but do not allow excess water to accumulate in excavation.

3.2.1.11 Forms for surfaces, which will be exposed, shall be coated with form oil.

3.2.1.12 Reshoring and/or back shoring shall be done when required to safety and adequately support the work, including construction loads.

3.2.1.13 Holding time of sheathing boards shall comply with Table 3.1 below and shall be determined from the results of concrete compressive strength tests.

Table: Age of Concrete to Determine Period Prior to Removal of Sheathing Boards



Member Foundation

Underground Beam

Side of Beam Column, Wall (with no Dead Load bending)

Under Floor Slab, Roof Slab and

Beam

Type of Cement

High Early Strength Portland Cement

Ordinary Portland Cement Type I

High Early

Strength Portland Cement


High Early

Strength Portland Cement


Age of Concrete (days)

1 2 3 4 5 6

3.2.1.14 Forms shall be le ft until confirmation has been made that the concrete has attained the compressive strength here under mentioned.

?? Under floor and roof slabs: 80% or more of the design strength at 28-days.

?? Under beams: 100% or more of the design strength at 28-days.

3.2.1.15 Forms shall not be removed without written authorization from COMPANY.

3.2.1.16 Supporting forms or shoring shall not be removed until the concrete structural members has reached 80% of the specified 28-days design compressive strength, but in no case shall they be removed in less than 7-days or before the expiration of curing period.

3.2.1.17 Concrete, mortar, and other foreign material shall be completely removed from the form surface before use or re-use.

3.2.1.18 Form ties may be used to maintain the thickness of concrete, and prevent distortion of formwork during concrete placement. Form ties shall be constructed so that the end fasteners can be removed without causing appreciable spilling at the faces of the concrete. After removal, the embedded portion of the ties shall terminate not less than two diameters or twice the minimum dimension of the tie from the formed faces of concrete to be permanently exposed.

3.2.1.19 Ties used through formwork shall be cut out to depth of 1 inch (25 mm) and epoxy grout sealed, after removal of formwork.

3.2.2. Reinforcement

3.2.2.1 The grade, type, and details of reinforcing steel shall be in accordance with related specification or procedure. Placement of reinforcement shall be in accordance with Section 5.7 of ACI 301 and applicable sections of ACI 315 and ACI 318, unless otherwise approved by COMPANY.

3.2.2.2 Place, support, and fasten reinforcing before placing concrete; do not insert dowels into fresh concrete; do not float welded wire fabric down into fresh concrete. Support slab reinforcement at the required depth and



secure prior to placing concrete; do not pull welded wire fabric up into fresh concrete as it is placed.

3.2.2.3 Secure at least 25 percent of bar intersections (including wall dowels) with wire in 2-way mats.

3.2.2.4 Splice reinforcing shall be as specified. Welded splices are not allowed.

3.2.2.5 Minimum concrete cover shall be in accordance with Specification No. SP-CI-GG-002 General Specification for Civil and Structural. Areas subject to chemical exposure shall have a minimum cover of 2-inches, unless noted otherwise.

3.2.2.6 All reinforcement shall be bent cold.

3.2.2.7 Reinforcement steel shall not be bent or straightened in a manner that will injure the material.

3.2.2.8 Cutting of reinforcing steel using oxygen acetylene equipment is not permitted.

3.2.2.9 Hooks and overlap joints shall be in accordance with engineering specifications and drawings.

3.2.2.10 Reinforcing bars shall be firmly bound with annealed steel wire at crossing points.

3.2.2.11 Reinforcement shall be placed accurately in accordance with design drawings and ACI 301 Section 5.4, 5.5, and 6.4, and shall be secured in position.

3.2.2.12 Oil shall be cleaned off reinforcing steel with petroleum naphtha or other suitable solvent.

3.2.2.13 Exposed reinforcing bars intended for bonding with future extensions shall be protected from corrosion.

3.2.3. Joints and Embedded Items

3.2.3.1 Joints and embedments shall be in accordance with Chapter 6 of ACI 301 unless otherwise approved by COMPANY.

3.2.3.2 Construction joint shall be located as shown on the concrete drawings. Any variation of location shall be approved by COMPANY. The concrete operation shall require the placement of an intermediate construction joint, the concrete shall be struck off square with the structure, water stops added if the normal joint has a water stop, the location completely recorded and reported to COMPANY in writing. Adjacent pour shall not be made until the disposition has been received from COMPANY.

3.2.3.3 Construction, isolation, and control joints in slabs on grade are to be built in accordance with and located according to the design drawings. Control joints in slab toppings are to be located directly above and in line with the control joints in the underlying concrete slab. Soft-Cut saw to a depth of 1.25 inches shall be used immediately after final finishing. Conventional saw cut joints are to begin as soon as the concrete is hard



enough to prevent raveling of the surface and dislodging of the aggregate, but no later than 12-hours after concrete placement. Prime and seal joints according to Sealant Manufacturer’s instructions. Control joints are to be cut using a Soft-Cut Saw and in strict accordance with the saw manufacturer’s written recommendations. Determine the sawing sequence based upon slab pour time and size.

3.2.3.4 The surface of construction joints shall be thoroughly cleaned from defective or contaminated concrete, surface film, and laitance removed. Prewet the remaining concrete followed by a brush application of a neat cement paste. Obtain COMPANY’s approval before using bonding agents. Coating of vertical construction joints is not required.

3.2.3.5 Locate construction joints in girders, beams, and framed slabs according to the design drawings. Obtain approval from COMPANY before placing any construction joints in locations other than that shown on the design drawings.

3.2.3.6 Locate construction joints in walls no more than 100 linear feet apart. Install weakened plane control joints at 25-feet maximum spacing between construction joints.

3.2.3.7 Provide and install water stops in joints as detailed on drawings. Join water stops sections according to the Manufacturer’s recommendations. Use anchor to prevent movement during concrete placement. Provide water stops at all joints subject to either groundwater or process fluids.

3.2.3.8 Continue reinforcing through construction joints.

3.2.3.9 Install isolation joints as located on the drawings and where paving adjoins vertical surfaces such as walls, columns, catch basins, manholes, and equipment foundations. Interrupt reinforcing at isolation joints; provide and install dowels. Gap width shall be ¾-inch unless otherwise detailed.

3.2.3.10 Control or construction joints, which are not specified on the design drawings, shall be located at the column centerlines and at intermediate intervals, so that each panel does not exceed 600 square feet in area. Concrete shall be placed in alternate paving lanes utilizing construction and control joints as specified.

3.2.4. Concrete Production

Production of concrete shall comply with Chapter 7 of ACI 301. Water may be added to the mix at the point of delivery in accordance with Section 11.7 of ASTM C94 when permitted by COMPANY’s testing agent, but in no case shall the total of amount of water added at the Site and batch plant exceed the quantity specified for the design mix.

3.2.5. Placing Concrete

3.2.5.1 Placement of concrete shall be in accordance with Chapter 8 of ACI 301. Hot and cold weather concreting shall be in accordance with ACI 305R and ACI 306R. Concrete shall not be placed before the entire preparation (i.e. formwork, reinforcement, expansion joint materials,



anchor, vapor barrier, and other embedded items) has been inspected and approved. Concrete shall not be placed on frozen subgrade. Where required, subgrade shall be sprinkled sufficiently to prevent absorption of water from the freshly placed concrete.

3.2.5.2 Color top surface of underground ducts; sprinkle colored iron oxide powder over fresh concrete:

??Red for underground electrical ducts, with minimum of 10-lb of red iron oxide per cubic yard of concrete.

??Yellow for underground instrument airline ducts, with minimum of 8-lb of yellow iron oxide per sack of cement.

3.2.5.3 Ensure that discharge of ready mixed concrete is completed within 1.5 hours after batching.

3.2.5.4 The concrete is to be transported from the batching plant to the job location with truck mixer. For site locations, which cannot be reached by truck, the large quantity of concrete is placed using a concrete pump and for smaller quantities of concrete, using a concrete bucket.

3.2.5.5 Maintain records of concrete placement, record date, location, quantity, air temperature, field test results, and test samples taken; maintain concrete delivery tickets with record for ready mixed concrete.

3.2.5.6 Re-dosage with the specified high range water-reducing admixture (superplasticizer) may be done with the prior approval of COMPANY regarding dosage and time periods.

3.2.5.7 Obtain replacement inspection and authorization from the construction manager before placing concrete.

3.2.5.8 Concrete conveying by pumping shall meet the requirements of ACI 304R, Chapter 9. Concrete conveying by belt conveyor shall meet requirements of ACI 304R, Chapter 10.

3.2.5.9 After concrete placement and form removal, clean exposed reinforcing steel and embedded items of concrete splatter, dirt, and other foreign matter.

3.2.5.10 Concrete that has achieved initial set or has been contaminated by foreign matter shall not be deposited in the structure. Re-tempered concrete shall not be used.

3.2.5.11 Concrete shall be limited to a maximum 5-feet free fall and horizontal flow shall not exceed 5-feet within the forms.

3.2.5.12 Concrete shall be vibrated during placing for the purpose of uniform spreading and release of entrapped air. The vibration of concrete shall continue until the slurry of cement emerges on the surface. There shall be a minimum of 2 pieces of vibration equipment onsite prior to commencing concrete placement.

3.2.5.13 Concrete shall be placed continuously or in layers of 18-inches. Vibrator heads shall extend into the previously placed layer. No



concrete will be deposited on concrete, which has hardened sufficiently to cause the formation of seams/planes of weakness within the section. The maximum interval between deliveries is 20 minutes. Install construction joints on the section that cannot be placed continuously.

3.2.5.14 Concrete shall be placed in such a way as to prevent segregation of aggregate. When concrete is poured from height of more than 4 feet, chutes or hose shall be used.

3.2.6. Slabs on Grade

3.2.6.1 Construct slab in accordance with Chapter 11 of ACI 301 and ACI 302.1R.

3.2.6.2 Place concrete in alternating strips.

3.2.6.3 When separate floor toppings are called for, place the floor toppings to required lines and grade after the base concrete has cured. Screed toppings level or sloped on the drawings.

3.2.6.4 Floor slab tolerance shall conform to Chapter 7, Section 7.15 of ACI 302.1R (unless noted otherwise on the design drawings). If vapor barrier is called for on the drawings and if sharp backfill may puncture the barrier, place a 4” compactable fill layer as a cushion.

3.2.6.5 Lap vapor barrier 6-inches at joints and seal with duct tape. Carefully fit vapor barrier around service openings.

3.2.7. Slab Finishes

3.2.7.1 Concrete slab surfaces shall be finished in accordance with ACI 302.1R.

3.2.7.2 Finish interior concrete floor slabs in accordance with ACI 302.1R for Class 5 (industrial) floors unless noted otherwise shown on the design drawings.

3.2.7.3 Provide a “floated finish” at equipment bases and exterior slabs according to ACI 301, Section 11.7.2. Provide a “broom finish” to stairs, steps, ramps, and walks.

3.2.7.4 If no finish is specified, refer to ACI 301, Section 11.8.

3.2.8. Finishing Formed Surfaces

Formed concrete surfaces shall be finished in accordance with Chapter 10 of ACI 301, unless otherwise noted on the design drawings.

3.2.9. Repair of Surface Defects

3.2.9.1 Unless otherwise specified or permitted by COMPANY, tie holes, honeycombs, and other concrete surface defects shall be repaired in accordance with Chapter 9 of ACI 301 and alternate methods in Section 9.2.2.4 of ACI 301, as soon as practicable after form removal at such times and in such manner as shall not delay, interfere with, or impair the proper curing of the fresh concrete. COMPANY shall be notified before proceeding with repair if the defect is greater than 5-inches deep and larger than 200 square inches in surface area, or if the depth is over 1/3



the thickness of the member and greater than 6-inches in any other direction.

3.2.9.2 Prepackaged grouts and patching compounds may be used after COMPANY’s approval is obtained. Patching mortar similar to the concrete mix minus the coarse aggregates can be used as an alternate. Do not use more than 1-part cement to 2½-parts sand by damp loose volume.

3.2.9.3 Remedy of Out-Of-Tolerance Slabs:

?? Grind down high points.

?? Raise low points by using the specified underlayment compound or repair topping if the areas are exposed.

?? Critical slab areas: Demolish and replace out-of-tolerance areas that are identified on drawings. Submit demolition and replacement plan to COMPANY for review and concurrence before demolition. Replacement slab shall meet tolerance requirements for critical slab areas.

3.2.10. Placing Grout

3.2.10.1 The minimum thickness of grout shall be 1-inch.

3.2.10.2 The extension of grout beyond the equipment base should not be less than 2-inches, nor more than 4-inches to ensure adequate bearing and to minimize excessive exposed area which is vulnerable to cracking.

3.2.10.3 Heaters, sunshades, shall be used to maintain the range for 24 hours after pouring. In hot climates, grout shall be poured at night.

3.2.10.4 Grout shall be chamfered at 45 degrees, in one direction to prevent pockets, from the lower outside edge of the equipment or structure base plate to the top of the concrete pedestal. Vibrating the grout into position is not permissible. Vent holes, with 1/4" minimum diameter, shall be provided in base plates at any blind or dead-end recesses.

3.2.10.5 Form shall be thoroughly braced and shall be designed for a grout head of at least 6-inches. Form shall be waxed as necessary to prevent sticking. Measures shall be taken to ensure that the grout can not squeeze out from below and around the form during placing and setting.

3.2.10.6 Leveling steel shims and wedges shall be removed unless otherwise specified by the equipment manufacturer. In this case, a ¾-inch recess shall be provided and sealed with grout to prevent rusting. Shims shall not be removed until the original grout has obtained sufficient strength to support the loads. Voids left by removal of shims shall be packed with a stiff mixture of identical grout.

3.2.10.7 Exposed cement grout surfaces shall be troweled to smooth finish. Non-shrink grout and epoxy grout shall be finished in accordance with the Manufacturer’s procedures.



3.2.10.8 Unit equipment shall not be placed in service before the grout has attained 80% of the specified 28-days designed compressive strength, but in no case less than 14-days.

3.2.11. Placing Mortar

3.2.11.1 Use mortar in each location of the type recommended in ASTM C270 and as follows:

??Type M: Used for masonry in contact with the ground.

??Type S: Used for exposed exterior walls not in contact with the ground and interior load bearing walls.

??Type N: Used for interior masonry partitions.

3.2.11.2 Retemper mortar stiffened by evaporation by mixing in additional water when required.

3.2.11.3 Used mortar within 2½-hours of initial mixing.

3.2.11.4 Discard mortar after initial sets has taken place.

3.2.11.5 Set interior masonry walls in masonry cement mortar.

3.2.11.6 Set exterior concrete block walls in cement lime mortar.

3.2.11.7 Set fire-rated masonry in cement lime mortar.

3.2.12. Weather Conditions

3.2.12.1 Cold Weather

?? In cold weather, the temperature of the concrete when delivered at the Site of the work shall conform to the following temperature limitations.

Minimum Concrete Temperature (?F) Air Temperature For Sections With Least

Dimension Less Than 12-in. For Sections With Least Dimension 12-in. or Greater

30 to 40 60 50 0 to 30 65 55

Below 0 70 60

??If water is heated above 100?F, the water shall be combined with the aggregate in the mixer before cement is added. Cement shall not be mixed with water or with mixtures of water and aggregate having a temperature greater than 100?F.

??Frozen or partially frozen aggregates shall not be used in concrete production.

3.2.12.2 Hot Weather

The ingredients shall be cooled before mixing. Flake ice or well-crushed ice of a size that will melt completely during mixing may be substituted for all or part of the mixing water if, due to high temperature, low slump, flash set, or cold joints are encountered.



3.3. Curing and Protection

3.3.1. Freshly deposited concrete shall be protected from premature drying and excessively hot or cold temperatures and shall be maintained with minimal moisture loss at a relatively constant temperature for the period of time necessary (7-days for Portland Cement type I) for the hydration of cement and proper hardening of the concrete. Curing shall conform to the requirements in Chapter 12 of ACI 301.

3.3.2. Follow the Manufacturer’s recommendation for curing and sealing when hardeners, metallic, or mineral aggregate toppings are specified on the design drawings.

3.3.3. Concrete Surfaces in Contact with Forms:

The time during concrete surfaces in contact with wood or metal forms may be considered as curing time. Wood forms shall be maintained in a moist condition until removal. After form removal, the concrete shall be cured until the end of curing period by one of the methods of concrete surfaces not in contact with forms. Moist wood forms in contact with concrete shall not be considered as curing for hydraulic structures. Curing time shall commence as soon as the wall forms have been loosened and sprinkling has begun. Wall forms shall be loosened between 24 and 48 hours after concrete placement and sprinkling begins. Wood forms shall be kept moist until the forms are loosened and the curing procedure begins.

3.3.4. Curing Hydraulic Structures:

Hydraulic structures shall only be cured by a wet cure procedure. This includes the use of ponding or sprinkling or a moisture retaining fabric. Curing shall occur for a minimum of 14-days. Wall forms are to be loosened and water continually sprinkled between the wall and forms.

3.3.5. Sealing and Dustproofing:

3.3.5.1 Exposed concrete floor surfaces shall be sealed and dustproofed. Where the concrete is cured by using a liquid membrane curing compound, this sealing and dustproofing can be a part of the curing process provided a suitable compound is used. Where some other curing method is used, the concrete surface shall be coated with a liquid sealing and dustproofing compound. Apply compounds in accordance with the manifacturer’s instructions.

3.3.5.2 Liquid membrane curing compounds that also seal and dustproof may be used on exposed concrete floors. Do not use membrane-forming compounds on surfaces to receive bonded treatments, tiles, adhered finishes, paint, epoxy toppings, and additional concrete. Unless otherwise noted, hydraulic structures are not to receive a sealing and dustproofing.

3.3.5.3 Wet cure concrete floors that are to receive bonded treatments, tiles, adhered finishes, paint, epoxy toppings, and additional concrete for a minimum of 7-days. Do not use ponding water, sprayed water, or wet sand on exposed concrete surfaces.



3.3.6. Concrete Surfaces Not in Contact with Forms:

Concrete surfaces not in contact with forms can utilize any of the methods indicated in ACI 301, Section 12.2.1 for preservation of moisture, except do not use ponding, sprayed water, or wet sand on exposed concrete slabs.

3.3.7. For massive concrete as defined in ACI 207, cure and protect in accordance with ACI 301, Chapter 14, and Section 14.5.

3.3.8. Curing Grout:

The manufacturer shall determine volume change during curing by lab tests in accordance with ASTM C827 or another test method approved by COMPANY. Cement grout exposed surfaces shall be protected and kept wet during the seven-day curing period.

3.4. Testing

3.4.1. To ensure that ingredient materials meet the specification requirements, the following preconstruction qualification tests shall be performed on the materials proposed to use. CONTRACTOR shall be responsible for compiling this documentation and for having these tests performed by a testing laboratory acceptable to COMPANY. Tests on cement and admixtures shall be performed by Vendor of the particular material.

3.4.1.1 Cement:

Physical and chemical properties from tests referenced in ASTM C150 or C595 as appropriate.

3.4.1.2 Aggregate:

Required Test Sand Stone Gradation ASTM C136 ASTM C136 Fineness Modulus ASTM C136 -- Material finer than no. 200 sieve ASTM C117 ASTM C117 Organic Impurities ASTM C40 -- Lightweight Pieces ASTM C123 ASTM C123 Friable Particles ASTM C142 ASTM C142 Specific Gravity and Absorption ASTM C128 ASTM C127 Los Angeles Abrasion -- ASTM C131 Potential Reactivity (chemical method) ASTM C289 ASTM C289 Potential Reactivity (mortar-bar method) ASTM C227 ASTM C227 Soundness ASTM C88 ASTM C88 Petrographic Examination ASTM C295 ASTM C295 Unit Weight and Voids ASTM C29 ASTM C29

Moisture content of both fine and coarse aggregates shall be determined on a regular basis and batch quantities for water and aggregate shall be adjusted to maintain maximum water/cement ratio.



3.4.1.3 Mixing Water and Ice:

Non-potable water, if used, shall be tested to determine if it produces mortar cubes having 7-days and 28-days strength equal to at least 90 percent of the strength of similar specimens made with distilled water. The strength comparison shall be made on mortars, identical except for the mixing water, prepared and tested in accordance with ASTM C109. The chloride content shall be determined in accordance with ASTM D512. The total water-soluble chloride content shall not exceed 0.15 percent by weight of cement.

3.4.1.4 Water reducing, Retarding, Accelerating, and Air Entraining Admixture:

Manufacturer shall certify that the admixture complies with ASTM C494 and ASTM C1017, Standard Specification for Chemical Admixtures for use in Producing Flowable Concrete.

3.4.1.5 Pozzolanic Admixtures:

The test for physical and chemical properties referenced in ASTM C618 shall be performed.

3.4.2. Concrete materials and operations shall be tested and inspected as the work progresses in accordance with Chapter 16 of ACI 301. Failure to detect any defective work or material shall not in any way prevent later rejection when such of defect is discovered nor shall it obligate COMPANY for final acceptance.

3.4.3. Testing shall include compressive tests of molded concrete cylinders (ASTM C39), tests for slump (ASTM C143), unit weight and air content (where air entrainment is required) according to ASTM C138, and fresh concrete temperature according to ASTM C1064. Concrete that has been rejected for failure to meet slump limit shall not be salvaged for use in the work. Increase mixing time, addition of dry materials, or similar modifications of a rejected batch to meet slump limits shall not be permitted.

3.4.4. The rate of sampling shall be in accordance with ACI 301, Section 16.3. Take additional samples when observations on tests indicate nonconformance with the specification. Cure five (5) test specimens for every 100 cubic yards of concrete in accordance with ASTM C31. Mold and test specimens in accordance with ASTM C39 at the following intervals: 2-cylinders at 7-days, 1-cylinder at 14-days, and 2-cylinders at 28-days.

3.4.4.1 Compressive Strength (28 days age)

The compressive strength of concrete (28-days age) shall conform to the design requirements. The standard age of specimens shall be 28 days, but the testing result on 7 day aged specimen may be used for prompt progress of the work, provided that the relation between 7 days and 28 days strength is already establish by test for design of the mix properties.

3.4.5. Testing of Reinforcing Steel:

3.4.5.1 Reinforcing steel shall be tested in accordance with ASTM A370.

3.4.5.2 Reinforcing steel with rust, mill scale, or a combination of both shall be considered satisfactory provided the minimum dimensions, including



height of deformations and weight of hard-wire-brushed test specimen, are not less than ASTM A615 requirement. Such test shall be at COMPANY’s discretion.

3.4.5.3 Reinforcing steel shall be free from mud, oil, or other nonmetallic coatings that adversely effect bonding capacity.

3.4.6. Testing of Grout:

3.4.6.1 Cement grout shall be sampled in the field and tested for volume change, bleeding, and compressive strength.

3.4.6.2 One sample of grout shall be taken for every 10-cuft of placed material or for every 50-sqft of joint grouted.

3.5. Field Quality Control

3.5.1. The construction manager shall establish procedures for inspection, testing, acceptance criteria, and documentation. These procedures shall define the documentation that shall be employed to ensure that the certifications, examinations, tests, and approvals required by the Contract specifications are accomplished. Inspection procedure shall provide for documented pre-placement inspections. Testing and acceptance of materials and concrete work shall comply with Chapters 16, 17, and 18 of ACI 301 and ASTM Standard Test unless otherwise modified herein.

3.5.2. Acceptance of concrete shall be based upon results for slump, air content, temperature, coarse aggregate size, and strength taken at the Site. Testing frequency shall be as specified in Section 16.3 of ACI 301 unless waived by COMPANY.

3.5.3. The finished structure shall be evaluated for acceptability in accordance with Chapter 18 of ACI 301. CONTRACTOR shall pay costs incurred for additional testing, analyses, and any corrective work required when the structure is found to be deficient in strength or other specified characteristics.

3.5.4. During construction, QC personnel from COMPANY (and CONTRACTOR) shall inspect, sample, and test concrete materials and production of concrete as required by COMPANY. Compressive test results for 7-days and 28-days breaks for each class of concrete shall be evaluated in accordance with ACI 214 including as a minimum graph of average strength, standard deviation, coefficient of variation, and required average strength. Failure to detect any defective work or material shall not prevent in any way later rejection when such defect is discovered, nor shall it obligate COMPANY for final acceptance.

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Sp Ci Cc 001 Concrete Work Specification

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