Concrete Formwork

SECTION 03100 CONCRETE FORMWORK
PART 1 - GENERAL
1.1
SCOPE OF WORK A. The work performed under this section of the Specifications shall consist of furnishing and installing formwork for cast-in-place concrete, with shoring, bracing, anchorage and all necessary accessories. Openings in the formwork for other work shall be provided. All stripping activities shall be included under this section.
1.2
RELATED SECTIONS A. B. Section 03200: Concrete Reinforcement. Section 03300: Cast-in-Place Concrete.
1.3
REFERENCES AB. C. D. E. F. ACI 347: Recommended Practice for Concrete Formwork. ACI 301: Standard Specifications for Structural Concrete. PS-1: Construction and Industrial Plywood. ACI 318: Building Code Requirements for Reinforced Concrete. ACI 350: Environmental Engineering Concrete Structures. ACI 117: Standard Specifications for Tolerances for Concrete Construction and Materials.
1.4
DESIGN REQUIREMENTS A. CONTRACTOR shall be responsible for the design, engineering and construction of formwork, shoring and bracing to conform to design and code requirements; resultant concrete to conform to required shape, line and dimension. Design and construction of formwork shall take into account live loads, dead loads, weight of moving equipment operating on formwork, concrete mix, height of concrete drop, vibrator frequency, temperature, foundation pressures, stresses, lateral stability and other factors pertinent to the safety of personnel and structures. CONTRACTOR shall provide shores, struts, and trussed supports as necessary.
Contract No. 07-037
03100- 1 Lake ForkWaterTransmission Line Concrete Formwork
1.5 OD 1.6
QUALITY ASSURANCE A. Work shall be performed in accordance with the standards referenced in Part 1.3 of this specification.
DELIVERY, STORAGE AND HANDLING A. Store off ground in ventilated and protected manner to prevent deterioration from moisture.
1.7
COORDINATION A. Coordinate this section with other sections of the Work which require attachment of components to formwork including blackouts, pipe sleeves, wall pipes, conduits, and other accessories. Structural drawings may or may not include all embedment components and openings, for clarity purposes. CONTRACTOR is responsible to coordinate with all discipline drawings to ensure installation and positioning of embedded components. Unless otherwise shown, all wall pipes shall be positioned within formwork prior to casting of walls. Blockouts for pipe work are not permitted.
PART 2- PRODUCTS 2.1 FORM MATERIALS Waterstops shall be resilient type unless otherwise indicated on drawings. A. Facing Materials: 1. Unexposed Finish Concrete: Any standard form materials that produce structurally sound concrete. Provide lumber dressed on at least two edges and one side for tight fit. 2. Exposed Finish Concrete: Materials selected to offer optimum smooth, stain free final appearance and minimum number of joints. Provide materials with sufficient strength to resist hydrostatic head without bow or deflection in excess of allowable tolerances, and as follows: a. Plywood: PS-1 "B-B (Concrete Form) Plywood," Class I, Exterior Grade, mill-oiled and edge-sealed. b. Lumber: Southern Pine special, No. 2 grade, with stamp grade clearly visible. c. Steel: Minimum 16 gauge sheet, well matched and tight fitting, stiffened to support weight of concrete without deflection detrimental to tolerances and appearances of finished concrete surfaces. d. Glass Fiber Fabric Reinforced Plastic Forms: Matched, tight fitting, stiffened to support weight of concrete without deflection detrimental to tolerances and appearance of finished concrete surfaces.
Contract No. 07-037
03100 - 2 Lake Fork Water Transmission Line Concrete Formwork
2.2
FORMWORK ACCESSORIES A. Form Ties: 1. Metal form ties, snap-off type, 1-1/2 inch break back dimension, galvanized metal, with waterproof washer at mid-point of rod, shall be used to hold forms in place. The ties, when removed, shall leave a smooth opening in the concrete surface not larger than 7/8 inch in diameter. 2. After the tie rods are broken back, the holes shall be thoroughly cleaned to remove all grease and loose particles; then non-shrink cement-sand mortar, as dry as practicable, shall be carefully placed into the holes in small quantities. After the holes are completely filled, all excess mortar shall be struck off flush and the surface finished in such a manner as to render the filled hole as inconspicuous as possible. If these patches appear to be darker than the other surface of the concrete, white cement shall be used in the mortar as required. 3. "Supertie" fiberglass form tie system as manufactured by RJD Industries, Inc., 26945 Cabot Road, Suite 107, Leguna Hill, California, (800)3444753. Provide spreader rod, ties, gripper and all necessary accessories and installation devices. Provide gray color rodc Install Supertie in accordance with supplier's instructions. After removal of forms, grind Supertie flush to wall. Form Release Agent: Colorless mineral oil which will not stain concrete, absorb moisture or impair natural bonding or color characteristics of coating intended for use on concrete. Corners: Chamfered, rigid plastic or wood strip type; 3/4" x 3/4" size; maximum possible lengths. Accurately formed to produce uniformly straight lines and tight edge joints. Nails, Spikes, lag bolts, Through bolts, Anchorages; Sized as required, of sufficient strength and character to maintain formwork in place while placing concrete. Waterstops: 1. Resilient Type - Polyvinyl chloride, minimum 2,000 psi tensile strength, 0F (15 0C) working temperature minimum 50 range, 6-inch wide for construction joints, 9-inch wide for expansion joints, maximum possible lengths, ribbed profile, preformed corner sections, heat welded jointing; "Wire Stop" as manufactured by Paul Murphy Plastic Co. Or approved equivalent. 2. Soft Type - Blend of refined hydrocarbons, resins, plasticizing compounds and mineral fillers extruded in a 5/8 inch by 1-1/2 inch oxidize or evaporate. Waterstop shall be: As manufactured by Synko-flex, 2100 Travis, Houston, Texas 77002, (713)686-8203; Swellseal Plus as manufactured by de neef America, Inc., 122 North Mill Street, St. Louis, Missouri 48880, (517)681-5791; or approved equivalent. Install in accordance with manufacturer's recommendations. Use primer recommended by manufacturer on surfaces.
B. * C.
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Contract No. 07-037
PART 3 - EXECUTION
3.1
EXAMINATION A. Verify lines, levels and centers before proceeding with formwork. Ensure that dimensions agree with Drawings.
3.2
EARTH FORMS A. Earth forms are not permitted.
3.3
INSTALLATION A. Formwork - General: Provide sloped surfaces steeper than 1.5 horizontal to 1 vertical with a top form to hold shape of concrete during placement, unless it can be demonstrated that top forms can be omitted. Construct the forms to correct shape and dimensions, mortar-tight, of sufficient strength, braced and tied together so that the forms shall be strong enough to maintain their shape under all imposed loads from the movement of workers, equipment, materials, or the placing and vibrating of the concrete. Camber where necessary to assure level finished soffits unless otherwise shown on the Drawings. Verify the horizontal and vertical positions of forms and correct all inaccuracies before placing concrete in any form. Complete all wedging and bracing before placing concrete. Forms for "Smooth Finish" Concrete: Use steel, plywood or lined board forms uniform in size. Clean and smooth plywood and form liners. Free edges and holes from damage. Form lining shall have close-fitting square joints between separate sheets and shall not be sprung into place. Sheets of form liners and plywood shall be full size wherever possible and joints shall be taped to prevent protrusions in concrete. Use special care in forming and stripping wood forms to protect corners and edges. Level and continue all horizontal joints. Wet wood forms at all times until stripping. Framing, Studding, and Bracing: Space studs at 16 inches on center maximum for boards and 12 inches on center maximum for plywood. Framing, bracing, centering, and supporting members shall be of adequate size and strength to carry safely, without deflection, all dead and live loads to which forms may be subjected, and shall be spaced sufficiently close to prevent any bulging or sagging of forms. Soffits of all beams forms shall be constructed of material a minimum of 2 inches thick. Distribute bracing loads over base area on which bracing is erected. When placed on ground, protect against undermining, settlement or accidental impact. Erect formwork, shoring and bracing to achieve design requirements, in accordance with the requirements of ACI 301. Arrange and assemble formwork to permit dismantling and stripping. Do not damage concrete during stripping. Permit removal of remaining principal shores. Align joints and make watertight. Keep form joints to a minimum.
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Contract No. 07-037
G. * H. I.
3.4
Obtain approval from OWNER or ENGINEER before framing openings in structural members which are not indicated on Drawings. Provide chamfer strips on exposed edges unless drawings note otherwise. Do not reuse wood formwork more than three times. Do not patch formwork.
APPLICATION - FORM RELEASE AGENT
A. B. C.
Apply form release agent on formwork in accordance with manufacturer's recommendations. Apply prior to placement of reinforcing steel, anchoring devices, and embedded items. Do not apply form release agent where concrete surfaces will receive special finishes or applied coverings which are affected by agent. Soak inside surfaces of untreated forms with clean water. Keep surfaces coated prior to placement of concrete. Reuse and Coating of Forms: Thoroughly clean forms and reapply form coating before each reuse. For exposed work, do not reuse any form which cannot be reconditioned to "like new" condition. Apply form coating to all forms in accordance with the manufacturer's specifications, except where "scored finish" is required as shown on the Drawings. Do not coat forms for concrete that is to receive a "scored finish".
D.
* 3.5
INSERTS, EMBEDDED PARTS AND OPENINGS A. B. C. Provide formed openings where required for items to be embedded in or passing through concrete work. Locate and set in place items that will be cast directly into concrete. Blockouts for pipe openings for grouting of pipe after wall concreting is not allowed. Coordinate with Work of other sections in forming and placing openings, slots, reglets, recesses, sleeves, bolts, anchors, other inserts, and components of other Work. Provide temporary ports or openings in formwork to facilitate cleaning and inspection. Locate openings at bottom of forms to allow flushing water to drain. Close temporary openings with tight fitting panels, flush with inside face of forms, and neatly fitted so joints will not be apparent in exposed concrete surfaces.
D. E. 3.6
FORM CLEANING A. B. Clean and remove foreign matter within forms as erection proceeds. Clean formed cavities of debris prior to placing concrete.
Contract No. 07-037
03100-5 Lake ForkWaterTransmission Line Concrete Formwork
C. D.
Flush with water or use compressed air to remove remaining foreign matter. Ensure that water and debris drain to exterior through clean-out ports. During cold weather, remove ice and snow from within forms. Do not use deicing salts. Do not use water to clean out forms, unless formwork and concrete construction proceed within heated enclosure. Use compressed air or other means to remove foreign matter.
3.7
FORMWORK TOLERANCES A. Construct formwork so as to maintain tolerances required by ACI 347, Chapter 3.3, except as otherwise noted.
3.8
FIELD QUALITY CONTROL A. Independent Testing Agency to inspect erected formwork, shoring, and bracing to ensure that work is in accordance with formwork design, and that supports, fastenings, wedges, ties, and items are secure. Notify the Architect/Engineer and Independent Testing Agency after placement of reinforcing steel in the forms, but prior to placing any concrete, so that inspection can be made.
B.
3.9
FORM REMOVAL A. The time for removal of forms shall comply with ACI 318. If curing temperatures 0 C), the time for are below 500F (15 removal shall be increased by fifty percent (50%). In no case shall the forms or bracing be removed until concrete has gained sufficient strength to carry its own weight and imposed loads. Loosen forms carefully. Do not wedge pry bars, hammers or tools against finish concrete surfaces scheduled for exposure to view. Store removed forms in manner that surfaces to be in contact with fresh concrete will not be damaged. Discard damaged forms. END OF SECTION
B. C.
Contract No. 07-037
SECTION 03200 *
PART 1 - GENERAL
CONCRETE REINFORCEMENT
1.1
SCOPE OF WORK A. The work included in this section of the Specifications shall consist of furnishing and installing reinforcing steel bars, welded wire fabric and accessories for castin-place concrete.
1.2
RELATED SECTIONS A. B. Section 03100: Concrete Formwork. Section 03300: Cast-in-Place Concrete.
1.3
REFERENCES A. B. C. D. E. F.
G.
ACI 301 - Standard Specifications for Structural Concrete. ACI 318/318R - Building Code Requirements for Structural Concrete and Commentary. ACI 315 - Details and Detailing of Concrete Reinforcement. ACI 350R - Environmental Engineering Concrete Structures ANSI/ASTM A82 - Cold Drawn Steel Wire for Concrete Reinforcement. ANSI/ASTM Al 85 - Welded Steel Wire Fabric for Concrete Reinforcement.
SP-66-88 - ACI Detailing Manual.
H. I. J. K. L. M. N.
ANSI/ASTM A496 - Deformed Steel Wire Fabric for Concrete Reinforcement. ANSI/ASTM A 497 - Welded Deformed Steel Wire Fabric for Concrete Reinforcement. ANSIUAWS DI.4 - Structural Welding Code for Reinforcing Steel. ANSI/AWS D12.1 - Reinforcing Steel Welding Code. ASTM A615 - Deformed and Plain Billet Steel Bars for Concrete Reinforcement. CRSI - Concrete Reinforcing Steel Institute Manual of Practice. CRSI 63 - Recommended Practice for Placing Reinforcing Bars.
Contract No. 07-037
03200 - 1
Lake Fork Water Transmission Line Concrete Reinforcement
0. 1.4
CRSI 65 - Recommended Practice for Placing bar Supports, Specifications and Nomenclature.
SUBMITTALS A. B. Submittals shall meet the requirements of the City of Dallas Material and Construction Specifications. Shop Drawings: Indicate bar sizes, spacings, locations and quantities of reinforcing steel and welded wire fabric, bending and cutting schedules, supporting and spacing devices, and joint and splice locations. Manufacturer's Certificate: Certify that products meet or exceed specified requirements. Comply with ACI 315, Chapters 1 through 8. Submit for review manufacturer's specifications and installation instructions for all proprietary products, including sleeves for welded splices and screw anchors.
C. D. E. 1.5
QUALITY ASSURANCE A. Perform work in accordance with referenced standards. Submit certified copies of mill test report of reinforcement materials analysis.
1.6
COORDINATION A. Coordinate work with other trades, placement of formwork, formed openings and other work.
PART 2 - PRODUCTS 2.1 REINFORCEMENT A. B. 2.2 Reinforcing Bars: New, deformed billet steel conforming to ASTM A615, Grade 60 for nonweldable bars and ASTM A706, Grade 60 for weldable bars. Welded Wire Fabric: ASTM Al 85 for smooth wire and ASTM A457 for deformed wire.
ACCESSORY MATERIALS A. B. C. Tie Wire: Minimum 16-gauge annealed type. Supports for Reinforcement: Conform to CRSI 63. Special Chairs, Bolsters, bar Supports, Spacers Adjacent to Weather Exposed Concrete Surfaces: Plastic coated steel or stainless steel type, size and shape as required.
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03200 - 2
D.
Splices: 1. Mechanical Connections: a. Compression: Gateway Building Products "G-Loc" or approved equivalent. b. Tension: Lenton Anchor or approved equivalent. Connection device shall develop 125 percent of yield strength of bar. 2. Welded Splices: "Cadweld", "Thermoweld" or approved equivalent. Size device to develop 125 percent of yield strength of bar. Mechanical Splicing may be used where splices are properly staggered to minimize congestion due to laps.
E. 2.3
FABRICATION A. B. Fabricate concrete reinforcing in accordance with CRSI Manual of Practice. Locate reinforcing splices not indicated on Plans at point of minimum stress. Review location of splices with OWNER or ENGINEER. Stagger taps/splices so that at least 50% of bars are continuous at any given section.
2.4
SETTING BASES, BEARING PLATES AND METAL INSERTS A. Prior to the placement of non-shrink grout beneath base and bearing plates, the bottom surface of the plates shall be cleaned of all bond-reducing materials, and concrete and masonry bearing surface shall also be cleaned of all bond-reducing materials and roughened to improve bonding. Loose and attached base plates, and bearing plates for structural members shall be set on wedges, leveling nuts, or other adjustable devices. Anchor bolts shall be tightened after the support members have been positioned and plumbed and the non-shrink grout has attained its specified strength. Base plates shall be grouted with non-shrink grout to assure full uniform bearing. Grouting shall be done prior to placing loads on the structure. Unless noted otherwise, metal inserts shall be 10" X 8" plate 1/2" thick with a minimum 4-314" studs 10' long.
* B. C. D. E. 2.5
EMBEDMENT OF DRILLED REINFORCING STEEL DOWELS A. Hole Preparation: 1. The hole diameter shall be as recommended by the epoxy manufacturer but shall be no larger than 0.25-inch greater than the diameter of the outer surface of the reinforcing bar deformations. 2. The depth of the hole shall be as recommended by the epoxy manufacturer to fully develop the bar but shall not be less than 12 bar diameters, unless noted otherwise. 3. The hole shall be drilled by methods, which do not interfere with the proper bonding of epoxy.
Contract No. 07-037
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4. 5. 6.
7.
Existing reinforcing steel in the vicinity of proposed holes shall be located prior to drilling. The location of holes to be drilled shall be adjusted to avoid drilling through or nicking any existing reinforcing bars. The hole shall be blown clean with clean, dry compressed air to remove all dust and loose particles. Epoxy shall be injected into the hole through a tube placed to the bottom of the hole. The tube shall be withdrawn as epoxy is placed but kept immersed to prevent formation of air pockets. The hole shall be filled to a depth that insures that excess material will be expelled from the hole during dowel placement. Dowels shall be twisted during insertion into the partially filled hole so as to guarantee full wetting of the bar surface with epoxy. The bar shall be inserted slowly enough to avoid developing air pockets.
PART 3 - EXECUTION 3.1 PLACEMENT A. B. C. D. E. 3.2 Place, support and secure reinforcement against displacement by means of accepted spacers, chairs or hangers. Do not deviate from required position. Do not displace or damage vapor barrier. Accommodate placement of formed openings. Conform to ACI 318 code for concrete cover over reinforcement. Clean reinforcement to remove all rust, mill scale, oil, earth, ice and other materials, which might reduce or destroy bond with concrete.
FIELD QUALITY CONTROL A. Concrete shall not be placed until reinforcing steel is inspected by OWNER's representative. All concrete placed in violation of this provision will be rejected. The CONTRACTOR shall give OWNER's representative 24 hours notice after completion of reinforcement placement prior to placement of concrete. END OF SECTION
Contract No. 07-037
03200 - 4
SECTION 03290 JOINTS IN CONCRETE

PART 1 - GENERAL
1.1
THE REQUIREMENT A. The CONTRACTOR shall construct all joints in concrete at the locations shown. Joints required in concrete structures are of various types and will be permitted only where shown, unless specifically accepted by the ENGINEER.
1.2
REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Federal Specifications: TT-S-0227E(3) Sealing Compound, elastomeric type, Multi-component for Calking, Sealing, and Glazing Buildings and Other Structures).
B.
U.S. Army Corps of Engineers Specifications: CRD-C572 PVC Waterstop.
C.
Commercial Standards: ASTM C 920 ASTM D 412 ASTM D 624 ASTM D 638 ASTM D 746 ASTM D 1056 ASTM D 1752 Specification for Elastomeric Joint Sealants Test Methods for Rubber Properties in Tension Test Method for Rubber Property - Tear Resistance Test Method for Tensile Properties of Plastics Test Method for Brittleness Temperature of Plastics and Elastomers by Impact Specification for Flexible Cellular Materials - Sponge or Expanded Rubber Specification for Preformed Sponge Rubber and Cork Expansion Joint Fillers for Concrete Paving and Structural Construction Test Method for Rubber Property - Durometer Hardness
ASTM D 2240 1.3 TYPE OF JOINTS A.
Construction Joints: When fresh concrete is placed against a hardened concrete surface, the joint between the two pours is called a construction joint. Unless otherwise specified, all joints in water bearing members shall be provided with a 03290 - 1 Lake Fork Water Transmission Line Joints in Concrete
Contract No. 07-037
waterstop and/or sealant groove of the shape specified and shown. The surface of the first pour may also be required to receive a coating of bond breaker as shown. B. Contraction Joints: Contraction joints are similar to construction joints except that the fresh concrete shall not bond to the hardened surface of the first pour, which shall be coated with a bond breaker. The slab reinforcement shall be stopped 41/2 inches from the joint; which is provided with a sleeve-type dowel, to allow shrinkage of the concrete of the second pour. Waterstop and/or sealant groove shall also be provided when specified or shown. Expansion Joints: To allow the concrete to expand freely, a space is provided between the two pours, the joint shall be formed as shown. This space is obtained by placing a filler joint material against the first pour, which acts as a form for the second pour. Unless otherwise specified, all expansion joints in water bearing members shall be provided with a center-bulb type waterstop as shown. Premolded expansion joint material shall be installed with the edge at the indicated distance below or back from finished concrete surface, and shall have a slightly tapered, dressed, and oiled wood strip secured to or placed at the edge thereof during concrete placement, which shall later be removed to form space for sealing material. The space so formed shall be filled with a joint sealant material as specified in the Paragraph in Part 2 entitled "Joint Sealant." In order to keep the two wall or slab elements in line the joint shall also be provided with a sleeve-type dowel as shown. Control Joints: The function of the control joint is to provide a weaker plane in the concrete, where shrinkage cracks will probably occur. A groove, of the shape and dimensions shown, is formed or saw-cut in the concrete. This groove is afterward filled with a joint sealant material as specified in the Paragraph in Part 2 entitled "Joint Sealant." Mass Concrete is defined as any structural element in thickness (least lateral dimension) greater-than or equal to 5 feet. Two (2) separate temperature control criteria are specified in the project specifications. Paragraph 3.5 specifies Hot Weather Requirements that are applicable to all concreting works and specify maximum allowable concrete temperature at the time of placing in forms. Paragraph 3.7 describes in-place concrete absolute and differential temperature requirements for mass concrete defined as element thickness > 5 feet. If the intent of this suggestion is to omit the Paragraph 3.7 temperature control requirements, the base slab may be poured in two pours each 4-feet in thickness. Temperature control requirements and associated temperature monitoring plan of Paragraph 3.7 may be omitted. Contract No. 07-037 03290 - 2
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Lake Fork Water Transmission Line Joints in Concrete
However, to compensate for the joint formation at a depth of maximum horizontal shear, the following measures shall be implemented. G. Joint Layout Each pour shall extend over the entire width of the base slab. No vertical joints are allowed to form in longitudinal direction. Vertical joints in transverse direction shall be so staggered that adjacent joints are offset by at least B-feet. H. Interface Preparation To prepare the joint for the adjacent pour, the aggregate shall be exposed if one pour does not immediately follow on the previous. This may be done by wire brushing, sand blasting and washing newly-placed concrete or by point tooling or scabbling the surface of concrete that has been allowed to harden. Cleaned roughened surface shall have a minimum profile depth of 14" or more. All loose material, mortar, cement dust, and fine sand shall be removed from the joint and a clean surface made prior to receiving new concrete. No bond enhancing material is required on this interface. However, curing process shall continue as per specifications. All standing water shall be thoroughly cleaned and wiped. Alternate cleaning methods may be necessary to clean the interface at locations of limited access such as locations of shear links. 1.4 CONTRACTOR SUBMITTALS A. Waterstops: Prior to production of the material required under this contract, qualification samples shall be submitted. Such samples shall consist of extruded or molded sections of each size or shape to be used, and shall be accomplished so that the material and workmanship represents in all respects the material to be furnished under this contract. The balance of the material to be used under this contract shall not be produced until after the ENGINEER has reviewed the qualification samples. Joint Sealant: Prior to ordering the sealant material, the CONTRACTOR shall submit to the ENGINEER for the ENGINEER'S review, sufficient data to show general compliance with the requirements of the Contract Documents. Certified test reports from the sealant manufacturer on the actual batch of material being supplied indicating compliance with the above requirements shall be furnished to the ENGINEER before the sealant is used on the job. Shipping Certification: The CONTRACTOR shall provide written certification from the manufacturer as an integral part of the shipping form, to show that all of the material shipped to this project meets or exceeds the physical property requirements of the Contract Documents. Supplier certificates are not acceptable. Joint Location: The CONTRACTOR shall submit placement shop drawings showing the location and type of all joints for each structure. Water Stop
B.
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Contract No. 07-037
03290 - 3
All joints in the base slab shall be fitted with continuous double water stop to prevent migration of water into joint interface. To accomplish the integrity of water stop, pre-manufactured specials such as ells, tees, and crosses of vertical type and flat type shall be used. All the joints on the perimeter as well as bottom surface of slab shall be fitted with water stop to prevent ground water migration. Forms at mid width of stop shall retain all vertical runs of water stop. Bentonite water stop is not permitted in this project. All electrical conduit work shall be installed in the lower pour. All other provisions for treatment of joint surfaces shall be implemented as per specification Section 03290 Paragraph 3.3 for a construction joint. Double water stops shall be required between all 4' thick adjacent pours. Top pour shall not be placed until 7 days from the date of bottom pour. 1.5 QUALITY ASSURANCE A. Waterstop Inspection: It is required that all waterstop field joints shall be subject to rigid inspection, and no such work shall be scheduled or started without having made prior arrangements with the ENGINEER to provide for the required inspections. Not less than 24 hours' notice shall be provided to the ENGINEER for scheduling such inspections. All field joints in waterstops shall be subject to rigid inspection for misalignment, bubbles, inadequate bond, porosity, cracks, offsets, and other defects, which would reduce the potential resistance of the material to water pressure at any point. All defective joints shall be replaced with material which shall pass said inspection, and all faulty material shall be removed from the site and disposed of by the CONTRACTOR at its own expense. The following waterstop defects represent a partial list of defects which shall be grounds for rejection: 1. Offsets at joints greater than 1/16-inch or 15 percent of material thickness, at any point, whichever is less. 2. Exterior crack at joint, due to incomplete bond, which is deeper than 1 /16-inch or 15 percent of material thickness, at any point, whichever is less. 3. Any combination of offset or exterior crack which will result in a net reduction in the cross section of the waterstop in excess of 1/1 6-inch or 15 percent of material thickness at any point, whichever is less. 4. Misalignment of joint which result in misalignment of the waterstop in excess of 1'/2-inch in 10 feet. 5. Porosity in the welded joint as evidenced by visual inspection. 6. Bubbles or inadequate bonding, which can be detected with a penknife test. (If, while prodding the entire joint with the point of a penknife, the knife breaks through the outer portion of the weld into a bubble, the joint shall be considered defective.) Waterstop Samples: Prior to use of the waterstop material in the field, a sample of a fabricated mitered cross and a tee constructed of each size or shape of materials to be used shall be submitted to the ENGINEER for review. These 03290 - 4 Lake Fork Water Transmission Line Joints in Concrete
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Contract No. 07-037
samples shall be fabricated so that the material and workmanship represent in all respects the fittings to be furnished under this contract. Field samples of fabricated fittings (crosses, tees, etc.) will be selected at random by the ENGINEER for testing by a laboratory at the OWNER'S expense. When tested, they shall have a tensile strength across the joints equal to at least 600 psi. E. Construction Joint Sealant: The CONTRACTOR shall prepare adhesion and cohesion test specimens as specified herein, at intervals of 5 working days while sealants are being installed. 1. The sealant material shall show no signs of adhesive or cohesive failure when tested in accordance with the following procedure in laboratory and field tests: 2. Sealant specimen shall be prepared between 2 concrete blocks (1-inch by 2-inch by 3-inch). Spacing between the blocks shall be 1-inch. Coated spacers (2-inch by 1- 1/2-inch by 1/2-inch) shall be used to insure sealant cross-sections of 1/2-inch by 2 inches with a width of 1-inch. 3. Sealant shall be cast and cured according to manufacturer's recommendations except that curing period shall not exceed 24 hours. Following curing period, the gap between blocks shall be widened to 11/2-inch. Spacers shall be used to maintain this gap for 24 hours prior to inspection for failure.
1.6
GUARANTEE A. The CONTRACTOR shall provide a 5-year written guarantee of the entire sealant installation against faulty and/or incompatible materials and workmanship, together with a statement that it agrees to repair or replace, to the satisfaction of the OWNER, at no additional cost to the OWNER, any such defective areas which become evident within said 5-year guarantee period.
0
2.1
PART 2- PRODUCTS GENERAL A. All joint materials specified herein shall be classified as acceptable for potable water use, by the Environmental Protection Agency, within 30 days of application.
2.2
PVC WATERSTOPS A. General: Waterstops shall be extruded from an elastomeric polyvinyl chloride compound containing the plasticizers, resins, stabilizers, and other materials necessary to meet the requirements of these Specifications. No reclaimed or scrap material shall be used. The CONTRACTOR shall obtain from the waterstop manufacturer and shall furnish to the ENGINEER for review, current test reports and a written certification of the manufacturer that the material to be shipped to the job meets the physical requirements as outlined in the U.S. Army Corps of Engineers Specification CRD-C572 and those listed herein. Flatstrip and Center-Bulb Waterstops: Flatstrip and center-bulb waterstops shall be as detailed and as manufactured by: Kirkhill Rubber Co., Brea, California; 03290 - 5 Lake Fork Water Transmission Line Joints in Concrete
B.
Contract No. 07-037
Water Seals, Inc., Chicago, Illinois; Progress Unlimited, Inc., New York, New York; Greenstreak Plastic Products Co., St. Louis, Missouri; or equal; provided, that at no place shall the thickness of flat strip waterstops, including the center bulb type, be less than 3/8-inch. C. Multi-Rib Waterstops: Multi-rib waterstops, where required, shall be as detailed and as manufactured by Water Seals, Inc., Chicago, Illinois; Progress Unlimited, Inc., New York, New York; Greenstreak Plastic Products Co., St. Louis, Missouri; or equal. Prefabricated joint fittings shall be used at all intersections of the ribbed-type waterstops. Other Types of Waterstops: When other types of waterstops, not listed above are required and shown, they shall be subjected to the same requirements as those listed herein. Waterstop Testing Requirements: When tested in accordance with the specified test standards, the waterstop material shall meet or exceed the following requirements: Physical Property. Sheet Material Value ASTM Std. D 638, Type IV D 638, Type IV D 746 D 747 D 638, Type IV D 638, Type IV Tensile Strength-min (psi) 1750 Ultimate Elongation-min (percent) 350 Low Temp Brittleness-max (degrees F) -35 Stiffness in Flexure-min (psi) 400 Accelerated Extraction (CRD-C572) Tensile Strength-min (psi) Ultimate Elongation-min (percent) Effect of Alkalies (CRD-C572) Change in Weight (percent) Change in Durometer, Shore A Finish Waterstop Tensile Strength-min (psi) Ultimate Elongation-min (percent) 2.3 JOINT SEALANT A. Joint sealant shall be polyurethane polymer designed for bonding to concrete, which is continuously submerged in water. No material will be acceptable which has an unsatisfactory history as to bond or durability when used in the joints of water retaining structures. Joint sealant material shall meet the following requirements (73 degrees F and 50 percent R.H.):
Work Life 45 - 180 minutes
D.
E.
1500 300 +0.25/-0.10 +5 1400 280
D 2240 D 638, Type IV D 638, Type IV
B.
Time to Reach 20 Shore "A" Hardness (at 77 degrees F, 200 gr quantity) Contract No. 07-037 03290 - 6
24 hours, maximum Lake Fork Water Transmission Line Joints in Concrete
Ultimate Hardness (ASTM D 2240) Tensile Strength (ASTM D 412) Ultimate Elongation (ASTM D 412) Tear Resistance (Die C ASTM D 624) Color C-
20 - 45 Shore "A" 200 psi, minimum 400 percent, minimum 75 pounds per inch of thickness,
minimum
Light Gray
All polyurethane sealants for waterstop joints in concrete shall conform to the following requirements: 1. Sealant shall be 2-part polyurethane with the physical properties of the cured sealant conforming to or exceeding the requirements of ANSI/ASTM C 920 Type M or Federal Specification TT-S-00227 E(3) for 2-part material, as applicable. 2. For vertical joints and overhead horizontal joints, only "non-sag" compounds shall be used; all such compounds shall conform to the requirements of ANSI/ASTM C 920 Class 25, Grade NS, or Federal Specification TT-S-0027 E(3), Type II, Class A. 3. For plane horizontal joints, the self-leveling compounds which meet the requirements of ANSI/ASTM C 920 Class 25, Grade P, or Federal Specification TT-S-0027 E(3), Type I shall be used. For joints subject to either pedestrian or vehicular traffic, a compound providing non-tracking characteristics, and having a Shore "A" hardness range of 35 to 45, shall be used. 4. Primer materials, if recommended by the sealant manufacturer, shall conform to the printed recommendations of the sealant manufacturer. All sealants, wherever shown, or required hereunder shall be Permapol RC-270 as manufactured by Products Research Company. Sealants for non-waterstop joints in concrete shall conform to the requirements of
Section 07920 - Sealants and Calking.
D. F. 2.4
JOINT MATERIALS A. B. Bearing Pad: Bearing pad to be neoprene conforming to ASTM D 1752 Type I, 40 durometer hardness unless otherwise noted. Neoprene Sponge: Sponge to be neoprene, closed-cell, expanded, conforming to ASTM D 1056, type RE-45-E1, with a compression deflection, 25 percent deflection (limits), 119 to 168 kPa (17 to 24 psi) minimum. Preformed Joint Filler: Preformed joint filler material shall be the preformed nonextruding type joint filler constructed of cellular neoprene sponge rubber or polyurethane of firm texture. Bituminous fiber type will be permitted. All nonextruding and resilient-type preformed expansion joint fillers shall conformed to the requirements and tests set forth in ASTM D 1752 for Type I, except as otherwise specified herein.
C.
2.4
JOINT MATERIALS 03290 - 7 Lake Fork Water Transmission Line Joints in Concrete
Contract No. 07-037
A.
Bearing Pad: Bearing pad to be neoprene conforming to ASTM D 1752 Type I, 40 durometer hardness unless otherwise noted. Neoprene Sponge: Sponge to be neoprene, closed-cell, expanded, conforming to ASTM D 1056, type RE-45-E1, with a compression deflection, 25 percent deflection (limits), 119 to 168 kPa (17 to 24 psi) minimum. Preformed Joint Filler: Preformed joint filler material shall be of the preformed non-extruding type joint filler constructed of cellular neoprene sponge rubber or polyurethane of firm texture. Bituminous fiber type will not be permitted. All nonextruding and resilient-type preformed expansion joint fillers shall conform to the requirements and tests set forth in ASTM D 1752 for Type I, except as otherwise specified herein.
B.
C.
2.5
BACKING ROD A. Backing rod shall be an extruded closed-cell, polyethylene foam rod. The material shall be compatible with the joint sealant material used and shall have a tensile strength of not less than 40 psi and a compression deflection of approximately 25 percent at 8 psi. The rod shall be 1/8-inch larger in diameter than the joint width except that a one-inch diameter rod shall be used for a 3/4inch wide joint.
2.6 *
BOND BREAKER A. Bond breaker shall be Super Bond Breaker as manufactured by Burke Company, San Mateo, California; Select Cure CRB as manufactured by Select Products Co., Upland, California; or equal. It shall contain a fugitive dye so that areas of application will be readily distinguishable.
2.7
BENTONITE WATERSTOP A. Where called for in the Contract Documents, bentonite type waterstop, which shall expand in the presence of water to form a watertight joint seal without damaging the concrete in which it is cast, shall be provided. The bentonite waterstop shall be composed of 75 percent bentonite. The balance of the material shall be butyl rubber-hydrocarbon with less than 1.0 percent volatile matter. The waterstop shall contain no asbestos fibers or asphaltics. The manufacturers rated application temperature range shall be from 5 to 125 degrees F. The service temperature range shall be from -40 to 212 degrees F. The cross sectional dimensions of the unexpanded waterstop shall be one inch by 3/4-inch. The waterstop shall be provided with an adhesive backing which will provide excellent adhesion to concrete surfaces.
B.
C. D. E.
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03290 - 8
2.8
SLIP DOWELS A. Slip dowels in joints shall be A36 smooth epoxy-coated bars, conforming to ASTM A 775.
2.9
PVC TUBING A. PVC tubing in joints be Sch. SDR 13.5, conforming to ASTM D 2241.
PART 3- EXECUTION 3.1 GENERAL A. Waterstops of the type specified herein shall be embedded in the concrete across joints, as shown. All waterstops shall be fully continuous for the extent of the joint. Splices necessary to provide such continuity shall be accomplished in conformance to printed instructions of manufacturer of the waterstops. The CONTRACTOR shall take suitable precautions and means to support and protect the waterstops during the progress of the work and shall repair or replace at its own expense any waterstops damaged during the progress of the work. All waterstops shall be stored so as to permit free circulation of air around the waterstop material. When any waterstop is installed in the concrete on one side of a joint, while the other half or portion of the waterstop remains exposed to the atmosphere for more than 2 days, suitable precautions shall be taken to shade and protect the exposed waterstop from direct rays of the sun during the entire exposure and until the exposed portion of the waterstop is embedded in concrete.
B.
3.2
SPLICES IN WATERSTOPS A. Splices in waterstops shall be performed by heat-sealing the adjacent waterstop sections in accordance with the manufacturer's printed recommendations. It is essential that: 1. The material not be damaged by heat sealing. 2. The splices have a tensile strength of not less than 60 percent of the unspliced materials tensile strength. 3. The continuity of the waterstop ribs and of its tubular center axis be maintained. Butt joints of the ends of 2 identical waterstop sections may be made while the material is in the forms. All joints with waterstops involving more than 2 ends to be jointed together, and all joints which involve an angle cut, alignment change, or the joining of 2 dissimilar waterstop sections shall be prefabricated by the CONTRACTOR prior to placement in the forms, allowing not less than 24-inch long strips of waterstop material beyond the joint. Upon being inspected and approved, such prefabricated waterstop joint assemblies shall be installed in the forms and the 03290 - 9 Lake Fork Water Transmission Line Joints in Concrete
B. C.
Contract No. 07-037
D.
ends of the 24-inch strips shall be butt welded to the straight run portions of waterstop in place in the forms. Where a centerbulb waterstop intersects and isjointed with a non-centerbulb waterstop, care shall be taken to seal the end of the centerbulb, using additional PVC material if needed.
3.3
JOINT CONSTRUCTION A. Setting Waterstops: In order to eliminate faulty installation that may result in joint leakage, particular care shall be taken of the correct positioning of the waterstops during installation. Adequate provisions must be made to support and anchor the waterstops during the progress of the WORK and to insure the proper embedment in the concrete. The symmetrical halves of the waterstops shall be equally divided between the concrete pours at the joints. The center axis of the waterstops shall be coincident with the joint openings. Maximum density and imperviousness of the concrete shall be insured by thoroughly working it in the vicinity of all joints. In placing flat-strip waterstops in the forms, means shall be provided to prevent them from being folded over by the concrete as it is placed. Unless otherwise shown, all waterstops shall be held in place with light wire ties on 12-inch centers, which shall be passed through the edge of the waterstop and tied to the curtain of reinforcing steel. Horizontal waterstops with their flat face in a vertical plane shall be held in place with continuous supports to which the top edge of the waterstop shall be tacked. In placing concrete around horizontal waterstops with their flat face in a horizontal plane, concrete shall be worked under the waterstops by hand so as to avoid the formation of air and rock pockets. In placing centerbulb waterstops in expansion joints, the centerbulb shall be centered on the joint filler material. Waterstop in vertical wall joints shall stop 6 inches from the top of the wall where such waterstop does not connect with any other waterstop and is not to be connected to for a future concrete placement. Joint Location: Construction joints, and other types of joints, shall be provided where shown. When not shown, construction joints shall be provided at 25-foot maximum spacing for all concrete construction, unless noted otherwise. Where joints are shown spaced greater than 40 feet apart, additional joints shall be provided to maintain the 25-foot maximum spacing. The location of all joints, of any type, shall be submitted for acceptance by the ENGINEER. Joint Preparation: Special care shall be used in preparing concrete surfaces at joints where bonding between 2 sections of concrete is required. Unless otherwise shown, such bonding will be required at all horizontal joints in walls. Surfaces shall be prepared in accordance with the requirements of Section 03300, "Cast-in-Place Concrete." Except on horizontal wall construction joints, wall to slab joints or where otherwise shown or specified, at all joints where waterstops are required, the joint face of the first pour shall be coated with a bond breaker as specified herein. 03290 - 10 Lake Fork Water Transmission Line Joints in Concrete
B.
C. D.
E.
F.
Contract No. 07-037
G.
Construction Joint Sealant: Construction joints in water-bearing floor slabs, and elsewhere as shown, shall be provided with tapered grooves, which shall be filled with a construction joint sealant. The material used for forming the tapered grooves shall be left in the grooves until just before the grooves are cleaned and filled with joint sealant. After removing the forms from the grooves, all laitance and fins shall be removed, and the grooves shall be sandblasted. The grooves shall be allowed to become thoroughly dry after which they shall be blown out; immediately thereafter, they shall be primed, bond breaker tape placed in the bottom of the groove, and filled with the construction joint sealant The primer used shall be supplied by the same manufacturer supplying the sealant No sealant will be permitted to be used without a primer. Care shall be used to completely fill the sealant grooves. Areas designated to receive a sealant fillet shall be thoroughly cleaned, as outlined for the tapered grooves, prior to application of the sealant. The primer and sealant shall be placed strictly in accordance with the printed recommendations of the manufacturer, taking special care to properly mix the sealant prior to application. The sides of the sealant groove shall not be coated with bond breaker, curing compound, or any other substance, which would interfere with proper bonding of the sealant. All sealant shall achieve final cure at least 7 days before the structure is filled with water. All sealant shall be installed by a competent waterproofing specialty contractor who has a successful record of performance in similar installations. Before work is commenced, the crew doing the WORK shall be instructed as to the proper method of application by a representative of the sealant manufacturer. Thorough, uniform mixing of 2-part, catalyst-cured materials is essential; special care shall be taken to properly mix the sealer before its application. Before any sealer is placed, the CONTRACTOR shall arrange to have the crew doing the WORK carefully instructed as to the proper method of mixing and application by a representative of the sealant manufacturer. Any joint sealant which, after the manufacturer's recommended curing time for the job conditions of the WORK hereunder, fails to fully and properly cure shall be completely removed; the groove shall be thoroughly sandblasted to remove all traces of the uncured or partially cured sealant and primer, and shall be resealed with the specified joint sealant. All costs of such removal, joint treatment, re-sealing, and appurtenant work shall be at the expense of the CONTRACTOR. Bentonite Waterstop: 1. Where a bentonite waterstop is called for in the Contract Documents, it shall be installed with the manufacturers instructions and recommendations; except, as modified herein. 2. When requested by the ENGINEER, the manufacturer shall provide technical assistance in the field. 3. Bentonite waterstop shall only be used where complete confinement by concrete is provided. Bentonite waterstop shall not be used in expansion or contraction joints nor in the first 6 inches of any intersecting joint. 4. The bentonite waterstop shall be located as near as possible to the center of the joint and it shall be continuous around the entire joint. The 03290 - 11 Lake Fork Water Transmission Line Joints in Concrete
H.
I. * J.
K.
L.
Contract No. 07-037
40
minimum distance from the edge of the waterstop to the face of the member shall be 5 inches. 5. Where the thickness of the concrete member to be placed on the bentonite waterstop is less than 12 inches, the waterstop shall be placed in grooves formed or ground into the concrete. The groove shall be at least 3/4 inch deep and 1-1/4 inches wide. When placed in the groove, the minimum distance from the edge of the waterstop to the face of the member shall be 2.5 inches. 6. Where a bentonite waterstop is used in combination with PVC waterstop, the bentonite waterstop shall overlap the PVC waterstop for a minimum of 6-inches and shall be placed in contact with the PVC waterstop. 7. The bentonite waterstop shall not be placed when the temperature of the waterstop material is below 40 degrees F. The waterstop material may be warmed so that it shall remain above 40 degrees F during placement; however, means used to warm the material shall in no way harm the material or its properties. The waterstop shall not be installed where the air temperature falls outside the manufacturers recommended range. B. The concrete surface under the bentonite waterstop shall be smooth and uniform. The concrete shall be ground smooth if needed. Alternately, the bentonite waterstop shall be bonded to the surface using an epoxy grout, which completely fills all voids and irregularities beneath the waterstop material. Prior to installation, the concrete surface shall be wire brushed to remove any laitance or other materials that may interfere with the bonding of epoxy. 9. The bentonite waterstop shall be secured in place with concrete nails and washers at 12-inch maximum spacing. This shall be in addition to the adhesive backing provided with the waterstop. END OF SECTION
S
Contract No. 07-037 03290 - 12 Lake Fork Water Transmission Line Joints in Concrete
SECTION 03300 CAST-IN-PLACE CONCRETE

PART 1 - GENERAL
1.1
SCOPE OF WORK This section includes all work required in placing, finishing and curing cast-in-place concrete associated with the following: A. B. C. D. Cast-in-place concrete for structures and components including, but not limited to, foundations, beams and slabs. Floors and slabs on grade. Control, and expansion and contraction joint devices associated with concrete work including joint sealants. Equipment pads, light pole bases, thrust blocks and manhole bases.
1.2
RELATED SECTIONS
A. Section 03100 - Concrete Formwork.
B 1.3
Section 03200-Concrete Reinforcement.
REFERENCES
A. ACI 207.1 R - Mass Concrete.
B. C. D.
E. F.
ACI 301 - Standard Specifications for Structural Concrete. ACI 302 - Guide for Concrete Floor and Slab Construction. ACI 304R - Guide for Measuring, Mixing, Transporting, and Placing Concrete.
ACI 305R - Hot Weather Concreting. ACI 306R - Cold Weather Concreting.
G. H. I. J. *
ACI 308 - Standard Practice for Curing Concrete. ACI 318/318R - Building Code Requirements for Structural Concrete and Commentary. ACI 350-01 - Environmental Engineering Concrete Structures. ACI 350.1-01 - Tightness Testing of Environmental Engineering Concrete Structures. 03300 - 1 Lake Fork Water Transmission Line Cast-In-Place Concrete
Contract No. 07-037
K. * L. M.
N.
ANSI/ASTM D1752 - Preformed Sponge Rubber and Cork Expansion Joint Fillers for Concrete Paving and Structural Construction. ACI 350.2 Concrete Structures for Containment of Hazardous Materials. ASTM C1074-98 - Standard Practice for Estimating Concrete Strengths by the Maturity Method.
ASTM C33 - Concrete Aggregates. ASTM C94 - Ready-Mixed Concrete. ASTM C150 - Portland Cement.
&
P.
Q. R. 1.4
ASTM C260 - Air-Entraining Admixtures for Concrete. ASTM C494 - Chemical Admixtures for Concrete.
SUBMITTALS A. B. C. D. Submit under provisions of Section 01301. Product Data: Submit data on joint devices, attachment accessories, concrete, admixtures, and fly ash to be used in concrete. Manufacturer's Installation Instructions: Submit installation procedures and interface required with adjacent work. Provide mill certificates from material supplier certifying that the following items have been tested and comply with the Contract Documents. 1. Portland Cement. 2. Fly Ash. Material supplier for concrete aggregates to provide written affidavit the following items have been tested and comply with the requirements of the Contract Documents: 1. Coarse and fine aggregates for normal weight concrete. Provide concrete mix designs for different classes of concrete required for the project. Mix designs to include field test data or trial mixture data as required by ACI 301. Submit quality control program of the proposed concrete supplier and provide copies of test reports.
E.
F.
G. 1.5
PROJECT RECORD DOCUMENTS A. Submit in accordance with Section 01720. Accurately record actual locations of embedded utilities and components, which are concealed from view.
Contract No. 07-037
03300 - 2
Lake Fork Water Transmission Line Cast-In-Place Concrete
1.6
QUALITY ASSURANCE A. All work shall be performed in accordance with the standards referenced in Part 1.3. Cement and aggregate shall be obtained form the same source for all work.
1.7
COORDINATION A. Coordinate the placement of joint devices with erection of concrete formwork and placement of form accessories.
PART 2 - PRODUCTS 2.1 CONCRETE MATERIALS A. B. Cement: ASTM C150, Type II unless noted. Fine and Coarse Aggregates: ASTM C33. 1. Do not use aggregates containing soluble salts or other substances such as iron sulfides, pyrite, marcasite, ochre, or other materials that can cause stains on exposed concrete surfaces. 2. Fine Aggregate: Clean, sharp, natural sand free from loam, clay, lumps or other deleterious substances. Dune sand, bank run sand and manufactured sand are not acceptable. 3. Coarse Aggregate: Clean, uncoated, processed aggregate containing no clay, mud, loam or foreign matter, as follows: a. Crushed stone, processed from natural rock or stone b. Wash gravel, either natural or crushed. Use of slag and pit or bank run gravel is not permitted. c. Coarse Aggregate Size: Size to be ASTM C33, Nos. 57 or 67. Water: Clean and not detrimental to concrete.
C. 2.2
ADMIXTURES A. B. Air Entrainment: ASTM C260; MB-VR manufactured by Master Builders Company or approved equivalent. Chemical Admixtures: ASTM C494, as follows: 1. Type A - Water Reducing-Pozzolith manufactured by Master Builders Company or approved equivalent.
2. 3. Type B - Retarding. Type C - Accelerating.
4. 5.
6.
Type D - Water reducing and Retarding. Type E - Water reducing and Accelerating.
Type F - Water-reducing, High Range.
2.3
ACCESSORIES A. Bonding Agent: Polymer resin emulsion.
Contract No. 07-037
03300 - 3
B.
Non-Shrink Grout: ASTM C1107, Grade A, premixed compound consisting of non-metallic aggregate, cement, water reducing and plasticizing agents, capable of developing minimum compressive strength of 2,400 psi in 48 hours and 7,000 psi in 28 days.
2.4
JOINT DEVICES AND FILLER MATERIALS A. B. Joint Filler Type B: ASTM D1752; Type II Cork and Type IlIl Self-Expanding Cork. Joint Sealing Filler: As specified in Section 02512.
2.5
CONCRETE MIX A. Provide concrete with the following mix design limitations where Class "A" concrete is specified to result in concrete placed in the field of minimum compressive strength of 4000 psi at 28 days based on test cylinders which are taken during concrete placement. Unit Measurement Minimum Compressive Strength (7 day) 3000 psi Minimum Compressive Strength (28 day) 4000 psi Coarse Aggregate ASTM C33, No. 57 or 67 Fine Aggregate ASTM C33 Water/Cement Ratio (maximum) 0.44 by weight Air Entrainment 5-7 percent Slump 3 inches plus or minus 1 inch Minimum Cement Content 564 pounds per cubic yard Provide concrete with the following mix design limitations where Class "B" concrete is specified to result in concrete placed in the field of minimum compressive strength of 3000 psi at 28 days based on test cylinders which are taken during concrete placement. Unit Measurement Minimum Compressive Strength (7 day) 2250 psi Minimum Compressive Strength (28 day) 3000 psi Coarse Aggregate ASTM C33, No. 467 Fine Aggregate ASTM C33 Water/Cement Ratio (maximum) 0.50 by weight Air Entrainment 4-6 percent Slump 3 inches plus or minus 1 inch Minimum Cement Content 470 pounds per cubic yard Provide concrete with the following mix design limitations where Class "C" concrete is specified to result in concrete placed in the field of minimum compressive strength of 2000 psi at 28 days based on test cylinders which are taken during concrete placement. Unit Measurement Minimum Compressive Strength (7 day) 1500 psi Minimum Compressive Strength (28 day) 2000 psi Coarse Aggregate ASTM C33, No. 467 Fine Aggregate ASTM C33 Water/Cement Ratio (maximum) 0.82 by weight Air Entrainment None 03300 - 4 Lake Fork Water Transmission Line Cast-In-Place Concrete
B.
C.
Contract No. 07-037
Slump Minimum Cement Content D.
4 inches plus or minus 1 inch 376 pounds per cubic yard
Provide concrete with the following mix design limitations where Class "D" concrete is specified to result in high early strength concrete placed in the field of minimum compressive of 4000 psi at 28 days based on test cylinders which are taken during concrete placement Unit Measurement Minimum Compressive Strength (1 day) 2000 psi Minimum Compressive Strength (3 day) 4000 psi Minimum Compressive Strength (28 day) 4000 psi Coarse Aggregate ASTM C33, No. 57 or 67 Fine Aggregate ASTM C33 Water/Cement Ratio (maximum) 0.44 by weight Air Entrainment 5-7% Slump 3 inches plus or minus 1 inch Minimum Cement Content 564 pounds per cubic yard Provide concrete with the following mix design limitations where Class "PC" concrete is specified to result in porecast/prestressed concrete placed in the shop of minimum compressive of 5000 psi at 28 days based on test cylinders which are taken during concrete placement Unit Measurement Minimum Compressive Strength (1 day) 2000 psi Minimum Compressive Strength (3 day) 3500 psi Minimum Compressive Strength (28 day) 5000 psi Coarse Aggregate ASTM C33, No. 57 or 67 Fine Aggregate ASTM C33 Water/Cement Ratio (maximum) 0.44 by weight Air Entrainment 5-7% Slump 3 inches plus or minus 1 inch Minimum Cement Content 658 pounds per cubic yard Trial design batches, mixture proportioning studies, and testing requirements for various classes and types of concrete specified shall be the responsibility of the CONTRACTOR. Mixture proportions shall be based on compressive strength as determined by test specimens fabricated in accordance with ASTM C 192 and tested in accordance with ASTM C 39. Provide samples of all materials used in mixture proportioning studies that are representative of those proposed for use in the project. Provide manufacturers or producer's test reports indicating compliance with these specifications. Make trial mixtures having proportions, consistencies, and air content suitable for the work based on methodology described in ACI 211.1, using at least three different water-cement ratios for each type of mixture, which will produce a range of strength encompassing those required for each class and type of concrete required on the project. The maximum water-cement ratios will be the equivalent water-cement ratio as determined by conversion from the weight ratio of water to cement plus pozzolan. Design laboratory trial mixtures for maximum permitted slump and air content. Make separate sets of trial mixture studies for each combination of cementitious materials and each combination of admixtures proposed for use. Do not use combination of either until proven by such studies, except that, if approved in 03300 - 5 Lake Fork Water Transmission Line Cast-In-Place Concrete
E.
F.
Contract No. 07-037
writing and otherwise permitted by these specifications, an accelerator or a retarder may be used without separate trial mixture study. Make separate trial mixture studies for concrete for any conveying or placing method proposed which requires special properties and for concrete to be placed in unusually difficult placing locations. Report the temperature of concrete in each trial batch. For each water-cement ratio, make at least three test cylinders for each test age and cure in accordance with ASTM C 192. Test cylinders at 7 and 28 days in accordance with ASTM C 39. From these test results, plot a curve showing the relationship between water-cement ratio and strength for each set of trial mix studies. In addition, plot a curve showing the relationship between 7 day and 28 day strengths. Design each mixture to promote easy and suitable concrete placement, consolidation and finishing, and to prevent segregation and excessive bleeding. G. Average Compressive Strength Required for Mixtures: Select the mixture proportions during mixture design studies to produce a required average compressive strength (fcr) exceeding the specified compressive strength (fCc) by the amount indicated below. This required average compressive strength, f cr, will not be a required acceptance criteria during concrete production. However, whenever the daily average compressive strength at 28 days drops below f cr during concrete production, or daily average 7-day strength drops below a strength correlated with the 28-day f'cr, adjust the mixture, as approved, to bring the daily average back up to f'cr. During production, adjust the required f cr, as appropriate, based on the standard deviation being attained on the job. Computations from Test Records: Where a concrete production facility has test records, establish a standard deviation in accordance with the applicable provisions of ACI 214.3R. Provide test records from which a standard deviation is calculated, which represents materials, quality control procedures, and conditions similar to those expected; represents concrete produced to meet a specified strength or strengths (fCc) within 1,000 psi of that specified for proposed work; and consists of at least 30 consecutive tests and be current to within the past 12 months. A strength test is the average of the strengths of two cylinders made from the same sample of concrete and tested at 28 days. For the required average compressive strength fcr used as the basis for selection of concrete proportions use the larger of the equations that follow based on the standard deviation determined above: f cr = fCc + 1.34S where units are in psi f cr = fCc + 2.33S - 500 where units are in psi Where S = standard deviation
H.
Contract No 07-037
03300 - 6
NUMBE OF ESTS NUMBER OF TESTS

15
MODIFICATION FOR STANDARDFACTOR DEVIATION

1.16
20 25 30 or more
1.08 1.03 1.00
Where a concrete production facility does not have test records meeting the equirements above but does have a record based on 15 to 29 consecutive tests, establish a standard deviation as the product of the calculated standard deviation and a modification factor from the following table: I. Computations without Previous Test Records: When a concrete production facility does not have sufficient field strength test records for calculation of the standard deviation, determine the required average strength f cr as follows: 1. If the specified compressive strength ftc is less than 3,000 psi:
fcr = flc + 1000 psi
2. J. K. L M. N.
If the specified compressive strength f'c is 3,000 to 5,000 psi: f'cr= f'c + 1,200 psi
Use accelerating admixtures in cold weather only when approved by ENGINEER. Use of admixture will not relax cold weather placement requirements. Do not use calcium chloride in concrete or in any admixture. Use set retarding admixture during hot weather only when approved by ENGINEER. Use air entraining agent in all concrete mix except for interior slabs subject to abrasion or unless otherwise shown. Maximum chloride ion content for corrosion protection shall meet table 4.4.1 listed in ACI 318/318R. Testing for chloride ion content shall conform to AASHTO T260.
PART 3 - EXECUTION 3.1 EXAMINATION A. B. C. Verify site conditions prior to construction. Verify requirements for concrete cover over reinforcement. Verify that anchors, seats, plates, reinforcement and other items to be cast into concrete are accurately placed, positioned securely and will not cause hardship in placing concrete.
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03300 - 7
3.2
PREPARATION A. B. Prepare previously placed concrete by cleaning with steel brush and applying bonding agent in accordance with manufacturer's instructions. In locations where new concrete is to be doweled to existing work, drill holes in existing concrete, insert steel dowels and pack solid with non-shrink grout, unless capsule anchors or other form of fastening is shown on Plans.
3.3
PLACING CONCRETE A. B. C. D. E. F. G. H. I. J. Place concrete in accordance with ACI 304R. Notify OWNER minimum 24 hours prior to commencement of operation. Ensure that reinforcement, inserts, embedded parts, formed joint fillers, joint devices and water stops are not disturbed during concrete placement. Install joint fillers, primer and sealant as shown in the Drawings in accordance with manufacturer's instructions. Screed floors, maintaining surface flatness of inch in 10 feet. Extend joint filler from bottom of slab to within 1/4 inch of the finished slab surface. Conform to Section 02512 for finish joint sealer requirements. Maintain records of concrete placement. Record date, location, quantity, air temperature and test samples taken. Place concrete continuously between predetermined expansion, control, and construction joints. Do not interrupt successive placement; do not permit cold joints to occur. Construction joints to be located as indicated or where approved. In general, locate construction joints for supported slabs, beams and girders near the middle of the span. If a beam intersects a girder at this point, offset the joint a distance equal to twice the width of the beam.
3.4
COLD WEATHER REQUIREMENTS A. Use special protection measures approved by the OWNER/ENGINEER, if freezing temperatures are anticipated before the expiration of the specified curing period. Maintain the ambient temperature of the air where concrete is to be placed and the temperature of surfaces to receive concrete above 40 degrees F. Maintain the temperature of the concrete when placed between 50 degrees F and 75 degrees F. Heating of the mixing water or aggregates will be required to regulate the concrete placing temperature. Provide materials entering the mixer free from ice, snow, or frozen lumps. Do not allow salt, chemicals or other materials on the concrete to prevent freezing. Upon written approval, an
Contract No. 07-037
03300 - 8
accelerating admixture conforming to ASTM C 494, Type C or E may be used, provided it contains no calcium chloride. Do not use calcium chloride. 3.5 HOT WEATHER REQUIREMENTS A. When the ambient temperature during concrete placing is expected to exceed 85 degrees F, place and finish the concrete with procedures previously submitted and as specified herein. Deliver the concrete at a temperature to the forms that does not exceed the temperature shown in the table below when measured in accordance with ASTM C 1064. Cool steel forms and reinforcements as approved prior to concrete placement when steel temperatures are greater than 120 degrees F. Cool conveying and placing equipment, if necessary, to maintain proper concrete-placing temperature. During periods of hot weather, take the following precautions to prevent the formation of plastic shrinkage cracks resulting from excessive loss of moisture from the concrete: Maximum Allowable Concrete Placing Temperature Relative Humidity, Percent, During Time of Concrete Placement Greater than 60 40 to 60 Less than 40 Maximum Allowable Concrete Temperature Degrees 90 F 85 F 80 F
3.6
PREVENTION OF PLASTIC SHRINKAGE CRACKING A. Be alert to the tendency for plastic shrinkage cracks to develop and shall institute measures to prevent this during hot weather with low humidity, and particularly with appreciable wind, as well as interior placements when space heaters produce low humidity. Take particular care if plastic shrinkage cracking is potentially imminent and especially if it has developed during a previous placement. Periods of high potential for plastic shrinkage cracking can be anticipated by use of Fig. 2.1.5 of ACI 305R. In addition further protect the concrete placement by erecting shades and windbreaks and by applying fog sprays of water, sprinkling, ponding or wet covering. Fill plastic shrinkage cracks that occur by injection of epoxy resin as directed, after the concrete hardens. Do not trowel over plastic shrinkage cracks or fill with slurry.
3.7
THERMAL STRESSES AND CRACKING IN MASS CONCRETE A. Dissipation of reaction heat is of concern in sections of large thicknesses (>5' thickness) The purpose of temperature monitoring is to provide a realtime temperature measurement at representative sections of poured in place concrete. Should the temperature values and differentials exceed limits specified herein, the CONTRACTOR shall implement forced cooling measures to dissipate 03300 - 9 Lake Fork Water Transmission Line Cast-In-Place Concrete
Contract No. 07-037
heat of hydration and thereby lower the temperatures and differentials. Temperature of in-place concrete shall be monitored by installing thermo couple devices at locations determined by the following criteria: B. Temperature monitoring sensors shall be located in base slab and in walls at representative locations determined by the following criteria. 1. At mid-thickness of base slab or wall (core location). 2. At locations 4" from surface (surface location). 3. If cooling water piping is installed at mid-thickness, two sensors shall be required for core location at lower and top quarter points. 4. A minimum of one pair of temperature sensors shall be installed for each continuous pour of mass concrete element without construction joints. In longer continuous pours, one pair of sensors shall be installed for every 250 cubic yards at a minimum. Each pair of sensors shall be securely fastened to the reinforcement. Wire leads shall be properly secured to prevent rupture and shall be of adequate length for ease of data collection. If wireless tags are used, each tag shall be tested for "life" immediately on concrete placement. Develop and submit for approval, a monitoring and implementation plan to ensure the following at any time during hydration period. 1. The temperature at the mid-thickness of the element shall not exceed 150'F. 2. The temperature difference between core and surface location shall not exceed 35"F. Employ temperature control measures including forced cooling by circulating refrigerated water through plastic pipes immediately on knowledge of noncompliance with the above criteria. 1. Cooling techniques such as refrigerated water circulation through embedded PVC pipe grids or use of insulated surface cover over concrete surface may be employed. 2. If high ambient temperatures cause high differential temperatures, measures shall be employed to cover surface of concrete with insulating material. 3. Concrete manufacture process may be modified to include precooling of aggregate and/or water, use of heat-reducing pozzolans such as Class F fly ash or slap. Reduced water-cementitious material ratio with addition of super plasticizers may be employed to achieve lowering of temperature differential. 4. CONTRACTOR shall explore all means and methods and develop a plan to control temperature differential in large sections of poured-in-place concrete. A plan describing such methods shall be submitted to the ENGINEER for approval. Cost of required number of thermo couple devise, data logger and software shall be included in contract price for temperature monitoring. Monitoring equipment shall be Intelli-Rock by Engius or approved equal. Data reader along with collected temperature data shall be delivered to the OWNERIENGINEER at the end of each pour for processing and data control.
C.
D.
Contract No. 07-037
03300 - 10
5. 6.
Cooling techniques such as refrigerated water circulation through embedded PVC pipe grids or use of insulated surface cover over concrete surface may be employed. Concrete manufacture process may be modified to include precooling of aggregate and/or water, use of heat-reducing pozzolans such as Class F fly ash or slag. Reduced water-cementitious material ratio with addition of super plasticizers may be employed to achieve lowering of temperature differential. a. CONTRACTOR shall explore all means and methods and develop a plan to control temperature differential in large sections of poured-in-place concrete. A plan describing such methods shall be submitted to the ENGINEER for approval. Cost of required number of thermo couple devices, data reader and software shall be included in contract price for temperature monitoring. Monitoring equipment shall be Intelli-Rock by Engius (972-4895863), Transtec (512-451-6233) or approved equal.
3.8
CONCRETE FINISHING A. General: Surfaces shall be free from fins, bulges, ridges, offsets, honeycombing, or roughness of any kind, and shall present a finished, smooth, continuous hard surface. Allowable deviations from plumb or level and from the alignment, profiles, and dimensions shown are defined as tolerances and are specified in Part 1, herein. These tolerances are tube distinguished from irregularities in finish as described herein. Aluminum finishing tools shall not be used. Formed surfaces: Formed surfaces are treated as per following schedule All formed surfaces are cured, definned, repaired of defective concrete, and surface defects, and tie rod holes filled. 1. Finish Fl: Architectural Finishes a. Finish Fl: No special treatment required after stripping of forms except curing, definning and filling of tie rods holes and repair of defective concrete and other surface defects. b. General: The following architectural finishes shall be required only where specifically called out on the drawings. c. Immediately after the forms have been stripped, the concrete surface shall be inspected and any poor joints, voids, rock pockets, or other defective areas shall be repaired and all form-tie holes filled as specified herein. d. Architectural finishes shall not be applied until the concrete surface has been repaired as required and the concrete has cured at least 14 days. e. All architecturally treated concrete surfaces shall conform to the accepted sample required herein in texture, color, and quality. It shall be the CONTRACTOR's responsibility to maintain and protect the concrete finish. 2. Finish F2: Smooth Concrete Finish a. The concrete surface shall be wetted, and a grout shall be applied with a brush. The grout shall be made by mixing one part Portland cement and one part of fine sand that will pass a No. 16 sieve with sufficient water to give it the consistency of thick paint.
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03300 - 11
3.
The cement used in said grout shall be 1/2 gray and 1/2 white portland cement, as determined by the ENGINEER. White Portland cement shall be Atlas white, or equal, furnished by the CONTRACTOR. Calcium chloride in the amount of 5 percent by volume of the cement shall be used in the brush coat. The freshly applied grout shall be vigorously rubbed into the concrete surface with a wood float filling all small air holes. After all the surface grout had been removed with a steel trowel, the surface shall be allowed to dry and, when dry, shall be vigorously rubbed with burlap to remove completely all surface grout so that there is no visible paint-like film of grout on the concrete. The entire cleaning operation for any area shall be completed the day it is started, and no grout shall be left on the surface overnight. b. Cleaning operations for any given day shall be terminated at panel joints. It is essential that the various operations be carefully timed to secure the desired effect, which is a light-colored concrete surface of uniform color and texture without any appearance of a paint or grout film. c. In the event that improper manipulation results in an inferior finish, the CONTRACTOR shall rub such inferior areas with carborundum bricks. d. Before beginning any of the final treatment on exposed surfaces, the CONTRACTOR shall treat in a satisfactory manner a trial area of at least 200 square feet in some inconspicuous place selected by the ENGINEER and shall said trial area undisturbed until the completion of the job. Finish F3: Sandblasted Concrete Finish a. Sandblasting shall be done in a safe manner acceptable to local authorities and per OSHA requirements. The sandblasting shall be a light sandblast to remove laitance and to produce a uniform fine aggregate surface texture with approximately 1/32- to 1/16inch of surface sandblasted off. Corners, patches, form panel joints, and soft spots shall be sandblasted with care. b. A 3-sq. ft. sample panel of the sandblasted finish shall be provided by the CONTRACTOR for acceptance by the ENGINEER prior to starting the sandblasting work. The sample panel shall include a corner, plugs, and joints and shall be marked after approval. All other sandblasting shall be equal in finish to the sample panel. c. Protection against sandblasting shall be provided on all surfaces and materials not requiring sandblasting but within or adjacent to areas being sandblasted. After sandblasting, the concrete surfaces shall be washed with clean water and excess sand removed.
B.
Unformed Surfaces: After proper and adequate vibration and tamping, all unformed top surfaces of slabs, floors, walls, and curbs shall be brought to a uniform surface with suitable tools. Immediately after the concrete has been screeded, it shall be treated with a liquid evaporation retardant. The retardant shall be used again after each work operation as necessary to prevent drying shrinkage cracks. The classings of finish specified for unformed concrete surfaces are designated and defined as follows: 03300 -12 Lake Fork Water Transmission Line Cast-In-Place Concrete
Contract No. 07-037
1. 2.
3.
4.
Finish U1 - Sufficient leveling and screeding to produce an even, uniform surface with surface irregularities not to exceed 3/8-inch. No further special finish is required. Finish U2 - After sufficient stiffening of the screeded concrete, surfaces shall be float finished with wood or metal floats or with a finishing machine using float blades. Excessive floating of surfaces while the concrete is plastic and dusting of dry cement and sand on the concrete surface to absorb excess moisture will not be permitted. Floating shall be the minimum necessary to produce a surface that is free from screed marks and is uniform in texture. Surface irregularities shall not exceed 1/4-inch. Joints and edges shall be tooled where shown or as determined by the ENGINEER. Finish U3 - After the floated surface (as specified for Finish U2) has hardened sufficiently to prevent excess of fine material from being drawn to the surface, steel troweling shall be performed with firm pressure such as will flatten the sandy texture of the floated surface and produce a dense, uniform surface free from blemishes, ripples, and trowel marks. The finish shall be smooth and free of all irregularities. Finish U4 - Steel trowel finish (as specified for Finish U3) without local depressions or high points. In addition, the surface shall be given a light hairbroom finish with brooming perpendicular to drainage unless otherwise shown. The resulting surface shall be rough enough to provide a nonskid finish.
C.
Unformed surfaces shall be finished according to the following schedule:
UNFORMED SURFACE FINISH SCHEDULE Area Grade slabs and foundations to be covered with concrete or fill material Floors to be covered with grouted tile or topping grout Slabs which are water bearing with slopes 10 percent and less Sloping slabs which are water bearing with slopes greater than 10 percent Slabs not water bearing Slabs to be covered with built-up roofing Interior slabs and floors to receive architectural finish Top surface of walls 3.9 CURING AND PROTECTION A. Curing shall conform to the requirements of ACI 308. 03300 - 13 Lake Fork Water Transmission Line Cast-In-Place Concrete Finish U1 U2 U3 U4 U4 U2 U3 U3
Contract No. 07-037
ID
B. C.
Curing operations shall follow finishing operations within 2 hours and shall continue for 7 days. Curing 1. 2. 3. shall be accomplished by one of the following methods: Ponding or continuously sprinkling. Absorptive mats or fabrics kept continuously wet. Use of approved curing compounds. Curing compounds shall not be used on any surface, which will receive additional concrete or where concrete hardeners or terrazzo floors are scheduled to be installed. Remove the compound film from all exposed surfaces at the end of the curing period.
3.10
FIELD QUALITY CONTROL A. Independent Testing Laboratory to provide testing services. Testing and inspection services to include the following items: 1. Review concrete mix design for each class of concrete. 2. If required by OWNER/ENGINEER, inspect concrete batching, mixing and delivery operation. 3. Provide testing of concrete for every 75 cubic yards of each class of concrete placed. If the total quantity of concrete placed on a given day is less than 75 cubic yards make one set of test cylinders. A set of test cylinders is defined as four concrete cylinders. Make the concrete cylinders per ASTM C 31. Test each set of test cylinders for the following items and prepare test reports and send to the OWNER, ENGINEER and CONTRACTOR: a. Compressive Strength Testing: Perform test per requirements of ASTM C 39. Test one cylinder at 7 days, two cylinders at 28 days. Extra cylinder will be tested at 56 days, if required. b. Determine slump for each set of test cylinders per requirements of ASTM C 143. c. Determine temperature of each set of test cylinders per requirements of ASTM C 1064. d. Determine amount of air content in each set of test cylinders per ASTM C 138, ASTM C 173 orASTM C 231. Independent Testing Agency to determine the appropriate test method. 4. When required by ENGINEER or OWNER, test hardened concrete as follows: a. Nondestructive Testing: Use the rebound hammer per requirements of ASTM C 805 or pulse velocity method per requirements of ASTM C 597. b. Core concrete per the requirements of ASTM C 42.Take one additional test cylinder during cold weather concreting and cure on job site under the same conditions as concrete it represents.
3.11
PATCHING A. Allow OWNER/ENGINEER to inspect concrete surfaces immediately upon removal of forms.
Contract No. 07-037
03300 - 14
B. C.
Excessive honeycomb or embedded debris in concrete is not acceptable notify OWNER/ENGINEER upon discovery. Repair form tie holes requiring repair and other defects whose depth is at least as great as their surface diameter but not over 4 inches, by the damp-pack mortar method. Ream form tie holes and cut out other similar defects to sound concrete. Thoroughly clean, thoroughly wet, brush-coat with a thin coat of neat cement grout and fill the void with mortar. Provide a stiff mix of mortar of I part portland cement to 2 parts fine aggregate passing the no. 16 mesh sieve, and minimum amount of water. Only use sufficient water to produce a mortar which, when used, will stick together on being molded into a ball by a slight pressure of the hands and will not exude water but will leave the hands damp. Mix mortar and allow to stand for 30 to 45 minutes before use with remixing performed immediately prior to use. Thoroughly tamp mortar in place in thin layers using a hammer and hardwood block. Completely fill holes passing entirely through walls from the inside face by forcing mortar through to the outside face. Pack all holes full. Moist cure damp-pack repairs for at least 48 hours. Remove defective concrete, extend removal into completely sound concrete. Use only approved equipment and procedures, which will not cause cracking or micro cracking of the sound concrete. If reinforcement is encountered, remove concrete so as to expose the reinforcement for at least 2 inches on all sides. Outline all such defective areas greater than 12 square inches by saw cuts at least 1 inch deep. Outline defective areas less than 12 square inches by a 1 inch deep cut with a core drill in lieu of sawing. Provide all saw cuts with straight lines in a rectangular pattern in line with the formwork panels. After concrete removal, thoroughly clean the surface by high pressure washing to remove all loose material. Keep surfaces continually saturated for the first 12 of the 24 hours immediately before placing mortar and keep damp but not wet at the time of commencing mortar placement. Either hand-placed mortar or mortar placed with a mortar gun may be used. If hand-placed mortar is used, provide the edges of the cut perpendicular to the surface of the concrete. Brush coat the prepared area with a thin coat of neat cement grout. Make the repair using a stiff mortar, preshrunk by allowing the mixed mortar to stand for 30 to 45 minutes and then remixed, thoroughly tamped into place in thin layers. If hand-placed mortar is used, test each repair area for drumminess by firm tapping with a hammer and inspect for cracks, in the presence of the independent testing agency, immediately before completion of the contract, and to replace any showing drumminess or cracking. If mortar placed with a mortar gun is used, use a small compressed air-operated gun to which the mortar is slowly hand fed and which applies the mortar to the surface as a high-pressure stream, as approved. Repairs made using shotcrete equipment will not be accepted. The mortar used to be the same mortar as specified for damp-pack mortar repair. If gun-placed mortar is used, bevel the edges of the cut toward the center at a slope of 1:1. Keep all surface applied mortar repairs continuously moist for at least 7 days. Provide moist curing consisting of several layers of saturated burlap applied to the surface immediately after placement is complete and covered with polyethylene sheeting, all held closely in place by a sheet of plywood or similar material rigidly braced against it. Keep burlap continually wet.
D.
Contract No. 07-037
03300 - 15
3.12
DEFECTIVE CONCRETE A. Definitions of defective concrete: 1. Concrete not conforming to required lines, details, dimensions, tolerances or specified requirements. 2. The entire unit of concrete for which strengths tests indicate inferior results than those specified. Unit of work is entire concrete work represented by the unsuccessful test samples but no less than the quantities specified for frequency of testing by the ACI 318-99. 3. Concrete is also classified defective if any honeycombing, voids, loose/unbonded gravel, and porous surfaces indicating loss of water are observed on removal of forms. 4. Rebar exposed due to inadequate cover. Owner reserves the right to reject any defective concrete defined above and require the CONTRACTOR to remove the entire unit of work and replace with new concrete complying with Contract Documents at no additional expense to the Owner. B. C. D. Repair or replacement of defective concrete will be as determined by the OWNER or ENGINEER. Do not patch, fill, touch-up, repair or replace defective concrete except upon express direction of OWNER or ENGINEER for each individual area. Acceptance/rejection of defective concrete. Evaluation of defective concrete not meeting strength requirements is based on provisions of ACI 318, Chapter 5. Further strength evaluation of questionable portion of the structure not meeting the cylinder tests is as per ACI 318, Chapter 18. If the strength evaluation results in a determination that concrete is unacceptable, the OWNER may reject entire unit of work and order removal and replacement. For the purpose of determining extent of defective concrete the following limits are set exceeding which, the OWNER may reject concrete work and order removal and replacement. Non conformance to lines and grades: Two times the tolerance limits set by ACI 318, ACI 117. Lack of compaction/honeycombing: One square foot over 4,000 sq. ft. of formed surface, and exposed rebar.
3.13
SCHEDULE - CONCRETE TYPES
A.
Class 1. 2. 3. 4. 5. 6. 7.
"A" concrete shall be steel reinforced and shall include the following: Foundations Walls Slabs Beams Girders Columns Equipment Bases.
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03300 - 16
B.
Class 1. 2. 3. 4. 5. 6. 7. 8.
"B" concrete shall be steel reinforced and shall include the following: Standard pipe supports Curbs and gutters Sidewalks Ductbanks Manhole bases Street paving Thrust blocks Pipe encasements.
C.
Class "C" concrete shall be placed with or without forms and shall be unreinforced. It is intended for use in the following applications: 1. Concrete fill 2. Working slab. Class "D" concrete shall be steel reinforced and shall be placed where high early strength cement is specified.
D.
3.14
SCHEDULE - CONCRETE FINISHES
A.
Pump room substructure up to El. 416.00. Provide Finish F1 for the following locations: 1. Interior and exterior exposed walls, columns, beams, and other interior vertical and horizontal formed surfaces. 2. Exterior exposed walls and other vertical surfaces down to flume level. 3. Exposed undersides of elevated slabs. 4. Interior vertical surfaces of liquid containing structures. 5. Exposed and internal vertical surfaces of earth filled cells. 6. All formed horizontal surfaces inside flumes. 7. At tops of walls, horizontal offsets, and similar unformed surfaces occurring adjacent to the formed surfaces, strike-off smooth and finish with a texture matching adjacent formed surfaces. Continue the final surface treatment of formed surfaces uniformly across the adjacent unformed surfaces unless otherwise shown. Provide Finish F1, with tie-holes and imperfections repaired and with fins and other projections exceeding 1/4 inch rubbed down or stripped off at the following locations: 1. Exterior vertical surfaces of liquid retaining structures. 2. Interior vertical surfaces of liquid containing structures. 3. Interior and exterior surfaces of conduit tunnel. 4. Pump room superstructure above 416.0. 5. Lay down area below 412.0. 6. Lay down area above 412.0. 7. Switchgear room above 416.0. 8. Valve vault external surfaces. 9. Miscellaneous structures. Provide Finish F2 Smooth Concrete Finish for following locations: 1. Switch gear room interior concrete surfaces including underside of precast concrete beams. 03300 - 17 Lake Fork Water Transmission Line Cast-In-Place Concrete
13B
C.
Contract No. 07-037
2. 3. D.
Valve vault interior surfaces of walls and roof slab. Operator room and storage area in Laydown area.
Chemical-Hardener Finish: Apply chemical-hardener finish to all interior concrete floors of main pump room, switch gear basement and switchgear room, storage and operator rooms and where shown on the Plans or in schedules. 1. Floor Hardener: Hardening agent for exposed concrete floors shall be a colorless aqueous solution of zinc and/or magnesium flousilicate, or of sodium silicate. Each gallon of the flousilicate solution shall contain not less than two pounds of crystals. The sodium silicate solution shall be 32 percent by volume of 42 degree Baume sodium silicate. A proprietary hardener may be used provided the solution is delivered ready for use in the manufacturer's original containers. No combination chlorinated rubber curing-hardening material will be considered in lieu of the material specified for chemical floor hardener. 2. The floors shall be thoroughly cured, cleaned, and perfectly dry with all work above them completed. Zinc and/or magnesium flousilicate shall be applied evenly, using 3 coats, allowing 24 hours between coats. The first coat shall be 1/4 strength, the second coat 1/2 strength, and the third coat 2/3 strength. Each coat shall be applied so as to remain wet on the concrete surface for 15 minutes. Sodium silicate shall be applied full strength at the rate of 1/3 gallon per 100 square feet. Proprietary hardeners shall be applied in accordance with manufacturers instructions. After the final coat is completed, the dry surplus hardener shall be removed from the surfaces by scrubbing and mopping with water. END OF SECTION
Contract No. 07-037
03300 - 18
SECTION 03600 GROUT

PART 1 - GENERAL
1.1
SCOPE OF WORK A. B. Provide grout as shown on the Plans and as specified herein. Grout 1. 2. 3. shall be placed at the following locations: Equipment bases. Foundation grouting. Wherever so indicated on the Plans.
C.
The types of grout used shall include the following: 1. Non-shrink, epoxy type. 2. Non-shrink, non-metallic type. 3. Ordinary cement-sand.
1.2
RELATED WORK AND SPECIFICATIONS A. Section 03300: Cast-In-Place Concrete.
1.3
REFERENCED STANDARDS A.
B.
ASTM C144 - Aggregate for Masonry Mortar.

ASTM C150 - Portland Cement.
C. D. E. F. G. H. 1.4
ACI 351.1 R - Grouting between Foundations and Bases of Equipment. ASTM C109 - Compressive Strength of Hydraulic Cement Mortars (using two inch or fifty millimeter Cube Specimens). ASTM C1 107 - Packaged Dry, Hydraulic-Cement Grout (Non Shrink). ASTM C1 91 - Time of Setting of Hydraulic Cement by Vicat Needle. CRD-C-588 - Specifications for Non-Shrink Grout. ASTM C33 - Standard Specifications for Concrete Aggregate.
SUBMITTALS In addition to all other appropriate requirements of Section 01301, the CONTRACTOR shall submit the following: A. Record Data: 1. Submit copies of manufacturer's specifications and installation instructions for all proprietary materials. 03600 - 1 Lake Fork Water Transmission Line Grout
Contract No. 07-037
B.
Reports and Certifications: 1. For proprietary materials, submit copies of reports on quality control tests. 2. For nonproprietary materials, submit certification that materials meet specification requirements.
1.5
PRODUCT DELIVERY, STORAGE AND HANDLING A. B. Delivery of Materials: Grout materials from manufacturers shall be delivered in unopened containers and shall bear intact manufacturer's seals and labels. Storage of Materials: Grout materials shall be stored in a dry shelter and shall be protected from moisture.
PART 2 - PRODUCTS 2.1 MATERIALS Unless otherwise specified, grout for equipment base grouting shall be non shrink, non metallic cementations grout. A. Non-metallic, 100 percent solids, high strength epoxy grout. 1. Use clean, well graded sand with epoxy resins suitable for use on dry or damp surfaces. 2. Product and Manufacturer: a. Euco High Strength grout by the Euclid Chemical Company. b. Sikadur Hi-Mod Grout by Sika Chemical Company. c. Five Star Epoxy Grout by U.S. Grout Corporation. Non-Shrink, Non-Metallic Grout: 1. Pre-mixed non-staining cementatious grout requiring only the addition of water at the jobsite. 2. Product and Manufacturer: a. Euco N-S by the Euclid Chemical Company. b. Masterflow 713 by Master Builders Company. c. Five Star by U.S. Grout Corporation. Ordinary Cement-Sand Grout: 1. Except where otherwise specified, use one part cement to three parts sand complying with the following: a. Cement: ASTM C150, Type IL b. Sand: ASTM C33. 2Where water repelling and shrinkage reducing requirements are shown or specified, use admixtures. 3. Product and Manufacturers: a. Integral Waterpeller by the Euclid Chemical Company. b. Omicron, Type OM by Master Builders Company. c. Hydrocide Powder by Sonneborn-Contech.
0
B.
C.
Contract No. 07-037
03600 - 2
Lake Fork Water Transmission Line Grout
D.
Water: 1. Use clean, fresh, potable water free from injurious amounts of oils, acids, alkalies or organic matter.
PART 3 - EXECUTION 3.1 INSTALLATION A. General: 1. Place grout as shown in accordance with manufacturer's instructions. If manufacturer's instructions conflict with the Specifications, do not proceed until OWNER or ENGINEER provides clarification. 2. Drypacking will not be permitted. 3. It shall be the CONTRACTOR's responsibility to obtain the services of a qualified, full time employee of the manufacturer to aid in assuring proper use of the product under job conditions. 4. Placing grout shall conform to temperature and weather limitations as stated in manufacturer's instructions. Equipment Bases: 1. After shimming equipment to proper grade, securely tighten anchor bolts. 2. Properly form around the base plates, allowing sufficient room around the edges for placing the grout. 3. Adequate depth between the bottom of the base plate and the top of concrete base must be provided to assure that the void is completely filled with non-metallic epoxy grout. Handrails and Railings: 1. After posts have been properly inserted into the holes or sleeves, fill the annular space between posts and sleeve with the non-shrink, nonmetallic grout. 2. Bevel grout at juncture with post so that moisture flows away from post. 3. Side mounted handrails do not require grout. END OF SECTION
B.
C.
Contract No. 07-037
03600 - 3
Lake Fork Water Transmission Line Grout

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SECTION 03100 CONCRETE FORMWORK

Contract No. 07-037

03100- 1 Lake ForkWaterTransmission Line Concrete Formwork

Contract No. 07-037

03100 - 2 Lake Fork Water Transmission Line Concrete Formwork

Contract No. 07-037

03100 - 3 Lake Fork Water Transmission Line Concrete Formwork

EARTH FORMS A. Earth forms are not permitted.

Contract No. 07-037

03100 - 4 Lake Fork Water Transmission Line Concrete Formwork

APPLICATION - FORM RELEASE AGENT

Contract No. 07-037

03100-5 Lake ForkWaterTransmission Line Concrete Formwork

Contract No. 07-037

03100 - 6 Lake Fork Water Transmission Line Concrete Formwork

Contract No. 07-037

Lake Fork Water Transmission Line Concrete Reinforcement

Contract No. 07-037

Lake Fork Water Transmission Line Concrete Reinforcement

Contract No. 07-037

Lake Fork Water Transmission Line Concrete Reinforcement

Contract No. 07-037

Lake Fork Water Transmission Line Concrete Reinforcement

SECTION 03290 JOINTS IN CONCRETE

U.S. Army Corps of Engineers Specifications: CRD-C572 PVC Waterstop.

ASTM D 2240 1.3 TYPE OF JOINTS A.

Contract No. 07-037

Lake Fork Water Transmission Line Joints in Concrete

Contract No. 07-037

Lake Fork Water Transmission Line Joints in Concrete

Contract No. 07-037

Contract No. 07-037

1500 300 +0.25/-0.10 +5 1400 280

D 2240 D 638, Type IV D 638, Type IV

24 hours, maximum Lake Fork Water Transmission Line Joints in Concrete

Contract No. 07-037

Contract No. 07-037

Lake Fork Water Transmission Line Joints in Concrete

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Contract No. 07-037

Contract No. 07-037

SECTION 03300 CAST-IN-PLACE CONCRETE

Section 03200-Concrete Reinforcement.

Contract No. 07-037

Contract No. 07-037

Lake Fork Water Transmission Line Cast-In-Place Concrete

ACCESSORIES A. Bonding Agent: Polymer resin emulsion.

Contract No. 07-037

Lake Fork Water Transmission Line Cast-In-Place Concrete

Contract No. 07-037

Slump Minimum Cement Content D.

4 inches plus or minus 1 inch 376 pounds per cubic yard

Contract No. 07-037

Lake Fork Water Transmission Line Cast-In-Place Concrete

NUMBE OF ESTS NUMBER OF TESTS

MODIFICATION FOR STANDARDFACTOR DEVIATION

1.08 1.03 1.00

Contract No. 07-037

Lake Fork Water Transmission Line Cast-In-Place Concrete

Contract No. 07-037

Lake Fork Water Transmission Line Cast-In-Place Concrete

Contract No. 07-037

Contract No. 07-037