SECTION 03 30 00 - CAST-IN-PLACE CONCRETE

PART 1 - GENERAL

1.01 - WORK INCLUDED

A. Formwork, shoring, bracing, and anchorage

B. Concrete reinforcement and accessories

C. Cast-in-place concrete

D. Grout

E. Concrete curing

F. Waterproofing

G. Final concrete finishes

1.02 - RELATED SECTIONS

1.03 - REFERENCES
A. ACI 301 - Specifications of Structural Concrete for Buildings.

B. ACI 304 - Recommended Practice for Measuring, Mixing, Transporting and

Placing Concrete.

C. ACI 305 - Hot Weather Concreting.

D. ACI 306 - Cold Weather Concreting.

E. ACI 308 - Standard Practice for Curing Concrete.

F. ACI 318 - Building Code Requirements for Reinforced Concrete.

G. ACI 350 - Concrete Sanitary Engineering Structures.

H. ANSI/ASTM A185 - Welded Steel Wire Fabric for Concrete Reinforcement.

I. ASTM A615 - Deformed and Plain Billet-Steel for Concrete Reinforcement.

J. ASTM C33 - Concrete Aggregates.

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K. STM C94 - Ready-Mixed Concrete.

L. ASTM C150 - Portland Cement.

M. ASTM C260 - Air Entraining Admixtures for concrete.

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

O. ASTM C494 - Chemical Admixtures for Concrete.

P. ASTM C618 - Fly Ash and Raw or Calcinated Natural Pozzolan for Use as a
Mineral Admixture in Portland Cement Concrete.

Q. ASTM D1751 - Preformed Expansion Joint Fillers for Concrete Paving and
Structural Construction.

R. ASTM D2103 - Polyethylene Film and Sheeting.

1.04 - SUBMITTALS
A. The Contractor shall comply with the requirements contained in Section 01 30
00.

B. Product data shall be submitted for all products specified herein.

C. Shop drawings shall be prepared and submitted in accordance with the

requirements specified in paragraph 1.08 below.

D. Provide proposed concrete mix design for each type of concrete, as specified in
paragraph 1.15, below to be used on the project at least 30 calendar days prior
to the first scheduled concrete pour. The Contractors testing laboratory shall
develop concrete mix designs and test all materials and mixes for conformance
with these specifications. The costs associated with development of the design
mix and testing of samples shall be paid for out of the stipulated cash allowance.

E. Furnish the Engineers field representative with the transit-mix delivery slips.

1.05 - QUALITY CONTROL

A. Comply with the referenced standards specified in paragraph 1.03 above.

B. Perform testing under the provisions of Section 01 45 00 - Quality Control.

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C. Laboratory testing costs associated with the work of this Section will be paid for
out of the stipulated cash allowance. The Contractor shall arrange to have a
qualified technician present at the prescribed time.

D. Perform all work in accordance with ACI 301.

E. Provide field quality control as specified herein this Section.

F. Procure concrete from a single approved central commercial batching plant. To

further insure consistency, coloring, finish and quality, all aggregates, cement,
water and other ingredients shall each be secured from the same source for the
duration of the project.

G. The batching plant and raw materials may be subject to inspections and tests
performed by the Engineer.

H. Contractor shall provide an adequately sized, insulated curing box to house

concrete test cylinders, at the discretion of the Engineer, for the 24-hour period
between concrete pour and sample pick-up by the testing lab. As directed by the
Engineer, the Contractor shall cure additional cylinders in the same fashion as
the in-place concrete.

1. Curing box shall be located away from the main construction area and
shall be blocked up off the ground.

2. A log sheet shall be provided in a waterproof sheet protector to log in the

placement and removal of the concrete test samples by the testing lab.

3. Minimum information to be logged for each pour date shall include: date of
pour, date of pick-up, weather conditions at time of pour, number of
cylinders added, number of cylinders removed, location of pour, testing lab
field technician name.

I. Maintain one copy of document on site.

1.06 - REGULATORY REQUIREMENTS

A. Conform to ACI 304 and all applicable codes for placement of concrete and
related work.

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1.07 - TESTS
A. Testing and analysis of concrete shall be performed under the requirements
contained in Section 01 45 00.

B. The testing laboratory shall take cylinders, perform slump, and air entrainment
tests in accordance with ACI 301. Unless directed otherwise by the Engineer,
the following samples and tests shall be taken:

1. Three (3) concrete test cylinders shall be taken for every 50 or less cubic
yard each class of concrete placed each day.

2. One (1) additional test cylinder shall be taken during cold weather and be
cured on site under the same conditions as concrete it represents.

3. One (1) slump test shall be taken for each set of test cylinders taken, and
each transit mix delivery.

1.08 - SHOP DRAWINGS

A. Submit shop drawings of reinforcing steel and formwork under the provisions of
Section 01 33 00.

B. Indicate reinforcement sizes, spacing, locations and quantities of reinforcing steel

and wire fabric, bending and cutting schedules, splicing and supporting and
spacing devices.

C. Indicate formwork dimensioning, materials, arrangement of joints and ties.

D. Submit formwork shop drawings prepared under the supervision of a professional

engineer registered in the State of New York who shall be qualified as a
structural engineer. Shop drawings shall bear the seal and signature of said
licensed Professional Engineer.

E. Manufacturers instructions: Indicate installation procedures and interface

required with adjacent work.

1.09 - COORDINATION
A. Coordinate work under provisions of Section 01 31 00 Project Management
and Coordination. The Contractor shall provide at least five (5) working days

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advance notice prior to formwork closure to the Engineer so that he can advise
the prime electrical contractor accordingly. Prime contractors shall be given the
opportunity to complete their contractual obligations.

B. Coordinate work of other Sections in forming and setting openings, slots,

recesses, chases, sleeves, bolts, anchors, and other inserts.

C. Notify Engineer a minimum of three (3) working days prior to commencement of

concrete pours.

1.10 - WARRANTY
A. Paragraph not used.

1.11 - DELIVERY, STORAGE AND HANDLING

A. Store cement off the ground in a dry, weatherproof, adequately ventilated
structure with provisions to prevent absorption of water.

B. Transport dry concrete batches from the central plant to the site in approved
truck mixers conforming to the requirements of the Truck Mixer Manufacturers
Agitating Standards. Each truck shall contain a plate stating the capacity, drum
speeds and be provided with a revolution counter.

1.12 - ENVIRONMENTAL REQUIREMENTS

A. Do not place concrete when the ambient temperature is below 40 deg. F. or
when the concrete temperature exceeds 85 deg. F. Under certain
circumstances, the Engineer may approve the placement of concrete under the
above conditions, provided that the procedures of ACI 305 and ACI 306 are
strictly adhered to.

B. Do not place concrete when the conditions may adversely affect the placing,
curing or finishing of concrete, or its strength.

C. Comply with the requirements contained in Section 01 65 00 - Product Delivery,

Storage and Handling.

1.13 - DESIGN MIXES

A. Submit the following related to design mixes:

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1. Name, address, and telephone number of Contractors laboratory.

2. Mix proportions.

3. Source of cement, type, brand, and certified copies of mill reports,

including physical and chemical analysis.

4. Source of fine aggregates and results of tests made in accordance with

ASTM C33 and ASTM C40.

5. Source of coarse aggregates and results of tests made in accordance with

ASTM C33.

6. Catalog cuts of all admixtures.

7. Furnish test results of slump, air entrainment and water-cement ratio for
each mix design.

8. For each mix proposed, make and cure four (4) standard 6 in. concrete
test specimens in the lab in accordance with ASTM C192. Furnish
compression test results made in accordance with ASTM C39. Break two
(2) cylinders at seven (7) days and two (2) at 28 days.

9. If the concrete is intended to be pumped, design mix accordingly and

submit certification that it has been tested for pumping.

B. If the adopted mix fails to produce concrete meeting the requirements for
strength and placeability, the Engineer may order additional cement or
adjustments to mix proportions at no extra cost to the Owner.

PART 2 - PRODUCTS

2.01 - MATERIALS
A. Plywood forms: Douglas Fir species, solid one side grade and sound undamaged
sheets. Thickness of wood shall be as required to support weight of concrete
with minimal deflection.

B. Steel forms: Minimum 16 gage (1.5 mm) thick, stiffened to support weight of
concrete with minimum deflection.

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C. Tubular column type forms: Round, spirally wound laminated fiber material;
inside surface treated with release agent.

D. Form ties: Snap-off metal, of fixed length, cone type with water-stopping washer.

E. Reinforcing: ASTM A615, 60 ksi (414 Mpa) yield grade billet steel deformed
bars; uncoated finish, size and dimensions as indicated on plans.

F. Welded steel wire fabric: Plain type, ANSI/ASTM A185; in flat sheets; uncoated
finish; size and dimensions as indicated on plans.

G. Cement: ASTM C150, Type IA, Air Entraining Portland type.

H. Fine and coarse aggregates: ASTM C33. (No. 57 or No. 67).

I. Water: Clean and not detrimental to concrete.

2.02 - ACCESSORIES
A. Air entraining admixture: ASTM C260.

B. Chemical admixture: ASTM C494, Type as required.

C. Bonding agent: Three (3) component, solvent free, moisture tolerant, epoxy-
modified cementitious product. Product Armatec 110 EpoCem as manufactured
by Sika Corp. or specifically approved equal.

D. Vapor barrier: ASTM D2103, 10 mil (0.25 mm) thick clear polyethylene film.

E. Non shrink grout: Premixed compound with non-metallic aggregate, cement,

water reducing and plasticizing agents; capable of minimum compressive
strength of 2400 psi (16.5 Mpa) at 48 hours and 7000 psi (48.3 Mpa) at 28 days.
Grout shall be suitable for contact with potable water. For equipment bases and
pipe supports use non-shrink grout by Master Builders, Embeco 636, Unisorb V-
1, or equal.

F. Flashing reglets: Galvanized steel; 26 gage (0.45 mm) longest possible lengths;
alignment splines for joints; securable to formwork; Type CO, manufactured by
FRY REGLET or equal.

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G. Expansion joints: ASTM D1751; 1/2-inch (13 mm) thick asphalt impregnated
fiberboard or felt.

H. Form release agent: FORMSHIELD by EUCLID CHEMICAL or equal; colorless,

water based, non-toxic, V.O.C. compliant, environmentally safe material which
will not stain concrete, absorb moisture or impair natural bonding or color
characteristics of coating intended for use on concrete; manufactured by SYMMS
CORPORATION or equal. Agent shall not be detrimental to the environment.

I. Sealant: ASTM D6690; hot applied rubber compound manufactured by BURKE

COMPANY or equal.

J. Clear Sealer: Siloxane type; manufactured by the BURKE COMPANY or equal.

K. Absorptive mat: Burlap-polyethylene, 8-oz/sq. yd (270-g/sq. m.), bonded to

prevent separation during use.

L. Membrane curing compound: Moisture Retention complying with ASTM C309.

Products: EUCOCURE VOX as manufactured by EUCLID CHEMICAL
COMPANY or equal.

M. Chairs, bolsters, bar supports, spacers: sized and shaped for strength and
support of reinforcement during concrete placement conditions including load
bearing pad on bottom to prevent vapor barrier puncture.

2.03 - MIXES
Cast in place concrete:

A. Mix concrete in accordance with ASTM C94, Alternative No. 2, to achieve the
following:

1. Compressive strength (28 day): 4000 psi

2. Maximum water (cement ratio by weight): 0.50

3. Slump:

a. Slabs, beams & columns - 4 1 inches

b. Plain footings, & foundation walls - 3 1 inches

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4. Air entrainment: 5 1 percent

5. Large aggregate: crushed stone, ASTM C33, No. 67

B. Use admixtures only when approved by the Engineer.

PART 3 - EXECUTION

3.01 - EXAMINATION
A. Verify lines, levels, and measurement before proceeding with formwork. Ensure
that dimensions agree with the plans.

B. Inspect the formwork and reinforcing that it has been properly set and secured
and that all items to be embedded, built-in or pass through concrete are at their
proper locations and elevations.

C. The General Contractor shall verify that all other prime contractors have installed
concrete inserts, sleeves and embedded elements of the project, such as
conduit, and that their work has been totally completed and inspected by the
Engineer.

3.02 - FORMWORK ERECTION

A. Hand trim sides and bottom of earth forms and remove loose soil to the
satisfaction of the Engineer.

B. Remove water from forms and excavations and divert flows of water to avoid
washing over, under or through freshly placed concrete.

C. Align form joints.

D. Do not apply form release agent where concrete surfaces are to receive special
finishes or applied coatings that may be affected by the agent.

E. Where new concrete is doweled to existing work, drill holes in existing concrete,
insert steel dowels and pack with non-metallic/non-shrink grout.

F. Prepare previously placed concrete by cleaning with steel brush and apply
bonding agent in accordance with manufacturer's instructions.

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G. Coordinate work of other sections in forming and setting openings, slots,

recesses, chases, sleeves, bolts, anchors, and other inserts.

3.03 - INSTALLATION
A. Place, support, and secure reinforcement against displacement at the locations
and to the dimensions as indicated on the plans.

B. Use reinforcing splices at a minimum of locations and only at locations of

minimum stress. Review locations of splices with Engineer.

C. Rebar splice overlap shall be the minimum length as per ACI 318.

D. Install vapor barrier under interior floor slabs on grade. Lap joints minimum 6
inches (150 mm) and seal. Do not disturb vapor barrier while placing
reinforcement.

E. Ensure reinforcement, inserts, embedded parts, formed joint fillers, joint devices
and waterstops are not disturbed during concrete placement.

F. Repair vapor barrier damaged during placement of concrete reinforcing. Repair

with vapor barrier material and lap over damaged areas minimum 6 inches (150
mm) and seal watertight.

G. Install joint fillers in accordance with manufacturers instructions.

H. Install joint devices in accordance with manufacturers instructions.

I. Install joint device anchors. Maintain correct position to allow joint cover flush
with floor and wall finish.

J. Install joint covers in one-piece length when adjacent construction activity is

complete.

K. Apply sealants in joint devices in accordance with manufacturers instructions.

L. Maintain records of concrete placement. Record date, location, quantity, air

temperature and test samples taken.

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M. Place concrete continuously between predetermined expansion, control and

construction joints as rapidly as possible by methods which shall prevent the
separation of ingredients.

N. Place concrete with the aid of mechanical vibrators and shall be capable of
transmitting to the concrete not less than 3,000 impulses per minute. Maintain at
least three (3) vibrators, in good working condition, ready for use when concrete
placement starts in any one area.

O. Do not interrupt successive placement. Do not permit cold joints to occur.

3.04 - INSTALLATION - FLOOR SLABS

A. Saw cut control joints at an optimum time after finishing. Cut slabs with 3/16-inch
(4.8 mm) thick blade, 1/4 depth of slab thickness.

B. Separate slabs on grade from vertical surfaces with 1/2 thick joint filler. Extend
joint filler from bottom of slab to within 1/4 inch (6 mm) of finished slab surface.

C. Steel trowel all other surfaces except as noted.

D. In areas with floor drains, maintain floor elevation at walls; pitch surfaces
uniformly to drains maintaining a minimum 1 percent slope.

E. Cure floor surfaces in accordance with ACI 308.

F. Apply curing compound in accordance with manufacturer's instructions in two (2)

coats with second coat at right angles to the first.

3.05 - TOLERANCES
A Provide Class A tolerance to floor slabs according to ACI 301. Tolerance shall
be true planes within 1/8 inch in 10 feet, as determined by a 10 foot straightedge
placed anywhere on the slab in any direction.

B. Foundation Walls and all other formed concrete structures shall conform to a
Class A tolerance as per ACI 301.

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3.06 - FIELD QUALITY CONTROL

A. Inspection and testing of concrete performed by the independent testing
laboratory shall be performed under provisions of Section 01 45 00 - Quality
Control.

3.07 - FINISHES
A. The Contractor shall finish all concrete by:

1. Filling all localized surface voids (bugholes), honeycombing, and pockets

exceeding 1/8 inch diameter and 1/8 inch depth, in the concrete with an
application of cement mortar as follows: White cement shall be added to
the mortar in an amount sufficient to tint the mortar a shade lighter than
the concrete to be repaired. Mortar shall be mixed approximately 45
minutes in advance of use. Care shall be exercised to obtain a good bond
with the concrete. After the mortar has thoroughly hardened, the surface
shall be rubbed with a carborundum stone in order to obtain the same
color in the mortar as in the surrounding concrete. The final appearance
shall be acceptable to the Engineer.

2. All fins caused by form joints, and other projections shall be completely
removed to the satisfaction of the Engineer.

3. Filling all snap tie voids with mortar as specified above.

B. All interior walking surfaces of all buildings shall be left with a steel float finish
and be readied for finish work of other Sections.

C. Housekeeping pads shall be left with a broom finish with a steel toweled rounded
edge.

D. All exterior-walking surfaces shall be left with a fine broom finish with a steel
trowel border and rounded edges.

E. All exposed horizontal and vertical wall and slab corners shall have a wide
chamfered edge.

F. Finish exposed concrete as specified in Section 09 90 00, and other Sections.

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3.08 - PROTECTION AND REPAIR

A. Protect concrete from damage and rust staining to the date that the Final
Completion Certificate has been issued by the Engineer. Immediately remove all
rust spots that have developed during the construction period as soon as
directed by the Engineer. Remove all rust spots that have formed by use of
temporary handrails.

3.09 - DEFECTIVE CONCRETE

A. Defective Concrete: Concrete not conforming to required lines, details,
dimensions, tolerances or specified requirements.

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

C. Do not patch, fill, touch-up, repair, or replace exposed concrete except upon
express direction of the Engineer for each individual area.

END OF SECTION

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