TABLE OF CONTENTS Foreword Introduction Definitions . DIVISION 1 - QUALITY SYSTEM 14 Objective. WA 4.2 Plant Quality Assurance Program 124 General . 14 1.22 Documented Procedures 12 123 Management Responsibilities. 13 1.3. Personnel 13.4 General. 14 1.3.2 Engineering... 14 133° Drafting... 14 113.4 Production 15 13.5 Quality Control 15 1.4 Design Responsibilities 1.4.4 General 16 1.4.2 Shop Drawings. 16 1.5 Project Samples 15.1 General... 152 Size and Shape. 1.5.3 Identification. 1.5.4 Visual Mock-ups and initial Production Approval of Finishes. ision 1 — Provisions for Special A1.5 Project Samples A154 General... A.1.8.4 Visual Mock: Approval of DIVISION 2 - PRODUCTION PRACTICES 21 General Objectives and Satety 1.9 $ and initial Production shes... (20 ee Generale 2d 24.2 Plant Safely 24 2.2 Production and Curing Faciliti 2.2.4 Area Requirements ... 2.2.2 Form Fabrication.. 2.2.3 Storage of Release Agents and Other Chemicals... . 2.2.4 Hardware Fabrication and Storage... 2.3 MNLAI6 4th Edition 2.2.5 Conerete Handling and Consolidation Equipment... eer 2.2.6 Curing and Finishing Areas. 2.2.7 Handling Equipment. 22.8 Storage Area for Fit Product 25 23 Welding 23.1 Welding of Structural Steel sn BS 232 Welding of Reinforcement. 28 233 Stud WelCIMG nnn 212 24 Forms 24.1. Materials and Construction _ 242 Verification and Maintenance 215 2.8 Hardware Installation BAB 2.6 Product Identification 2.7 Product Handling 27.1 General. 2.7.2 Stripping... 273 Yard Storage 27.4 Loading . 2.8 Surface Finishes 281 General...... et 28.2 As-Cast Formed Surface Finishes......2.21 2.8.3 Exposed or Visible Unformed Surface Finishes 2.22 28.4 Applied Coatings... 2.23 2.9 Repairs.. 2.28 2.40 Acceptability of Appearance 2.26 241 Sealers and Clear Surface Coatings.2.25 ion 2 — Provis ishes ns for Special Fi A2.2_ Production \d Curing Facilities A2.2.6 Curing and Finishing Areas. 2.28 24 Forms A241. Materials and Construction 0.02.26 2.7 Product Handling 42.7.2. Stripping 2.7.3 Yard Storage 2.7.5 Cleaning 42.8 Surface Fi A281 General 2.27 Page viA2.8.2. As-Cast Formed Surface Finishes.......2.29 A2.8.5 Sand or Abrasive Blast Finish 2.30 A288 Acid Etched Finish, 231 A287 Retarded Finish 2.8.8 Tooled or Bush-Hammered Finish A2.8.9 Honed or Polished Finish. A2.8.10 Fm Linen ‘A2.8.11 Embedded Veneer Facing Materials. A2.8.12Sand Embedded Materials... 2:32 2.33 2.34 2.35 2.37 A240 Acceptability of Appearance..........2.38 A241 Sealers and Clear Surface Coatings. 2.40 DIVISION 3 - RAW MATERIALS AND: ACCESSORIES A Concrete Materials 1.1. General. 4.2 Cement... 4.3. Fine Aggregate... 1.4 Coarse Aggregate .. 15 16 17 Aggregates for Lightweight Concrete. Mixing Water... Admixtures. 3.2 Reinforcement and Hardware 3.2.1. Reinforcing Steel. ae 35 3.2.2 Prestressing Mater 3.2.3 Hardware and Miscellaneous Material... 3.2.4 Handling and Lifting Devices 3.2.5 Strand Restraining Devices 0... 3.16 3.3 Insulation 3.4 Welding Electrodes 347 Division 3 - Provisions for Special Finishes ASA Concrete Material 3.1.4 General sennee 3.20 3.4.2 Cement... seennnnnnnnnnneee 8.20 3.1.3. Fine AQGrEDAES on 324 43.1.4. Coarse Aggregates 324 A3.1.5. Aggregates for Lightweight Concrete... 3.22 3.1.6 Mixi . 3.22 ABA7 3.22 A3.2 Reinforcement and Hardware A3.2.4. Reinforcing Steel 3.24 Page vit ABS Facing Materials... 3.24 DIVISION 4 - CONCRETE Baae 43 434 432 433 434 44 45 454 452 453 46 47 4qA 472 473 474 48 49 4.10 Mix Proportioning .. i Qualification of New Concrete Mixes.....4.1 ‘Specified Concrete Strength eaealg Statistical Concrete Strength Considerations... Proportioning to Ensure Durability of Concrete, 43 Special Considerations for Air Entrainment... 4A Mix Proportioning for Concrete Made with Structural Lightweight Aggregate 4.5 Lightweight Aggregates - Absorption and Moisture Content Lightweight Agareg: Water-Cementitious Material Ratio for Lightweight Aggregate Concrete 47 Air Entrainment for Lightweight Aggregate Concrete. eee) Proportioning for Concrete Workability........ 47 Water-Cementitious Material Ratio General. 48 Relationship of Water-Gementitious Material Ratio to Strength, Durability and ‘Shrinkage A® Relationship of Water-Cementitious Material Ratio to Workabilty......0008.9 Effects of Admixtures......n0sesusiic4.9 Storage and Handling of Concrete Materials General 7 Storage and Handling of Aggregates...4.11 Storage and Handling of Cement.....4.13, Storage and Handling of Admixtures....4.13 Batching Equipment Toleranc Scale Requirements. Requirements for Water Measuring Equipment... nh AB MNL-116 4th Eaton4at BERS 442 4424 4.122 4.16.4 4.16.2 4.16.3 4.16.4 4165 4.18.6 4.16.7 416.8 4.16.9 47 47a 4472 Requirements for Batchers and Mixing Plants General oo AAB Requirements for Concrete Mixers ....4.19 Mixer Placard Requirements ... Maintenance Requirements for Concrete Mixers: eee 420) Concrete Transportation Equipment General 421 Requirements for Concrete Aang Delivery Equipment... 421 Placing and Handling Equipment..... 4.22 Batching and Mixing Operations General Batching of Aggregates .. Batching of Cement. Batching of Water. Batching of Admixtures..... Mixing of Concrete General... Methods of Concrete Mixing Mixing Time and Concrete Uniformity. 4.27 Mixing Time ~ Stationary Mixers... 4.28 ‘Mixing Time ~ Shrink Mixing. 428 Mixing Time — Truck Mixing 4.28 Special Batching and Mixing Requirements for Lightweight Aggregates 4.29 Cold Weather Mixing. 4.29 Hot Weather Mixing 4.30 Requirements for Transporting and Placing of Concrete General. 4.30 ‘Transporting and Placing Concrete... 4.31 Preventing Aggregate Segregation......4.31 Preparation of the Forms .. 4.32 Placing Concrete Under Severe Weather Conditions.. sone 4.82 Placing Concrete in Wet and Rainy Conditions. 4,33 Placing Concrete in Hot or Windy Conditions.. 4.33 Placing Concrete in Gold Weather Conditions.. . Placing Concrete... 4.34 Consolidation of Concrete General. 4.35 Consolidation of Lightweight Concrete. 4.36 MNLA116 4th Eton 4473 4474 4475 4178 4477 418 4.18.4 4182 4.18.3 4.18.4 4.19 4.194 4.19.2 4193 4.20 4.201 4.20.2 4.203 Consolidation of Concrete in Complex Precast Concrete Products. 4.36 Use of Intemal Vibrators 4.36 Use of External Form Vibrators .nn..4.37 Use of Surface Vibrators.. 437 Use of Vibrating Tables, 437 Requirements for Curing Concrete General Curing Temperature Requirements . Curing to Attain Specified Stripping or Transfer Strength. Monitoring of Concrete Curing 4.39 Temperatures. 4.39 Accelerated Curing of Concrete General. 4.40 Curing with Live Steam... 142 ‘Curing with Radiant Heat and Moisture 42 Curing by Moisture Retention Without ‘Supplemental Heat General Moisture Retention Enciosures.. uring wit Membrane Cun ‘Compound. 43 Post-Tensioning Tendon Grout Scope and Purpose .. Materials for Post-Tensioning Tendon Grout Proportioning of Grout Grout Mixing and Pumping Equipment : Mixing ofthe Grout Grout Temperature . n 4 — Provisions for Special Finishes Mix Proportioning 448 Qualification of New Concrete Mixes... ns 48 ‘Specified Concrete Strength 4.49 Proportioning to Ensure Durability 2 448 448 Proportioning for Appearance of Concrete Surface... 4.50 Proportioning for Concrete Workability..... 4.50 Page‘4.7 Storage and Handling of Concrete Materials . 4.50 ‘A414 Batching and Mixing Operations ‘A4.14.5Batching of Admidures... 4.50 A4.A6 Requirements for Transporting and Placing of Concrete ‘A4.16.8Placing Concrete in Wet and Rainy Conditions. ¥ ‘A4.16.9Placing Facing Concrete 451 ‘A4.16.10 Placing Backup Concrete ... 452 A4AT Consolidation of Concrete ‘A4.17.7 Consolidation of Face and Backup Mixes: 4.52 Vs eb aela ci ed A418.1 General ce 4.52 DIVISION 5 ~ REINFORCEMENT AND: PRESTRESSING Reinforcing Steel 1 General. . :2 Storage of Reinforcing Steel ‘3. Fabrication of Reinforcing Steel ‘4 Installation of Reinforcing Stee! 5.2 Tensioning 52.1 General Tensioning Requirements... 5.6 5.22. Tensioning of Tendons....... 5.2.3 Methods of Force Measurement. 5.24 Gauging Systems. 5.2.5 Control of Jacking Force.. 526 Wire Failure in Strand or Tendons.. 527 Calibration Records for Jacking Equipment sn 8.3 Pretensioning 83.4 Storage of Prestressing Stee 5.3.2 General... 53.3. Strand Surfaces . 5.3.4 Stringing of Strand . 535 Strand Chucks and Spice Chucks... 5.13 5.3.8 Strand S| 2 5.18 5.3.7 Strand Position 5.14 5.3.8 Spacing of Strands. 5.3.9 Initial Tensioning 5.3.10 Measurement of Elongation... Pagex 5.3.11 Elongation Calculation and Corrections... 5.3.12 Force Corrections 5.3.13. Final Tensioning of Straight Strands....5.20 5.3.14 Final Tensioning of Harped Strands ...5.20 5.3.15. Equal Distribution of Force in Harped Strand 5.3.18 Strand Debonding.. 5.3.17 Detensioning, 5.3.18. Detensioning of Harped Strand . 5.3.19 Detensioning of Dry Mix, Machine Cast Products... 5.3.20 Protection of Strand Ends and Anchorages ..... oS 25) 5.4 — Post-Tensioning of Plant-Produced Products 5.4.1 General. 5.4.2 Details and Positions for Duds. 5.4.3 Friction in Ducts. 5.4.4 Tensioning... 5.4.5 Anchorages 5.4.6 Grouting... 5.4.7 Sealing of Anchorages Division 5 — Provisions for Special Finishes A5.1_ Reinforcing Steel AS.1.4. Installation of Reinforcing Steel... DIVISION 6 — QUALITY CONTROL, 5.31 6.1 Inspection 6.1.1 Necessity for Inspection.....nnnnnnBl 6.1.2 Scope of Inspection 6.1 62 6.24 26.3 62.2 Acceptance Testing of Materials . 6.3 6.2.3 Production Testin 6.2.4 Special Testing. 63 Records 6.3.1 Recordkeeping 6.3.2 Suppliers’ Test Repor 63.3 Tensioning Records... 6.3.4 Concrete Records. 6.3.5 Calibration Records for Equipment. 6.4 Laboratory Facilities 64.1 General. MNL-116 4th EatonConnection — A device for the attachment of precast concrete units to each other or to the building or structure. Covermeter — See R-meter. Crazing — A network of visible, fine hairline cracks in random directions breaking the exposed face of a panel into areas from 1/4 in. to 3 in. (6 to 75 mm) across. Creep ~ The time dependent deformation (shortening) of prestressing steel or concrete under sustained loading, Curing - The maintenance of moisture and temperature within freshly placed concrete during ‘some defined period following placing, casting, or finishing to assure satisfactory hydration of ‘the cementitious materials and proper hardening of the conerete. Deflected Strand ~ Strand that is deflected from a straight-line position in a member to enhance the moment-resisting capacity of the member. Deflected strand may be spaced apart or bundled together. If bundled at a point, the strand must be splayed-out from the bundle to the end of the member to develop bond on each strand. Detensioning of strand or wire ~ The transfer of strand or wire tension from the bed anchorage to the concrete. Draft - The slope of concrete surface in relation to the direction in which the precast concrete element is withdrawn from the mold; it is provided to facilitate stripping with a minimum of mold breakdown. Dunnage ~ See Blocking. Elastic shortening - The shortening of a member that occurs immediately after the application of the prestressing force. Elongation - Increase in length of the prestressing steel (strand) under the applied prestressing force. Exposed aggregate concrete - Concrete ‘manufactured so that the aggregate on the face is left protruding, Face mix - The concrete at the exposed face of a concrete unit used for specific appearance purposes. Page xv Fine aggregate - Aggregate passing the 9/8 in, (8.5 mm) sieve and almost entirely passing the No. 4 (4.75 mm) sieve and predominately retained on the No. 200 (75,am) sieve; or that portion of an aggregate passing the No. 4 (4.75 mm) sieve and predominately retained on the No, 200 (75yan) sieve. Form ~ The container or surface against which fresh concrete is cast to give it a desired shape; sometimes used interchangeably with mold. (The term "mold" is, used in this Manual for custom-made forms for specific jobs while “form” is used for standard forms or forms of standard cross section.) Formed surface ~ A concrete surface that has been cast against formwork. Form release agent — A substance applied to the ‘mold for the purpose of preventing bond between the ‘mold and the concrete cast init Friction loss — In post-ensioning applications, the stress (force) loss in a prestressing tendon resulting from friction created along the tendon profile during stressing. Gap-graded concrete - A mix with one or a range of normal aggregate sizes eliminated, and/or with a heavier concentration of certain aggregate sizes over and above standard gradation limits. It is used to obtain a specific exposed aggregate finish. Grout — A mixture of cementitious materials and water, with or without sand or admixtures. Hardware - Items used in connecting precast concrete units or attaching or accommodating adjacent materials or equipment. Hardware is normally divided into three categories: Contractor's hardware — Items to be placed on or in the structure in order to receive the precast concrete units, e.g., anchor bolts, angles, or plates with suitable anchors. Plant hardware ~ Items to be embedded in the concrete units themselves, either for connections and precast concrete erector’s work, or for other trades, such as mechanical, plumbing, glazing, miscellaneous — iron, masonry, oF roofing trades. Erection hardware ~ All hardware necessary for the installation of the precast concrete units. MNL-116 4th Eaton