MINISTRY OF HOUSING

Western Sector Projects

Sitework & Infrastructure
OMRANIA and ASSOCIATES

Project Specification

SECTION 03 41 00
STRUCTURAL PRECAST CONCRETE
PART 1: GENERAL
1.01

SECTION INCLUDES

A.

Structural precast concrete units together with all necessary fixings, anchors etc.

B.

For precast concrete construction this Section takes precedence over all other related
sections.

1.02

RELATED SECTIONS

A.

Section 01 33 00

Submittal Procedures.

B.

Section 03 11 00

Concrete Forming.

C.

Section 03 15 00

Concrete Accessories

D.

Section 03 20 00

Concrete Reinforcing.

E.

Section 03 33 00

Cast in Place Concrete.

F.

Section 03 35 23

Exposed Aggregate Concrete Finishing.

1.03
A.
1.04

DESIGN REQUIREMENT
The design of all precast reinforced members shall comply with ACI 318, except when
otherwise defined in the Specification or on the Drawings.
REFERENCES

A.

ACI 301

Structural Concrete for Buildings.

B.

ACI 304

Recommended Practice for Measuring, Mixing, Transporting and

Placing Concrete.

C.

ACI 318

Building Code Requirements for Reinforced Concrete.

D.

ASTM A 36

Structural Steel.

E.

ASTM A 153

Zinc Coating (Hot Dip) on Iron and Steel Hardware.

F.

ASTM A 185

Welded Steel Wire Fabric for Concrete Reinforcement.

G.

ASTM A 416

Uncoated Seven-Wire Stress Relieved Strand for Prestressed

Concrete.

H.

ASTM A 497

Welded Deformed Steel Wire Fabric for Concrete Reinforcement.

I.

ASTM A 615

Deformed and Plain Billet-Steel Bars for Concrete Reinforcement.

J.

ASTM A 666

Austenitic Stainless Steel, Sheet, Strip, Plate, and Flat Bar for

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MINISTRY OF HOUSING
Western Sector Projects
Sitework & Infrastructure
OMRANIA and ASSOCIATES

Project Specification

Structural Applications.
K.

ASTM B 221

Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Shapes

and Tubes.

L.

ASTM C 42

Obtaining and Testing Drilled Cores and Sawed Beams of Concrete.

M.

ASTM C 150

Standard Specification for Portland Cement.

N.

AWS D 1.1

Structural Welding Code.

O.

AWS D1.4

Structural Welding Code Reinforcing Steel.

P.

PCI MNL-116

Manual for Quality Control for Plants and Production of Precast and
Prestressed Concrete Products.

Q.

PCI MNL-120

Design Handbook Precast and Prestressed Concrete.

R.

PCI MNL-123

Manual on Design of Connections for Precast Prestressed Concrete.

S.

PCI MNL-124

Design for Fire Resistance of Precast Prestressed Concrete.

T.

UL

Underwriters Laboratories.

1.05

SUBMITTALS

A.

Comply with Section 01 33 00.

B.

Product Data: Submit manufacturers details for manufactured materials and products.
Include manufacturers certifications and laboratory test reports as required.

C.

Shop Drawings:
1. Shop drawings showing complete information for fabrication and installation of precast
concrete units.
2. Indicate member dimensions and cross-section, location, size and type of reinforcement,
including special reinforcement and lifting devices necessary for handling and erection.
3. Indicate layout, dimensions, and identification of each precast unit corresponding to
sequence and procedure of installation.
4. Indicate welded connections by AWS standard symbols. Detail inserts, connections, and
joints, including accessories and construction details at openings in precast units.

D.

Provide location and details of anchorage devices that are to be embedded in other
construction. Furnish templates if required for accurate placement.

E.

Include erection procedure and sequence of erection for precast units.

F.

Check design of units for lifting and handling conditions. Provide additional reinforcement if
necessary. Submit calculations and details for approval by the Engineer.

1.06

QUALITY ASSURANCE

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MINISTRY OF HOUSING
Western Sector Projects
Sitework & Infrastructure
OMRANIA and ASSOCIATES

A.

Project Specification

Fabricator Qualifications:
1. Firms which have 2 years successful experience in fabrication of precast concrete units
similar to units required for this project. Fabricator shall have sufficient production
capacity to produce required units without causing delay in work.
2. Produce precast concrete units at fabricating plant engaged primarily in manufacturing
of similar units, unless plant fabrication or delivery to project site is impractical.

B.
1.07

Where units are not produced at precast concrete fabricating plants, maintain procedures and
conditions for quality control which are equivalent to plant production.
DELIVERY, STORAGE AND HANDLING

A.

Deliver precast concrete units to project site in such quantities and at such times to assure
continuity of installation.

B.

Deliver anchorage items which are to be embedded in other construction before start of such
work. Provide setting diagrams, templates, instructions and directions as required for
installation.

C.

Lift and support precast concrete members during manufacturing, stockpiling, transporting
and erection operations only at the lifting or supporting point, or both, as shown on the shop
drawings, and with approved lifting devices. Lifting inserts shall have a minimum safety
factor of 4. Exterior lifting hardware shall have a minimum safety factor of 5.
1. Perform transportation, site handling and erection with acceptable equipment and
methods, and by qualified personnel.

D.

Storage:
1. Store all units off the ground.
2. Place stored units so that identification marks are discernible.
3. Separate stacked members by battens across the full width of each bearing point.
4. Stack so that lifting devices are accessible and undamaged.
5. Do not use upper member of stacked tier as storage area for shorter members or heavy
equipment.

PART 2: PRODUCTS
2.01

ACCEPTABLE MANUFACTURERS
Not used.

2.02

FORMWORK

A.

Comply with Section 03 11 00.

B.

Provide forms and form facing materials of acceptable material that are non-reactive with
concrete and will produce required finish surfaces.

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MINISTRY OF HOUSING
Western Sector Projects
Sitework & Infrastructure
OMRANIA and ASSOCIATES

Project Specification

C.

Design and accurately construct forms, mortar-tight, of sufficient strength to withstand

pressures due to concrete placing operations, temperature changes and during pretensioning
and detensioning operations. Maintain formwork to provide completed precast concrete
units of shapes, lines, and dimensions indicated, within specified fabrication tolerances
specified in PCI MNL 116.

D.

Forms and end-shutters shall be stripped prior to detensioning prestressed concrete units.

E.

Moulds shall be set up on firm foundations so that no settlement occurs under the weight of
the fresh concrete.

F.

Release agents used for demolding shall not stain reinforcement and concrete or affect its
properties in any way.

2.03

REINFORCEMENT

A.

Reinforcing steel: Comply with the requirements of Section 03 20 00.

B.

When preformed cages are used, fabricate the cages on jigs to ensure dimensional accuracy
and carefully support them within the mould in such a way that they cannot move when
concrete is placed.

C.

Provide cover to main reinforcement as shown on the Drawings. Space bars so that the
minimum clear distance between them is the maximum nominal aggregate size plus five
millimeters but in any case not less than the diameter of the bar.

D.

Spacer blocks shall comply with the requirements of Section 03 20 00. In addition, the use of
concrete or plastic spacer blocks shall not be permitted against a concrete face which is
exposed in the finished works.

E.

Tensioning steel tendons: In accordance with ASTM A 416 of sufficient strength

commensurate with member design.

2.04
A.
2.05
A.

CEMENT, AGGREGATES AND WATER

Cement, aggregates, lightweight aggregates and water in precast concrete shall comply with
the requirements of Section 03 30 00.
METAL FIXINGS
All inserts or fixings permanently cast within the concrete shall be of stainless steel or
phosphor bronze.
1. Stainless steel inserts or fixings of alloy type 316.S16 or 316.S12 complying with
ASTM B 221.
2. Phosphor bronze inserts and fixings shall be alloy type PB102.

2.06
A.

FABRICATION
General:
1. Fabricate precast concrete units complying with manufacturing and testing procedures,
quality control recommendations, and dimensional tolerances of PCI MNL-116, and as
specified for types of units required.

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MINISTRY OF HOUSING
Western Sector Projects
Sitework & Infrastructure
OMRANIA and ASSOCIATES

Project Specification

2. Check the various individual units for all temporary stresses/loads imposed by
fabrication, handling, transporting and erecting, and provide all necessary reinforcing
and inserts required for successful fabrication, transporting and erecting and bracing
each unit to its final position in the work including all required connections.
B.

Ready-Mix Concrete: Comply with requirements of ASTM C 94, and as herein specified.
Delete references for allowing additional water to be added to batch for material with
insufficient slump. Addition of water to batch shall not be permitted.

C.

During hot weather, or under conditions contributing to rapid setting of concrete, a shorter
mixing time than specified in ASTM C 94 may be required. When the air temperature is
between 30 oC, and 32 oC, reduce mixing and delivery time from 1-1/2 hours to 75 minutes,
and when air temperature is above 32 oC, reduce mixing and delivery time to 60 minutes.

D.

Built-in Anchorages: Accurately position built-in anchorage devices and secure to

framework. Locate anchorages without affecting position of main reinforcement or placing
of concrete. Do not relocate bearing plates in units without Engineers approval.

E.

Coat surfaces of forms with bond-breaking compound before reinforcement is placed.

Provide commercial formulation form-coating compounds that will not bond with, stain nor
adversely affect concrete surfaces, and will not impair subsequent treatments of concrete
surfaces requiring bond or adhesion. Apply in compliance with manufacturers instructions.

F.

Clean reinforcement of loose rust and mill scale, earth and other materials which reduce or
destroy bond with concrete.

G.

Accurately position, support and secure reinforcement against displacement by formwork,

construction, or concrete placement operations. Locate and support reinforcing by metal
chairs, runners, bolsters, spacers and hangers, as required.

H.

Place reinforcement to obtain at least the minimum coverages for concrete protection.
Arrange, space and securely tie bars and bar supports to hold reinforcement in position
during concrete placement operations. Set wire ties so that ends are directed into concrete,
not toward exposed concrete surfaces.

I.

Accomplish pretensioning of tendons for prestressed concrete units either by single strand
tensioning method or multiple-strand tensioning method. Comply with PCI MNL-116
requirements.

J.

Place concrete in a continuous operation to prevent formation of seams or planes of

weakness in precast units, complying with requirements of ACI 304. Thoroughly
consolidate placed concrete by internal and external vibration without dislocation or damage
to reinforcement and cast-in items.

K.

Identification: Provide permanent markings to identify pick-up points and orientation in

structure, complying with markings indicated on final shop drawings. Imprint date of casting
on each precast unit on a surface which will not show in finished structure.

L.

Curing by low-pressure steam, by steam vapor, by radiant heat and moisture, or other similar
process may be employed to accelerate concrete hardening and reduce curing time, but in no
case shall the temperature rise exceed 10 C/hr until the maximum allowable curing
temperature of 65 C is attained for a maximum 16 hr curing period.

M.

Delay detensioning of prestressed units till concrete has attained at least 70% of designed
stress, as established by test cubes.

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MINISTRY OF HOUSING
Western Sector Projects
Sitework & Infrastructure
OMRANIA and ASSOCIATES

N.

2.07

Project Specification

Accomplish detensioning of pretensioned tendons either by gradual release of tensioning

jacks or by cutting tendons, using a sequence and pattern to prevent shock or unbalanced
loading.
DIMENSIONAL TOLERANCES

A.

Cast precast concrete elements and erect such that dimensions of finished construction are
within the tolerances quoted in ACI 301, except where the tolerances given in this
Specification are more onerous.

B.

Units delivered to site shall comply with the following tolerances unless greater dimensional
variations do not affect the correct assembly, performance and appearance of the building or
cause unacceptable variations to finishes or other works.
1. Height, Width:
a. up to 2 m

0 to -3 mm

b. 2 to 6 m

0 to -5 mm

c. over 6 m

0 to -7 mm

2. Cross Section:
a. up to 250 mm

+/- 3 mm

b. 250 to 500 mm

+/- 5 mm

c. 500 to 750 mm

+/- 6 mm

3. Straightness or Bow (Deviation from intended line):

a. up to 3 m

+/- 4 mm

b. 3 to 6 m

+/- 6 mm

c. 6 to 12 m

+/- 8 mm

4. Squareness (difference in sides): up to 3 m - 6 mm

C.

2.08

The position of individual concreting bolts, bolt holes, projecting steel or other devices in
any associated group (e.g. the joint of two precast units) shall be within 5 mm of their true
position in the group in which they are cast. The longitudinal location of any such group
shall be within 8 mm of its true position in the unit in which it is cast, provided that such
tolerance does not adversely affect the proper assembly of the whole structure.
SURFACE FINISH

A.

The formed faces of precast units shall be finished to class F3 and the unformed faces to
class U2, all as defined in Sections 03 11 00 and 03 30 00, unless another class of finish is
specified on the Drawings.

B.

In cases where a special finish is required, construct a trial panel which, after acceptance of
the Engineer is kept available for inspection at the place of casting and production units shall
thereafter match the approved pattern.

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MINISTRY OF HOUSING
Western Sector Projects
Sitework & Infrastructure
OMRANIA and ASSOCIATES

C.

Project Specification

Cast exterior cladding units using white cement.

PART 3: EXECUTION
3.01

SITE ACCESS AND PREPARATION

A.

Site Access: Provide suitable access to the building, proper drainage and firm level bearing
area for hauling and erection equipment to operate.

B.

Preparation:
1. Provide true level bearing surfaces on all field placed bearing walls and other field
placed supporting members.
2. Place and align accurate anchor bolts, plates or dowels in column footings, grade beams
and other field placed supporting members.
3. Provide shoring required for composite beams and slabs. Shoring shall have a minimum
load factor of 1.5 times (dead load plus construction loads).

C.

Installation: Perform installation of precast, prestressed concrete by the manufacturer or a

competent erector. Lift the units by means of suitable lifting devices at points provided by
the manufacturer. For temporary shoring and bracing, comply with manufacturers
recommendations.

D.

Alignment: Properly align and level members as required by the approved shop drawings.
Adjust the variations between adjacent members by packing, loading, or any other feasible
method as recommended by the manufacturer and acceptable to the Engineer.

3.02

INSTALLATION, GENERAL

A.

Bearing Pads: Install flexible bearing pads where indicated, as precast units are being
erected. Set pads on level, uniform bearing surfaces and maintain in correct position until
precast units are placed.

B.

Welding: Perform welding in compliance with AWS D 1.1, including qualification of

welders.

C.

Protect units from damage by field welding or cutting operations and provide noncombustible shield as required.

D.

Repair damaged metal surfaces by cleaning and applying a coat of liquid galvanizing repair
compound to galvanized surfaces and compatible primer to painted surfaces.

E.

Power-Actuated Fasteners: Do not use power-actuated fasteners for surface attachment of

accessory items in precast, prestressed units unless otherwise accepted by precast
manufacturer.

F.

Grouting Connections and Joints: After precast concrete units have been placed and secured,
grout open spaces at connection and joints as follows:
1. The bearing surfaces of precast units shall have grouted bed joints. Thoroughly clean all
joint surfaces. Form bed joints by leveling the units on stainless steel shims, the shims
being bedded in grout. The top surface of the shims shall, before placing the unit, be
below the surface of the grout and finally the shims shall have a cover of 25 mm of

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MINISTRY OF HOUSING
Western Sector Projects
Sitework & Infrastructure
OMRANIA and ASSOCIATES

Project Specification

grout.
2. Use a non-shrink grout. Perform mixing, placing and curing of grout strictly in
accordance with the manufacturers recommendations.
3. All sockets, bolt holes, etc. shall be grouted under pressure using non-shrink grout as for
bed joints.
3.03

PLANT QUALITY CONTROL EVALUATIONS

A.

Employ a independent testing laboratory to evaluate precast manufacturers quality control

and testing methods.

B.

The precast manufacturer shall allow Engineer access to the testing facility, material storage
areas, concrete production equipment, and concrete placement and curing facilities.
Cooperate with testing laboratory and provide samples of materials and concrete mixes as
may be requested for additional testing and evaluation.

C.

Dimensional Tolerances: Units having dimensions smaller or greater than required, and
outside specified tolerance limits, shall be subject to additional testing as herein specified.

D.

Precast units having dimensions greater than required will be rejected where appearance or
function of the structure is adversely affected, or when larger dimensions interfere with other
construction. Repair, or remove and replace rejected units as required to meet construction
conditions.

E.

Strength of Units: The strength of precast concrete units shall be considered potentially
deficient when the manufacturing processes fail to comply with any of the requirements
which may affect the strength of the precast units, including the following conditions:
1. Failure to meet compressive strength test requirements.
2. Reinforcement, and pretensioning and detensioning of tendons of prestressed concrete,
not conforming to specified fabrication requirements.
3. Concrete curing, and protection of precast units against extremes in temperature, not as
specified.
4. Precast units damaged during handling and erection.

F.

Testing Precast Units: When there is evidence that strength of precast concrete units does
not meet specification requirements, the concrete testing service shall take cores drilled from
hardened concrete for compressive strength determination, complying with ASTM C 42 and
as follows:
1. Take at least 3 representative cores from precast units of suspect strength, from locations
directed by Engineer.
2. Test cores in a saturated-surface-dry condition per ACI 318 if concrete will be wet
during use of completed structure.
3. Test cores in an air-dry condition per ACI 318 when concrete will be dry during use of
completed structure.
4. Strength of concrete for each series of cores will be considered satisfactory when their

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MINISTRY OF HOUSING
Western Sector Projects
Sitework & Infrastructure
OMRANIA and ASSOCIATES

Project Specification

average compressive strength is at least 85% of 28-day design compressive strength.

5. Tests results to be made available in writing on same day that tests are made, with copies
to Engineer. Include in test reports the project identification name and number, date,
name of precast concrete manufacturer, name of concrete testing service, identification
letter, number, and type of member or members represented by core tests, design
compressive strength, compression breaking strength and type of break (corrected for
length-diameter ratio), direction of applied load to core with respect to horizontal plane
of concrete as placed, and moisture condition of core at time of testing.
G.

Patching: Where core test results are satisfactory and precast units are acceptable for use in
work, fill core holes solid with patching mortar, and finish to match adjacent concrete
surfaces.

H.

Defective Work: Replace precast concrete units which do not conform to specified
requirements, including strength, tolerances and finishes, with precast concrete units that
meet requirements of this Section. Make corrections to other works affected by or resulting
from corrections to pre-cast concrete work.

END OF SECTION

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SECTION 03 41 00 - 9