Construction of 32 Residential Villas with Services Blocks

at Plot No. TW-EU-E09 - Heart of Europe, The World

SECTION 03400

PRECAST CONCRETE-GENERAL

PART 1 - GENERAL

1.01 DESCRIPTION OF WORK

A. Extent of Work: The extent of precast concrete work is shown on the

drawings.

1.02 QUALITY ASSURANCE

A. Codes and Standards: Comply with the applicable requirements of the

following codes and standards:

1. ASTM - American Society for Testing and Materials.

A 167 Specification for Stainless and Heat Resisting

Chromium Nickel Plate, Sheet and Strip.

A 193 Specification for Alloy-Steel and Stainless Steel Bolting

Materials for High-Pressure and High-Temperature
Service.

A 276 Specification for Uncoated Seven-wire Stress-Relieved

Strand for Prestressed Concrete.

2. BS - British Standards.

12 Specification for Portland Cement.

297 Precast Concrete Cladding (Non-load Bearing).

476 Fire tests on Building Materials and Structures Part:7-

1987. Method for Classification of the Surface Spread
of Flame of Products.

812 Testing Aggregates.

882 Specification For Aggregates From Natural Sources for

Concrete.

1014 Pigments for Portland Cement and Portland Cement

Products.

1199 & 1200 Specification for Building Sands From Natural Sources.

03400-~1 - 1 / 9
Construction of 32 Residential Villas with Services Blocks
at Plot No. TW-EU-E09 - Heart of Europe, The World

1449 Steel Plate Sheet and Strip.

1881 Specification of Testing Concrete with all applicable

parts.

4027 Specification for Sulphate Resisting Portland Cement.

4449 Specification for Carbon Steel Bars For the

Reinforcement of Concrete.

4482 Specification for Hard Drawn Steel Wires.

4550 Sampling and Testing of Sand (Including All Parts).

4870 Approval Testing of Welding Procedures.

4871 Approval Testing of Welders Working To Approved

Welding Procedures.

5328 Specification for Concrete.

Guide To Specifying Concrete (Including Parts 2,3 & 4)

5642 Sills and Copings. Part:2-1983.

Specification for Copings of Precast Concrete, Cast

Stone, Clayware, Slate and Natural Stone.

6717 Precast Concrete Paving Blocks.

Part:1-1986. Specification for Paving Blocks.

Part:3-1989. Specification for Sand Required and

Different Patterns for Laying Blocks.

6920 Suitability for Non-Metallic Products for use in contact

with Water Intended for Human Consumption with
regard to their effect on the Quality of the water. (1990)

7263 Specification for Precast Concrete Flags, Kerbs,

Channels, Edging and Quadrants.

Part:1-1990. Specification Used in the Construction of

Carriageways and Footways.

8110 Structural Use of Concrete 1985.

3. DIN Deutsces Intitut Fûr Normang, e.v., Berlin.

03400-~1 - 2 / 9
Construction of 32 Residential Villas with Services Blocks
at Plot No. TW-EU-E09 - Heart of Europe, The World

DIN 1048 Part 1, Deutsche Normen (German) Test Methods for

Concrete.

4. AASHTO American Association of State Highway and

Transportation Officials.

T259-80 Standard Test Methods of Resistance of Concrete to

Chloride Ion Penetration (1990).

T260-84 Standard Method of Sampling and Testing for Total

Chloride Ion in Concrete and Concrete Raw Materials.

5. NSF National Sanitation Foundation

61 International “Drinking Water Systems Components,”

U.S.A.

6. UBC Uniform Building Code.

B. Precast concrete suppliers shall be capable of manufacturing and designing all

precast units and shall be officially approved by the Engineer.

C. Fabrication Qualifications:

1. Produce precast concrete units at a fabricating plant approved by the

Engineer engaged primarily in the manufacture of similar units unless
plant fabrication or delivery to project site is impractical.

2. If units are produced at locations other than precast concrete fabricating

plants, maintain procedures and conditions for quality control which
are equivalent to plant production.

D. Quality Control: Contractor shall institute quality control procedures for the
manufacture, inspection and testing of precast units as required by the
Engineer. Furnish the Engineer with copies of test reports and/or certification
for materials and quality control testing of precast units.

E. Installation Tolerances: Install precast units without exceeding the following

tolerance limits:

1. Variations from Plumb: 6.4 mm in any 6.10 meters run or story height;
12.7 mm total in any 12.20 meters or longer run.

2. Variations from Level or Elevation: 6.4 mm in any 6.10 meters run;

12.7 mm in any 12.20 meters run; total plus or minus 12.7 mm at any
location.

3. Variation from Theoretical Position in Plan: Plus or minus 6.4 mm

maximum at any location.

03400-~1 - 3 / 9
Construction of 32 Residential Villas with Services Blocks
at Plot No. TW-EU-E09 - Heart of Europe, The World

4. Offsets in Alignment of Adjacent Members at Any Joint: 1.6 mm in

any 3.05 meters run; 6.4 mm maximum.

1.03 SUBMITTALS

A. Manufacturer's Data: Submit design calculations, shop drawings,

manufacturer's specifications and instructions for all manufactured materials
and products. Include manufacturer's certifications and laboratory test reports
as required. Include erection procedure for precast units, sequence of erection
and required handling equipment.

B. Shop Drawings:

1. Submit shop drawings showing complete information for the

fabrication and installation of precast concrete units. Indicate member
dimensions, cross-section; location, size and type of reinforcement,
including special reinforcement and lifting devices necessary for
handling and erection.

2. Provide layout, dimensions and identification of each precast unit

corresponding to the sequence and procedure of installation. Detail
inserts, connections and joints, including accessories and construction
at openings in precast units.

3. Provide location and details of anchorage devices that are to be

embedded in other construction. Furnish templates if required for
accurate placement.

4. Provide complete design calculations prepared by a registered

engineer.

C. Samples: Submit one full size sample of each required precast concrete unit to
the project site prior to start of installation work. Acceptable samples may be
incorporated in the construction. The Engineer’s review of samples will be for
color, texture and general condition only. Compliance with all other
requirements shall be the exclusive responsibility of the Contractor.

1.04 PRODUCT DELIVERY, STORAGE AND HANDLING

A. Deliver precast concrete units to the project site in such quantities and at such
times as will assure the continuity of the installation. Store units at the project
site to ensure against cracking, distortion, staining, or other physical damage
and so that markings are visible. Lift and support units at the designated lift
points only.

03400-~1 - 4 / 9
Construction of 32 Residential Villas with Services Blocks
at Plot No. TW-EU-E09 - Heart of Europe, The World

1.05 JOB CONDITIONS

A. Verify dimensions of supporting structures at the project site and adjust

approved shop drawings to reflect actual field dimensions.

B. Design modifications may be made only as necessary to meet field conditions

and to ensure proper fitting of the work and only as acceptable to the Engineer.
Maintain the general design concept as shown without increasing or
decreasing sizes of members or altering profiles and alignment.

C. Provide complete design calculations and drawings prepared by a registered

engineer, if design modifications are anticipated.

D. Provide anchorage items which shall be embedded in other construction before

the start of such work. Provide setting diagrams, templates, instructions and
directions as required for installation.

PART 2 - PRODUCTS

2.01 FORMWORK

A. Provide forms and, where required, form facing materials of metal, plastic,
wood or other acceptable material that is non-reactive with concrete and will
produce the required fairface finished surfaces or fractured fin surface as
indicated on drawings. Unless otherwise specified, comply with Section
"FORMWORK FOR CONCRETE".

B. Accurately construct forms, mortar-tight, and of sufficient strength to

withstand all pressures due to concrete placing operations and temperature
changes. Maintain formwork to provide completed precast concrete units of
the shapes, lines and dimensions indicated, within the specified fabrication
tolerances.

2.02 REINFORCING MATERIALS

A. Comply with the specified and applicable requirements of Section

"REINFORCEMENT FOR CONCRETE".

2.03 CONNECTION MATERIALS

A. Stainless Steel Bars and Shapes: Cold formed stainless steel bars and shapes,
complying with ASTM A 276, Type 316, Condition B.

B. Stainless Steel Plate and Sheet: Comply with ASTM A 167, Type 316.

C. Stainless Steel Bolts and Nuts: Comply with ASTM A193, Identification
symbol B8M, (AISI Type 316), Class 2.

03400-~1 - 5 / 9
Construction of 32 Residential Villas with Services Blocks
at Plot No. TW-EU-E09 - Heart of Europe, The World

D. Accessories: Provide all clips, hangers and other accessories required for
installation of precast units and for support of subsequent construction or
finishes.

2.04 GROUT MATERIALS

A. Cement Grout: Portland cement, BS 12, and clean natural sand, to BS 1199
and BS 1200. Testing to BS 4550 with all applicable parts.

B. Shrinkage Resistant Grout: Premixed and packaged ferrous aggregate type to

comply with BS 812 with all applicable parts.

C. Non-Metallic, Non-Shrink Grout: Premixed, non-metallic, non-corrosive, non-

staining product containing selected silica sands, portland cement, shrinkage
compensating agents, plasticizing and water reducing agents complying with
BS 812 with all applicable parts.

2.05 PROPORTIONING AND DESIGN OF MIXES

A. Comply with the requirements of Section "CAST-IN-PLACE CONCRETE"

and as specified herein:

1. Produce standard weight concrete consisting of the specified portland

cement, aggregates, admixtures, and water to produce the following
properties:

- 28-day Compressive Strength (cube): 35.0 MPa

- Maximum Aggregate Size : 19 mm
- Slump at Point of Discharge : 75 mm Max.

2.06 FABRICATION

A. General: Fabricate precast concrete units complying with the manufacturing

and testing procedures, quality control recommendations, and dimensional
tolerances for the types of units as required by the Engineer.

B. Concrete shall comply with the specified requirements of Section "CAST-IN-

PLACE CONCRETE". Where precast concrete elements are required to be
white finished, white Portland cement shall be used in the manufacture of such
elements.

C. Built-in Anchorages: Accurately position any built-in anchorage devices and

secure to the formwork. Locate anchorages where they do not affect the
position of main reinforcement or the placing of concrete.

D. Cast-in holes for openings in accordance with approved shop drawings.

E. Coat surfaces of forms with a bond-breaking compound before reinforcement

is in place. Provide form-coating compounds that will not bond with, stain nor

03400-~1 - 6 / 9
Construction of 32 Residential Villas with Services Blocks
at Plot No. TW-EU-E09 - Heart of Europe, The World

adversely effect concrete surfaces and will not impair subsequent treatments of
concrete surfaces requiring bond or adhesion. Apply in compliance with
manufacturer's instructions.

F. Observe weather limitation and requirements for hot weather and cold weather
concreting. Place concrete in a continuous operation to prevent the formation
of seams or planes of weakness in precast units. Thoroughly consolidate
placed concrete in each precast unit by internal and external vibration without
dislocation or damage to reinforcement and built-in-items.

G. Identification: Provide permanent markings in precast units to identify pick-up

points and orientation in the structure, complying with the markings indicated
on the approved shop drawings. Imprint the date of casting on each precast
unit where it will not show in the finished structure.

H. 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
to reduce the curing time.

I. Provide finish of exposed-to-view surfaces of precast concrete units to match

color and texture of approved sample panels.

J. Decorative Pattern: Where indicated to have decorative designs and patterns

achieve finish by applying liners to the inside of forms.

K. Quality Control: Contractor shall institute quality control procedures for the
manufacture, inspection, and testing of precast units as directed by the
Engineer. Furnish the Engineer with copies of test reports and/or certifications
for materials and quality control testing of precast units.

PART 3 - EXECUTION

3.01 INSPECTION

A. The Contractor shall examine the substrates and the conditions under which
the precast concrete work shall be performed and correct any unsatisfactory
conditions. Do not proceed with the work until unsatisfactory conditions have
been corrected in a manner acceptable to the Engineer.

3.02 INSTALLATION, GENERAL

A. Welding: Perform all welding in compliance with BS 4870 and BS 4871.

B. Protect units from damage by field welding or cutting operations and provide
non-combustible shields as required.

03400-~1 - 7 / 9
Construction of 32 Residential Villas with Services Blocks
at Plot No. TW-EU-E09 - Heart of Europe, The World

C. Powder-Actuated Fasteners: Do not use powder-actuated fasteners for surface

attachment of accessory items in any precast, unless otherwise accepted by the
Engineer.

D. Grouting Connections and Joints: After precast concrete units have been
placed and secured, grout open spaces at connections and joints with
shrinkage-resistant grout consisting of pre-mixed, non-staining compound and
only enough water to provide a flowable mixture without segregation or
bleeding.

E. For sealants comply with applicable requirements of "JOINT SEALANTS

AND CAULKING" section.

3.03 QUALITY CONTROL EVALUATIONS

A. The Contractor shall provide all the requirements for quality control and
testing methods to be used in evaluating the production of precast concrete
units to the satisfaction of the Engineer. The Contractor shall keep records in
an approved form of dimensions of all work as constructed. These records
shall be available for inspection and shall be submitted immediately after
manufacture.

B. Dimensional Tolerances:

1. Units having any dimension smaller or greater than required, and

outside the specified tolerance limits, will be considered deficient and
subject to rejection.

2. Precast units having any dimension greater than required will be

rejected if in the opinion of the Engineer the appearance or function is
adversely affected, or if the larger dimensions interfere with other
construction. Repair, or remove and replace rejected units as required
to meet the construction conditions.

C. Strength of Units: The strength of precast concrete units will be considered

potentially deficient if 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 tests requirements.

2. Reinforcement 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.

03400-~1 - 8 / 9
Construction of 32 Residential Villas with Services Blocks
at Plot No. TW-EU-E09 - Heart of Europe, The World

5. Poor workmanship and quality control likely to result in deficient

strength.

D. Testing Precast Concrete Units for Strength: When there is evidence that the
strength of precast concrete units does not meet specification requirements, the
Contractor shall take cores drilled from hardened concrete for compressive
strength determination, complying with the applicable parts of BS 1881 and
BS 5328 and as follows:

1. Take at least 3 representative cores from precast units of suspect

strength, from locations directed by the Engineer.

2. Test cores in a saturated surface-dry condition if the concrete will be

wet during the use of the completed structure.

3. Test cores in an air-dry condition if the concrete will be normally dry

during use of the completed structure.

4. Strength of concrete for each series of cores will be considered

satisfactory if their average compressive strength is at least 85% and no
single core is less than 75%, of the 28-day required compressive
strength.

5. Test results shall be made in writing to the Engineer on the same day
that tests are made. Include in test reports the work identification name
and number, date, name of precast concrete manufacturer,
identification letter, number and type of member or members
represented by core tests, nominal maximum size aggregate, 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 the concrete as placed, and the
moisture condition of the core at time of testing.

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

F. Defective Work: Precast concrete units which do not conform to the specified
requirements, including strength, tolerances, and finishes shall be replaced by
the Contractor with units that meet the requirements of this section. The
Contractor shall also be responsible for the cost of corrections to any other
work affected by or resulting from corrections to the precast concrete work.

3.04 MEASUREMENT AND PAYMENT

Measurement and payment for the work prescribed in this section will be as
listed in the Bills of Quantities and as specified in “CAST-IN-PLACE
CONCRETE” Section.
** END OF SECTION **

03400-~1 - 9 / 9