SECTION 03400 PRECAST CONCRETE

PART 1 - GENERAL 1.1 A. DESCRIPTION OF WORK This Section establishes general criteria for materials, mixes, and evaluations of precast concrete as required for this and other related sections of these specifications. All precast reinforced concrete surfaces exposed to soil at and below finish grade shall be waterproofed as per Section 03300.1.1.D. Related Work: 1. 2. 3. 4. 5. 6. 7. Section 03100: Concrete Formwork Section 03200: Concrete Reinforcement Section 03210: Epoxy Coated Concrete Reinforcement Section 03300: Cast-In-Place Concrete Section 03740: Concrete Repairs Section 07100: Waterproofing and Dampproofing Section 07110: Membrane Waterproofing for Concrete Structures

B.

C.

1.2 A.

QUALITY ASSURANCE Codes and Standards: 1. Comply with the provisions of the following codes, specifications, and standards, except as otherwise shown or specified: a. ACI 211.1 "Recommended Practice for Selecting Proportions for Normal and Heavy Weight Concrete." ACI 301 "Specifications for Structural Concrete for Buildings." ACI 304 "Recommended Practice for Measuring, Mixing, Transporting and Placing Concrete." "Recommended Practice for Concrete Inspection."

b. c.

d. ACI 311

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e.

ACI 318 "Building Code Requirements for Reinforced Concrete." "Recommended Practice for Concrete Formwork."

f. ACI 347

g. Concrete Reinforcing Steel Institute, "Manual of Standard Practice." h. Prestressed Concrete Institute, "Manual for Quality Control" MNL 116. Comply with MARAFIQ Structural Code requirements which are more stringent than the above.

i.

B.

Installation Tolerances: 1. Install precast units without exceeding the following tolerance limits: a. Variations from Plumb: 6 mm in any 6 m run or story height; 12mm total in any 12 m or longer run. Variations from Level or Elevation: 6 mm in any 6 m run; 12 mm in any 12 m run; total plus or minus 12 mm at any location. Variation from Theoretical Position in Plan: Plus or minus 6 mm maximum at any location. Offsets in Alignment of Adjacent Members at Any Joint: 1.5 mm in any 3 m run; 6 mm maximum.

b.

c.

d.

1.3 A.

SUBMITTALS Manufacturer's Data: 2. Submit copies of 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. Indicate that copy of each instruction has been transmitted to the erector.

3.

B.

Shop Drawings: 1. Submit shop drawings showing complete information for the fabrication and installation of precast concrete units. Indicate member dimensions and cross-section, location, size and type of reinforcement, including special reinforcement and lifting devices necessary for handling and erection. Provide layout, dimensions, and identification of each precast unit corresponding to the sequence and procedure of installation. Indicate

2.

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welded connections by AWS standard symbols. Detail inserts, connections, and joints, including accessories and construction at opening in precast units. 3. Provide location and details of anchorage devices that are to be embedded in this and other construction. Furnish templates if required for accurate placement. Provide manufacturer's complete design calculations prepared by a professional engineer prequalified to structural design background.

4.

C.

Samples: 1. Submit 3 sets of samples approximately 300 mm x 300 mm x 50 mm to illustrate the quality, color, and texture of the surface finish. Submit one full-size sample of each required precast concrete units to the project site prior to start of installation work. Acceptable samples may be incorporated in the construction. MARAFIQ's review of samples will be for color, texture, and general condition. Compliance with all additional requirements is the responsibility of the Contractor and subject at all times to further approval by the MARAFIQ.

2.

3.

1.4 A.

DELIVERY, STORAGE AND HANDLING Deliver precast concrete units to the project site in such quantities and at such time 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. JOB CONDITIONS Examine all parts of the supporting structure and the condition under which the precast concrete work is to be erected. Do not proceed with the installation until unsatisfactory conditions have been corrected. Verify dimensions of supporting structures at the project site and adjust final shop drawings to reflect actual field dimensions. 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 MARAFIQ. Maintain the general design concept as shown without increasing or decreasing sizes of members or altering profiles and alignment. 1. Provide complete design calculations and drawings prepared by the professional engineer, if design modifications are anticipated.

1.5 A.

B.

C.

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D.

Deliver anchorage items which are to 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 2.1 A. GENERAL Proprietary names used for materials are intended to imply that products of the named Saudi manufacturers are required. Equivalent products of other manufacturers may only be used where local supply is not available. FORMWORK 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 finish surfaces. Accurately construct forms, mortar-tight, and of sufficient strength to withstand all pressures due to concrete placing operations, temperature changes, and when prestressed, pretensioning and detensioning operations. Maintain formwork to provide complete precast concrete units of the shapes, lines, and dimensions indicated, within the specified fabrication tolerances. Unless forms for plant-manufactured prestressed concrete units are stripped prior to detensioning, design forms so that stresses are not induced in precast units due to deformation of concrete under prestress or to movement during detensioning. REINFORCING MATERIALS Reinforcing Bars: Deformed, conforming to ASTM A615, Grade 60. Steel Wire: ASTM A82, plain, cold-drawn, steel. Supports for Reinforcement: Provide supports for reinforcement including bolsters, chairs, spacers and other devices for spacing, supporting and fastening reinforcing, complying with PCI and CRSI recommendations. 1. For exposed-to-view concrete surfaces, where legs of supports are in contact with forms, provide supports with legs which are plastic coated or stainless steel protected.

2.2 A.

B.

C.

2.3 A. B. C.

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D.

For additional requirement refer to Sections 03200 and 03210.

TABLE 2.1A ADDITIONAL REQUIREMENTS Limit For Type V Cement 0.6% Maximum 3.0% to 5.0% 40% to 60% 15% Maximum 400 Maximum 12 Minimum 20 Minimum 30 Minimum Limit For Type I Cement

PROPERTY

Alkalis (Na2O + 0.658K2O Tricalcium Aluminate (3CaO.A12O3) Tricalcium Silicate (3CaO.SiO2) Tetracalcium Aluminoferrite (4Ca0. A12O3.Fe2O3) Fineness (Air Permeability) in m2/Kg

0.6% Maximum 8% to 14% 40% to 60% 15% Maximum 400 Maximum

Compressive Strength (Mpa) at 3 Days 7 Days 28 Days

12 Minimum 20 Minimum 30 Minimum

Time of Setting (Vicat Needle ASTM C 191) Initial Set (minutes) Final Set (hours)

120 Minimum 6 Maximum

120 Minimum 6 Maximum

2.4 A.

CONCRETE MATERIALS Portland Cement: Portland cement shall be Type I or Type V conforming to ASTM C 150, SASO 142 and 143 and the additional requirements specified in Table 2.1A: Unless otherwise shown on drawings or in other Sections, Type I with pozzolan shall be used for all concrete below grade and up to one meter above grade; all other concrete shall be Type I plain.

B.

Pozzolan Admixtures: 1. 2. Silica fume shall conform to the requirements of ASTM C 1240. Fly ash shall conform to ASTM C 618 requirements for Class F fly ash.

C.

Blended Cement: the blended cement shall meet the requirements for IP(MS) cement and shall conform to all other requirements of ASTM C 595. Pozzolan to be used shall be fly ash or silica fume. Coarse Aggregate: Coarse aggregate shall consist of crushed or uncrushed gravel, crushed stone or a combination of the three. Aggregate delivered to the stockpile prior to being washed at quarry shall be washed with potable water and left to dry before charging into the bins. Coarse aggregate shall be selected, recrushed, finish screened and rinsed as necessary. Coarse aggregate shall comply with the requirements of ASTM C33 and test requirements listed therein and with requirements specified in Table 2.1B below:

D.

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TABLE 2.1A ADDITIONAL REQUIREMENTS Limit For Type V Cement 0.6% Maximum 3.0% to 5.0% 40% to 60% 15% Maximum 400 Maximum 12 Minimum 20 Minimum 30 Minimum Limit For Type I Cement

PROPERTY

Alkalis (Na2O + 0.658K2O Tricalcium Aluminate (3CaO.A12O3) Tricalcium Silicate (3CaO.SiO2) Tetracalcium Aluminoferrite (4Ca0. A12O3.Fe2O3) Fineness (Air Permeability) in m2/Kg

0.6% Maximum 8% to 14% 40% to 60% 15% Maximum 400 Maximum

Compressive Strength (Mpa) at 3 Days 7 Days 28 Days

12 Minimum 20 Minimum 30 Minimum

Time of Setting (Vicat Needle ASTM C 191) Initial Set (minutes) Final Set (hours)

120 Minimum 6 Maximum

120 Minimum 6 Maximum

E. Fine Aggregate: Fine aggregate shall consist of clean natural sand with rounded or sub-rounded particles. Fine aggregate shall be selected to comply with the requirements of ASTM C33 and test requirements therein and with requirements specified in Table 2.1C below:
TABLE 2.1A ADDITIONAL REQUIREMENTS Limit For Type V Cement 0.6% Maximum 3.0% to 5.0% 40% to 60% 15% Maximum 400 Maximum 12 Minimum 20 Minimum 30 Minimum Limit For Type I Cement

PROPERTY

Alkalis (Na2O + 0.658K2O Tricalcium Aluminate (3CaO.A12O3) Tricalcium Silicate (3CaO.SiO2) Tetracalcium Aluminoferrite (4Ca0. A12O3.Fe2O3) Fineness (Air Permeability) in m2/Kg

0.6% Maximum 8% to 14% 40% to 60% 15% Maximum 400 Maximum

Compressive Strength (Mpa) at 3 Days 7 Days 28 Days

12 Minimum 20 Minimum 30 Minimum

Time of Setting (Vicat Needle ASTM C 191) Initial Set (minutes) Final Set (hours)

120 Minimum 6 Maximum

120 Minimum 6 Maximum

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F.

Combined Aggregate Gradation: Coarse and fine aggregates shall be combined to require the least amount of sand (passing 4.75mm) and mixing water. The gradation limits for mix designs and tolerances for the control of approved mix design gradations are given in Table 2.1D below:
TABLE 2.1A ADDITIONAL REQUIREMENTS Limit For Type V Cement 0.6% Maximum 3.0% to 5.0% 40% to 60% 15% Maximum 400 Maximum 12 Minimum 20 Minimum 30 Minimum Limit For Type I Cement

PROPERTY

Alkalis (Na2O + 0.658K2O Tricalcium Aluminate (3CaO.A12O3) Tricalcium Silicate (3CaO.SiO2) Tetracalcium Aluminoferrite (4Ca0. A12O3.Fe2O3) Fineness (Air Permeability) in m2/Kg

0.6% Maximum 8% to 14% 40% to 60% 15% Maximum 400 Maximum

Compressive Strength (Mpa) at 3 Days 7 Days 28 Days

12 Minimum 20 Minimum 30 Minimum

Time of Setting (Vicat Needle ASTM C 191) Initial Set

120 Minimum 6

120 Minimum 6

G. H.

Lightweight Aggregate: ASTM C330. Water: Water for mixing, ice production, washing and cooling of aggregates shall be free from injurious amounts of oil, acid, salt, alkali, organic matter and other potentially deleterious substances when examined in accordance with ASTM C 94. Chemical Admixtures and Additives: 1. All chemical admixtures shall be free of chlorides and shall conform to ASTM C 494. Plasticizers may be used for all concrete to require the least amount of mixing water. Retarding and accelerating admixtures shall not be used without the appropriate justification and recommendation of the Contractor and acceptance by the MARAFIQ. When air entrained concrete is specified, the total air content, as measured in accordance with ASTM C 231, shall be 7 + 1% for gradation B and 4 + 1% for gradation A. Air entrainment shall not be used when mineral admixtures are used. Air entraining admixtures shall conform to ASTM C 260.

I.

2.

2.5

CONCRETE DURABILITY To ensure durability of produced concrete, the following tests shall be carried out.

A.

Salt Limits: The total acid soluble chloride ion in hardened concrete as determined by ASTM C 1152 at 28 days shall not exceed 0.1% by weight of the

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cement. The total soluble sulfate salt expressed as S04, as determined by BS 1377, shall not exceed 4.0% by weight of the cement. B. The testing of hardened concrete for chloride impermeability shall be as follows:

Test Description Standard Maximum Charge Passed Rapid Chloride AASHTO T277 1000 coulombs for silica fume permeability at 28 days concrete, 2000 coulombs for fly ash concrete, and 4000 coulombs for plain concrete. C. Ice Content: The amount of ice batched shall be sufficient to provide concrete meeting maximum temperature requirement of 30C at the point of discharge. GROUT MATERIALS Non Metallic Shrinkage-Resistant Grout: Premixed, non-metallic, non-corrosive, non-staining product containing selected silica sands, portland cement Type I with silica fume, shrinkage compensating agents, plasticizing and water reducing agents. Non-shrink grout shall be non-metallic/non-shrink cementicious grout meeting the requirements of CRD-621 specification, or ASTM C 1107. 2.6 CALCIUM CHLORIDE Do not use calcium chloride in concrete. 2.8 CHLORIDE ION Maximum Chloride Ion Content: Maximum water soluble chloride ion concentrations contributed from all ingredients of concrete including water, aggregates, cementitious materials and admixtures shall not exceed 0.10% by mass of cement. 2.9 A. B. C. CONNECTION MATERIALS Steel Plates: Structural quality, hot-rolled carbon steel, ASTM A283, Grade C. Steel Shapes: ASTM A36. Anchor Bolts: ASTM A307, low-carbon steel bolts, regular hexagon nuts and carbon steel washers. Galvanized finish of connections: Connections shall be hot-dip galvanized in accordance with ASTM A153.

2.6 B.

D.

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E.

Accessories: Provide all clips, hangers, and other accessories required for installation of precast units and for support of subsequent construction or finishes. PROPORTIONING AND DESIGN OF MIXES Prepare mix designs for each type of concrete required. Mix designs may be prepared by an independent testing facility or by qualified precast manufacturing plant personnel, at precast manufacturer's option. Concrete shall comply with the applicable provisions of Section 03300 except for the following specific requirements: 1. Produce standard-weight concrete consisting of the specified portland cement, aggregate, admixtures, and water to produce the following properties: a. b. c. Compressive strength; 35 MPa minimum at 28 days. Maximum aggregate size; 20 mm. Minimum cement content; 400 kilograms per cubic meter of concrete. Slump at point of discharge; 75 mm maximum.

2.10 A.

B.

d. 2.

Produce lightweight concrete consisting of the specified portland cement, aggregates, admixtures, and water to produce the following properties: a. b. c. Compressive strength; 35 MPa minimum at 28 days. Maximum aggregate size; 20 mm. Minimum cement content; 400 kilograms per cubic meter of concrete. Air-dry density; not less than 1440 kilograms nor more than 1842 kilograms per cubic meter.

d.

3.

Cure compression test cylinders using the same methods as will be used for the precast concrete work.

C.

Submit written reports to the MARAFIQ of proposed mix for each type of concrete prior to start of precast unit production. Do not begin concrete production until mixes and evaluations have been reviewed by the MARAFIQ. Laboratory Trial Batches: Laboratory trial batches are used to select concrete proportions for bridges. Prepare test specimens in accordance with ASTM

D.

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C192 and conduct strength tests in accordance with ASTM C39, as specified in ACI 318. 1. Establish a curve showing relationship between water-cement ratio (or cement content) and compressive strength, with at least 3 points representing batches which produce strengths above and below that required. Use not less than 3 specimens tested at 28 days, or an earlier age when acceptable to the MARAFIQ, to establish each point on the curve. The maximum permissible water-cement ratio for the concrete to be used shall be that shown by the curve to produce a strength 15 percent greater than called for by the plans or specifications. No changes in materials may be made without establishing new curves from tests as described above.

2.

3.

E.

Adjustment to Concrete Mixes: Mix design adjustments shall be requested when characteristics of materials, job conditions, weather, test results, or other circumstances warrant. Laboratory test data for revised mix designs and strength results must be submitted to and accepted by the MARAFIQ before using in the work. Admixtures: 1. Use water-reducing admixtures in strict compliance with the manufacturer's directions. Admixtures to increase cement dispersion, or to provide increased workability for low-slump concrete, may be used subject to the MARAFIQ's acceptance. Use amounts of admixtures as recommended by the admixture manufacturer for climatic conditions prevailing at the time of placing. Adjust quantities of admixtures as required to maintain quality control.

F.

2.

PART 3 - EXECUTION 3.1 A. FABRICATION General: Fabricate precast concrete units complying with the manufacturing and testing procedures, quality control recommendations, and dimensional tolerances of PCI MNL-116, and as specified for the types of units required. Ready-mix Concrete: Comply with the requirements in Section 03300, and as herein specified. 1. Delete the references for allowing additional water to be added to the batch for material with insufficient slump. Addition of water to the batch will not be permitted.

C.

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2.

During hot weather, or under conditions contributing to rapid setting of concrete, a shorter mixing time than specified in ASTM C94 may be required. a. When the air temperature is between 29C and 35 C, reduce the mixing and delivery time from 1 hours to 75 minutes, and when the air temperature is above 35C, reduce the mixin g and delivery time to 60 minutes.

D.

Built-in Anchorages: Accurately position 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. Do not relocate bearing plates in units unless acceptable to MARAFIQ. Cast-in holes for openings larger than 250 mm diameter or 250 mm square in accordance with final shop drawings. Other smaller holes will be field cut by trades requiring them. Coat surfaces of forms with a 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 manufacturer's instructions. Clean reinforcement of, earth, oil, and other materials which reduce or destroy bond with concrete. 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. For reinforcement cover, follow Sections 03200 and 03210. Arrange, space and securely tie bars and bar supports to hold reinforcement in position during concrete placement operations. Set wire ties so ends are directed into concrete, not toward exposed concrete surfaces. Place concrete in a continuous operation to prevent the formation of seams or planes of weakness in precast units, complying with requirements of applicable standard. Thoroughly consolidate placed concrete in each precast units by internal and external vibration without dislocation or damage to reinforcement and built-in items. Identification: Provide permanent markings in precast units to identify pick-up points and orientation in the structure, complying with the markings indicated on the final shop drawings. Imprint the date of casting on each precast unit where it will not show in the finished structure.

D.

E.

F.

G.

H.

I.

J.

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K.

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. Finish of Formed Surfaces: Provide finishes for formed surfaces of precast concrete as indicated for each type of unit, and as follows: 1. Standard Finish: Normal plant run finish smooth finish to the concrete. Small bubbles, normal form joint marks, and tolerated, but no major or unsightly structures defects will be permitted. produced in forms that impart a surface holes caused by air minor chips and spalls will be imperfections, honeycomb, or

L.

M.

Quality Control: Precast unit manufacturer shall institute quality control procedures for the manufacture, inspection, and testing of precast units in compliance with recommendations of PCI MNL-116. Furnish the MARAFIQ copies of test reports and/or certifications for materials and quality control testing of precast units. INSTALLATION, GENERAL Refer to other precast concrete sections for installation requirements for those particular precast units. Welding: Perform all welding in compliance with AWS D1.1 and D12.1, including qualification of welders. Protect units from damage by field welding or cutting operations and provide non-combustible shields as required. Repair damaged metal surfaces by cleaning and applying a coat of liquid galvanizing repair compound to galvanized surfaces and compatible primer to painted surfaces. Powder-Actuated Fasteners: Do not use powder-actuated fasteners for surface attachment of accessory items in any precast, prestressed unit unless approved in writing by the precast manufacturer. Grouting Connections and Joints: After precast concrete units have been placed and secured, grout open spaces at connection and joints as follows: 1. Shrinkage-resistant grout consisting of premixed compound and only enough water to provide a flowable mixture without segregation or bleeding. Provide forms or other acceptable method to retain the grout in space until sufficiently hard to support itself. Pack spaces with stiff grout material, tamping until voids are completely filled. Place grout to finish smooth, plumb, and level with adjacent concrete surfaces. Keep grouted joints damp for not less than 24 hours after it has taken its initial set.

3.2 A.

B.

C.

D.

E.

F.

2.

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Promptly remove any grout material for exposed surfaces before it hardens. 3.3 A. QUALITY CONTROL TESTING The Contractor shall employ an independent testing laboratory to evaluate precast manufacturer's quality control, testing of materials and testing methods. The precast manufacturer shall allow the Contractor's testing facility access to materials storage areas, concrete production equipment, and concrete placement and curing facilities. Cooperate with Contractor's testing laboratory and provide samples of materials and concrete mixes as may be requested for additional testing and evaluation. Dimensional Tolerances: 1. Units having any dimension smaller or greater than required, and outside the specified tolerance limits, will be considered deficient in strength and subject to additional testing as herein specified. Precast units having any dimension greater than required will be rejected if the appearance or function of the structure 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.

B.

C.

2.

D.

Strength of Units: 1. 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. a. b. Failure to meet compressive strength tests requirements. Reinforcement, and pretensioning and detensioning of tendons of prestressed concrete, not conforming to specified fabrication requirements. Concrete curing, and protection of precast units against extremes in temperature, not as specified. Precast units damaged during handling and installation.

c.

d. E.

Testing Precast Concrete Units for Strength: 1. When there is evidence that the 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 C42 and as follows:

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a.

Take at least 3 representative cores from precast units of suspect strength, from locations directed by MARAFIQ. Test cores in a saturated-surface-dry condition per ACI 318 if the concrete will be wet during the use of the completed structure. Test cores in an air-dry condition per ACI 318 if the concrete will be dry at all times during use of the completed structure. Strength of concrete for each series of cores may be considered satisfactory if their average compressive strength is at least 90% of and if no single core tests less than 80% of the 28 day design compressive strength. Tests results will be made in writing on the same day that tests are made, with copies to the MARAFIQ, Contractor, and precast manufacturer. 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, 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.

b. c.

d.

e.

2.

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

F.

Defective Work: 1. Precast concrete units which do not conform to the specified requirements, including strength, tolerances, and finishes, shall be replaced with precast concrete units that meet the requirements of this section. The Contractor shall be responsible for the cost of corrections to any other work affected by or resulting from corrections to the precast concrete work. + + END OF SECTION 03400 + +

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