DIVISION 3 - CONCRETE SECTION 03300 - CAST-IN-PLACE CONCRETE PART 1 - GENERAL 1.

01 DESCRIPTION This Section covers providing all On-Site concrete including, but not limited to the following: 1. 2. 3. 4. 5. 6. 7. 8. 1.02 1.03 Foundations. Guardrail and traffic sign foundations. Building outdoor slab Building floor slab Precast concrete perimeter fence foundation Sidewalk, curb and gutters Light standard and flagpole foundations Trash bin

REFERENCE CODES AND STANDARDS: Comply with applicably SAUDI ARAMCO Standards and Codes and Standards as specified herein. QUALITY ASSURANCE A. All testing, including requests, reports, etc. are the responsibility of the CONTRACTOR, or an independent agency employed by the CONTRACTOR and acceptable to Company Representative. Company Representative reserves the right to verify the tests with a SAUDI ARAMCO testing laboratory or other independent agency. Failure to detect defective WORK or materials during testing will neither prevent rejection later when such defects are discovered, nor will it obligate Company Representative to make final acceptance. 1. Compressive Strength Test: WORK Site sampling and testing of the concrete shall be provided by the CONTRACTOR. The frequency of testing for compressive strength shall be a minimum of one (1) set of cylinders per 40 m 3 (50 yd3) per job per day or fraction thereof for each class of concrete delivered. Each set of cylinders shall consist of four 152 mm x 305 mm (6 in x 12 in) cylinders made and tested in conformance with ASTM Standard C-31 and C-39. Cylinders shall be tested at 3 days (1 cylinder), 7 day (1 cylinder), 28 days (2 cylinders) of age. The 28 day individual strength results shall be averaged and the resulting value shall be referred to as the 28-day strength. At the option of Company Representative, the frequency of testing may be reduced for small or isolated concrete batches for concrete not subject to flexural stresses. SECTION 03300

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To verify compliance to all quality requirements of this Specification the right to obtain samples, deemed necessary by Company Representative, shall always be retained by the Contractor. 2. Slump Test: The allowable slump, tested per ASTM C-143 at the point of delivery, shall be within the following ranges: Type of Construction a. b. Foundation walls and footings Building beams, walls and columns Slabs on grade Maximum* 130 mm (5 in) 100 mm (4 in) 75 mm (3 in) Minimum 50 mm (2 in) 50 mm (2 in) 50 mm (2 in)

c. *

When concrete pumps are used, the slump shall be determined at the discharge point of the concrete placement hose.

Workability of concrete shall not be improved by adding more water to the established mixture. When necessary, Workability shall be varied by changing mix proportions, while maintaining the required water/cement ratio specified. Once mix designs have been established, and approved changes must have written approval from Company Representative. Retempering or adding water in excess of the design water/cement ratio to compensate for slump loss resulting from delays in delivery or placing is prohibited. Slump may be increased by addition, at the WORK Site, of a high range water reducing admixture (super plasticizer) conforming to ASTM C-494, Type F or G. The admixture shall be placed into the concrete mixer and the plastic concrete mixed for 5 minutes (approximately 70 revolutions) at mixing speed. The concrete shall be placed within 30 minutes after completion of the mixing cycle. The slump of the concrete shall not exceed the following: a. b. As delivered 100 mm (4 in.) After addition of super plasticizer 250 mm (10 in.)

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3.

Evaluation and Acceptance: Evaluation of all compressive strength data shall be done in accordance with ACI 214, "Recommended Practice for Evaluation of Strength Test Results of Concrete". Upon testing and evaluation, concrete shall be considered acceptable if all the following criteria are met: a. b. c. Not more than 10% of the 28-day strength tests shall have values less than the specified strength, f'c. The average of any three (3) consecutive strength tests shall be equal to or greater than the specified strength, f'c. No individual strength test is more than 3.45 MPa (500 psi) below the specified strength, f'c.

4.

Failure to Meet Strength Requirements: In the event that concrete fails to meet the above strength requirements in-place testing for concrete strength will be conducted by SAUDI ARAMCO. In-place testing will be conducted by one or a combination of the following methods: a. ASTM C42 "Method of Obtaining and Testing Drilled Cores and Beams of Concrete". If concrete in the structure will be dry under service conditions, cores shall be air dried at temperature 15 degrees C to 25 degrees C , relative humidity less than 60% for 7 days before test and shall be tested dry. If concrete in the structure will be more than superficially wet under service conditions, cores shall be immersed in water for at least 48 hours and tested wet. b. c. d. ASTM C-803 "Standard Test Method for Penetration Resistance of Hardened Concrete". ASTM C-805 "Rebound Number of Hardened Concrete". BS 4408, Part 5 "Measurement of Velocity of Ultrasonic Pulses". The foregoing nondestructive test methods shall include calibrating against known concrete strengths for evaluation of in-place strengths. If criteria of the preceding paragraphs are not met, and if structural adequacy remains in doubt, Company Representative may order load tests as outlined in Section 2620 of UBC Codes and Standards for the questionable portion of the structure, or take other action appropriate to the circumstances. SECTION 03300

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C.

Responsibilities and Duties of CONTRACTOR: 1. 2. Labor and Tools: Provide labor and tools necessary to obtain and handle samples at WORK Site or at other sources of material. Samples: Secure and deliver to CONTRACTOR's Testing Laboratory representative samples of materials proposed for use which require testing. Secure samples in accordance with ASTM C183 and D75. Design Mixes: Design concrete mixes to produce strengths specified; See PART 2 - PRODUCTS.

3. 1.04 SUBMITTALS A.

Test Reports: Submit to Company Representative for approval the proposed concrete design mixes and results of concrete tests made using proposed concrete mixes. Submit to Company Representative three (3) copies of all test reports. Placement Schedule: Prepare and submit to Company Representative placement schedules for review prior to start of concrete placement operations.

B. 1.05

PRODUCT STORAGE A. B. Cement: Store cement in watertight buildings, bins or silos. Aggregate: Stockpile aggregate in a manner which will prevent contamination with other materials or with other sizes of aggregate. To insure purity, conduct tests for determining conformance to requirements at point of batching. Before using, allow sand to drain until it reaches a uniform moisture content. Admixtures: Store admixtures in a manner which will prevent contamination. Protect admixtures from extreme temperatures which would adversely affect their characteristics.

C.

PART 2 - PRODUCTS 2.01 MATERIALS A. Cement: Portland cement of standard manufacturer; free from earth, trash and damp set; brand subject to Company Representative approval. Unless otherwise permitted by Company Representative, conform to ASTM C-150, Type V, cement for all structures resting on soil or below grade and Type I cement shall be used for above grade structures. Do not change brand or type of cement without prior approval of Company Representative.

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B.

Aggregates: 1. General: All aggregates are subject to Company Representative approval. Do not change source of aggregates without prior approval of Company Representative. All aggregates shall comply with SAUDI ARAMCO Standards, 09-SAMSS-088 and SSA 278/1982. Fine Aggregate: Natural sand conforming to ASTM C33; free of injurious amounts of shale, alkali, organic matter, loam or other deleterious substances. Do not use manufactured sand without approval of Company Representative. Coarse Aggregate: Clean, crushed stone or gravel conforming to ASTM C33. Unless otherwise approved by Company Representative, use size Number 57; however, in no case shall coarse aggregate exceed 3/4 of clear space between reinforcing bars or 1/5 of narrowest dimension between forms or 1/3 of depth of slabs.

2.

3.

C.

Water: Clean and free from injurious amounts of oils, acid, alkali, organic matter or other deleterious substances, and shall not contain more than 500 parts per million of total dissolved solids as per the requirements of SAUDI ARAMCO Standard, 09-SAMSS-097. Admixtures: With exception of air-entraining, water reducing and retarding admixtures do not use admixtures unless approved by Company Representative. Use air-entraining, water reducing and retarding admixtures only as specifically permitted by this Construction Specifications or approved by Company Representative. When admixtures are permitted, conform to: 1. 2. Air-Entraining Admixtures: ASTM C260, Fosroc CONPLAST AEA, or approved equal. Water Reducing/Retarding Admixture:

D.

The admixture shall meet ASTM C-494, Type F, water reducing, Type D, retarder requirements shall be used in all hot weather concrete. The admixture shall have a reliable history of performance with the materials used and shall be used in accordance with the manufacturer's directions. Fosroc CONPLAST SP430, CONPLAST SP430, or approved equal. 2.02 MOISTURE BARRIER A. Provide moisture barrier cover over prepared base material. Use only materials which are resistant to decay when tested in accordance with ASTM E 154. Polyethylene sheet shall not be less than 0.2mm thick. Manufactured by BMTC, model WSC-3019, clear or approved equal.

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2.03

PROPORTIONS A. General: The proportions of cement and aggregate shall be such as to produce a mixture which will WORK readily into corners and around reinforcing bars without segregating or honeycombing, which will not produce water on the surface, and which will produce a homogeneous dense concrete of the required strength. The concrete design mix shall be submitted to Company Representative for approval at least 30 days prior to proposed use. Proportioning of Ingredients: CONTRACTOR's Testing Laboratory shall determine exact proportions to be used. The proportions of ingredients shall be selected in accordance with provisions of ACI 211.1, using a minimum cement content of 350 Kg per cubic meter and a maximum cement of 370 Kg per cubic meter. Concrete shall obtain a minimum compressive strength of 27.6 MPa (4000 psi) at 28 days. Maximum water/cement ratio shall be 0.40. In some instances, maximum water-cement ratios and minimum cement factors may not be compatible due to aggregate characteristics, weather conditions, etc. Under these conditions, a water reducing admixture may be introduced into mix. In hot weather, a retarding admixture may be added to mix in accordance with manufacturer's recommendations.

B.

2.04

MIXING A. B. Concrete shall be supplied by ready-mix truck delivery from a SAUDI ARAMCO approved plant. Retempering: Mix concrete in quantities for immediate use only. Discard concrete which has set; do not retemper. Adding water to ready-mixed concrete at WORK Site will not be permitted. Hot Weather Concreting 1. Hot weather concreting shall comply with ACI-305R. For purpose of this Specifications, hot weather is defined as any combination of high air temperature, low relative humidity, and wind velocity, tending to impair the quality of fresh or hardened concrete. Concrete temperature at time of placement shall be limited in accordance with Attachment A so that the evaporation rate of the mixing water will not exceed 1 kg/sq.m/hr. (0.2 lbs/sq. ft/hr.). In no case shall the temperature of concrete delivered at the jobsite exceed 32 deg. C. Concrete delivered at a temperature in excess of 32 deg. C or that fails to maintain a temperature of 32 deg. C or less for at least 15 minutes or until used, SECTION 03300

C.

2.

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whichever comes first, shall be rejected and replaced CONTRACTOR at no additional cost to SAUDI ARAMCO.

by

the

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3.

One or more of the ingredients may have to be cooled to keep the concrete temperature from being excessive at the time of placement. An equal weight of crushed ice may replace part of the mixing water. The ice shall be added directly to the mixer and shall be completely melted by the time mixing is completed. Time period between mixing and placing shall be as short as possible to avoid slump loss and cold joints. Provisions shall be made for wind breaks, shading, fog spraying or wet cover on fresh concrete, when necessary, to prevent rapid moisture loss. Water used for curing shall conform to SAUDI ARAMCO Standard SAESQ-001, Paragraph 11.2, maximum 1000 ppm. Dampen subgrade, forms and reinforcing steel prior to replacement of concrete. Remove excess water just before concrete placement begins. Where possible continue cooling during placement. The spray application of a monomolecular finishing aid to prevent loss of moisture in fresh concrete may be applied immediately to all horizontal concrete surfaces following screeding, at the rate of not less than 40 liters per 200 square meters (10 gallons per 2000 square feet) of sprayable solution. Use of a monomolecular finishing aid does not eliminate curing as described under Section-03500, Concrete Finishing and Curing.

4. 5.

6.

7.

PART 3 - EXECUTION 3.01 GENERAL A. Quality Standard: Unless otherwise specified, place all concrete in accordance with SAUDI ARAMCO Engineering Standard, SAES-Q-001. Floor surfaces shall not deviate from a plane by more than 3 mm when measured with a 3 meter straight edge. (SAES-Q-001, Para. 10.2.2). Review of Test Breaks: Do not place any concrete until the Company Representative has reviewed results of design mix seven day test breaks and has given approval to proceed; see PART 1-GENERAL and Section-01400, Quality Control.

B.

3.02

PREPARATORY WORK A. Subgrades: Place concrete on subgrades that are well compacted in accordance with Section-02210 Earthwork to level and true grade. Before concrete is deposited between slabs on grade previously placed, recheck compaction of subgrade and, if necessary, recompact to avoid settlement of slabs at joints. Sprinkle semiporous subgrades sufficiently to eliminate absorption. Seal SECTION 03300

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extremely porous subgrades in a manner approved by Company Representative. Remove all debris and excess water from subgrades.

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B.

Slabs On Grade: 1. At all locations required, perform termite treatment as specified in Section02900, Termite Protection prior to placing vapor barrier, reinforcing, embedded items and concrete. Secure and brace bulkheads to prevent displacement. Terminate all reinforcement and other embedded items as specified in Section-03200, Concrete Reinforcement.

2.

C.

Installation of Other Materials: Prior to placing concrete install form WORK, preformed joint fillers, vapor barrier (where required) and reinforcing. Between erection of forms and placing of concrete, allow sufficient time for other trades to install and test their WORK. Before placing concrete on grade, inspect and test piping and other utilities under slabs and compact backfilled excavations to solid bearing. Set and secure against displacement edge forms and intermediate screed strips to produce required elevations and contours. Building Other Materials and Fixtures Into Concrete 1. 2. Anchor Bolts: Install all anchor bolts for steel bearing plates per Section03400, Concrete Accessories. Miscellaneous Items: Accurately place and secure against displacement all steel, pipe sleeves, inserts, anchors, blocking, nailer strips and similar items. Temporarily fill voids in sleeves and inserts with readily removable material. All items provided under other Section of Specifications to be installed under this Section. these Construction

D.

3. E. 3.03

Cleaning Equipment: Remove hardened concrete and foreign materials from mixing and conveying equipment, prior to placing concrete.

WEATHER CONDITIONS Protection: Do not place concrete when it is raining.

3.04

CONVEYING A. B. Adequate manpower and equipment shall be available for rapid, continuous placement of concrete. Concrete shall be conveyed from concrete truck or mixer, to final deposit by methods that prevent segregation, slump loss or loss of materials. Movement of concrete after placement shall be by shovel only; raking is prohibited. Free dropping of concrete from a height greater than 1m is prohibited. SECTION 03300

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C.

Equipment for conveying, chuting, concrete bucket, pumps, tremie, or conveyer belts shall be of the size and design to ensure a continuous flow of concrete at the point of placement, and shall not be supported by forms or reinforcement. No aluminum parts shall be in contact with the concrete.

3.05

DEPOSITING A. Just prior to placement of concrete, forms shall be cleaned of all debris, sand and standing water. In tall or narrow forms, windows shall be provided on the bottom for cleaning. Concrete shall be deposited at or near its final position, eliminating the tendency to segregate when it has flowed laterally into place. Concrete will be moved by shovel method only. No rakes will be used in concrete placement. On sloping surfaces, concrete placement shall start at the lower portion of the slope and progress upward. No concrete that has partially hardened or been contaminated by foreign material shall be placed in the forms. Concrete shall not be dropped freely from a height of more than 1 m (3 ft) and shall be distributed in uniform layers not to exceed 600 mm (2 ft) in height, avoiding inclined layers and cold joints. Slabs and beams shall be placed in one operation. Concreting once started, shall be continuous until a section is completed. When stoppage occurs, construction joints shall be placed horizontally or vertically. As needed, provide keys and dowels. All concrete shall be thoroughly consolidated by vibrators, working concrete around reinforcement and embedded fixtures and into corners of the forms. Vibrators shall be adequately sized as per ACI-309, Table 5.1.4. Vibrators shall not be used to move concrete laterally. Vibrators should be inserted and withdrawn vertically at intervals of five to twenty seconds duration and at points 450 mm to 750 mm (18 in to 30 in) apart, penetrating previously placed fresh concrete. Do not over-vibrate. Special care shall be taken in preventing vibrator head from hitting any epoxy coated rebar.

B.

C. D. E.

F. G.

H.

I.

3.06

FINISHING See Section-03500. Concrete Finishing and Curing for finishing.

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3.07

PATCHING A. For the purpose of preparing concrete surfaces for application of waterproofing or a finish, as soon as the forms are removed, tie wire, form ties and any other embedded items shall be cut back 25 mm (1 in) and the holes neatly and smoothly patched with a 1:2 cement sand mortar. Holes left by mechanical form ties or accessories shall be similarly patched. Honeycombing shall be repaired after inspection and clearance by the Company Representative. Small spots and places with loose aggregate shall be thoroughly cleaned and patched with 1:2 cement sand mortar immediately after stripping. Structural defects shall be repaired in accordance with appropriate sections of SAUDI ARAMCO Standard, SAES-Q-001 and only as approved by the Company Representative. Epoxy grouts and bonding components may be used for repairs only when approved by Company Representative.

B.

3.08

CONSTRUCTION JOINTS A. CONTRACTOR shall prepare shop drawings showing the locaitons and detailing of the construction and expansion joints and shall submit to Company Representative for approval. Locate construction joints perpendicular to the main reinforcement. Reinforcement to continue across joints. Arrange construction joints in a manner that will allow the concrete to be placed in one continuous operation. Immediately prior to placing adjacent concrete, thoroughly clean and wet the joint surface. After wetting, apply a uniform coat of neat cement grout. Locate joints in walls at the undersides of slabs, tops of footings or pedestal. Do not install any joints unless approved by Company Representative. When such joints are approved, install in a manner that will least impair the structures. CONTRACTOR shall provide on the shop drawings showing location of all construction and control joints.

B.

C. D.

3.09

CONTROL JOINTS A. Control joints shall be provided at a maximum spacing of every 3.0 meters in both directions of floor slabs to control cracking. Submit shop drawings showing location and type of control points to Company Representative for approval. Control joints shall be constructed by saw cutting the concrete to a depth of 1/4 of the thickness of the slab within 24 hours after placing the concrete, or other methods as approved by the Company Representative.

B.

3.10

Replace or repair damage materials and defective WORK as directed by Company Representative at no additional cost to SAUDI ARAMCO. SECTION 03300

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END OF SECTION

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