SECTION REINFORCING STEEL. 1. Reinforcing Steel for Cast-In-Place Concrete Structures

Transcription

1 SECTION REINFORCING STEEL PART 1- GENERAL 1.1 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.2 SUMMARY A. This Section includes the following: 1. Reinforcing Steel for Cast-In-Place Concrete Structures PART 2- PRODUCTS 2.1 MATERIALS A. Reinforcing Steel for Concrete Structures shall be in accordance with section of the MoDOT Standard Spec. All reinforcement shall be uncoated. PART 3- EXECUTION 3.1 CONSTRUCTION A. Furnishing and placement of Reinforcing Steel for Concrete Structures shall be in accordance with section 706 of the MoDOT Standard Spec. 1. Any reference to method of measurement and basis of payment included in the MoDOT Standard Spec. DOES NOT apply to this section. END OF SECTION

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3 SECTION CAST-IN-PLACE CONCRETE PART 1- GENERAL 1.1 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.2 SUMMARY A. This Section includes the following: 1. Concrete for existing substructure modifications to the abutments and piers 2. Concrete for Approach Rail Piers 3. New substructure concrete 4. Adhesives for concrete anchorage or rebar anchorage 1.3 ACTION SUBMITTALS A. Mix Design B. Concrete Work Plan which includes concrete placement methods, provisions for hot and cold weather concreting and curing. PART 2- PRODUCTS 2.1 MATERIALS A. Concrete shall be in accordance with section 501 of the MoDOT Standard Spec. Concrete shall be class B-1 Concrete with f' c = 4,000 psi unless otherwise noted. Concrete shall be class A-1 Concrete with f'c = 4,000 psi for the pier repair details on the following sheets: 1. S S S S

4 B. Adhesives for Rebar Dowels, and Threaded Rod Anchors: 1. Shall be an injectable, two component, epoxy based anchoring adhesive formula. 2. Shall be approved for exterior use. 3. Shall be code listed for cracked and uncracked concrete per an ICC-ES report. 4. Shall meet the requirements of ACI with a minimum characteristic bond stress in cracked concrete of 750 psi for a 5/8" anchor using 2,500 psi concrete evaluated at a maximum short term temperature of 130 F and maximum long term temperature of ll0 F. 5. Shall be one of the following or an approved equal meeting the requirements of sections 1 through 3 directly above: A. Hit HY-200 Hilti, Inc South 122nd East A venue Tulsa, OK B. SET-XP Simpson Strong-Tie PO Box Pleasanton, CA C. AClOO+Gold Powers Fasteners, Iric. 2 Powers Lane Brewster, NY PART 3-EXECUTION 3.1 CONSTRUCTION A. Concrete construction shall be in accordance with section 703 of the MoDOT Standard Spec. 1. Any reference to method of measurement and basis of payment included in the MoDOT Standard Spec. DOES NOT apply to this section. B. Where new concrete is to be placed against existing concrete surfaces, the existing concrete shall be thoroughly cleaned. Surface cleaning shall remove all foreign matter, laitance, efflorescence and dirt by pressure washing with a minimum of 3,000 psi. C. Field Drilled Anchors 1. Adhesives shall be installed in accordance with manufacturer's recommendations. Holes shall be THOROUGHLY CLEANED in accordance with manufacturer's recommendations. 2. If reinforcement is encountered during drilling operations contractor shall cut or core the reinforcement encountered. END OF SECTION

5 SECTION PRECASTSTRUCTURALCONCRETEPANELS PART 1- GENERAL 1.1 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.2 SUMMARY A. This Section includes the performance criteria, materials, design, production, and erection of precast structural concrete for the entire project. The work performed under this Section includes all labor, material, equipment, related services, and supervision required for the manufacture and erection of the precast structural concrete work shown on the Contract Drawings. B. This Section includes the following: 1. Precast Deck Panels 2. Neoprene between bottom of deck panels and structural steel. 3. Epoxy Adhesive used to adhere deck panels to neoprene. 4. Non-Shrink Grout for transverse shear keys on bridge Water Reactive Crystalline Admixture used in shear keys on bridge Penetrating Crystalline Cementitious Coating used in shear keys on bridge C. Related Sections include the following: 1. Section "Structural Steel for Bridges" material properties of embeds and hardware. D. Any reference to method of measurement and basis of payment included in the MoDOT Standard Spec. DOES NOT apply to this section. 1.3 ACTION SUBMITTALS A. Concrete Mix Design

6 B. Shop Drawings: 1. Detail fabrication of precast structural concrete units including connections at member ends and to each adjoining member. 2. Indicate locations, plan views, elevations, dimensions, tolerances, shapes, and cross sections of each unit, support conditions and types of reinforcement, including special reinforcement. 3. Indicate aesthetic intent including joints, rustications or reveals, and extent and location of each surface finish. 4. Indicate welded connections by AWS standard symbols. Show size, length, and type of each weld. 5. Detail loose and cast-in hardware, lifting and erection inserts, connections, and joints. Include Catalog Cut Sheets for any aftermarket products or the appropriate design calculations. 6. Indicate locations, tolerances and details of anchorage devices to be embedded in or attached to structure or other construction. 7. Indicate location of each precast structural concrete member by same identification mark placed on unit. 8. Indicate relationship of precast structural concrete members to adjacent materials, and adjacent memebers. 9. Indicate locations and details of joint treatment. 10. Design Modifications: If design modifications are proposed to meet performance requirements and field conditions, notify the Engineer and submit Shop Drawings. Do not affect the appearance, durability or strength of members when modifying details or materials. Maintain the general design concept when altering size of members and alignment. 11. No work or ordering of materials for this item shall be done until the submittal has been approved by the engineer. C. Deck Panel Erection Plan: refer to Deck Panel Erection Notes and Tolerances on sheet G-1 01 of the plans for a general discussion of minimum requirements for the Deck Panel Erection Plan. 1. No work or ordering of materials for this item shall be done until the submittal has been approved by the engineer. D. Non-shrink grout technical data sheet E. Water Reactive Crystalline Admixture technical data sheet F. Penetrating Crystalline Cementitious Coating technical data sheet G. Neoprene Technical Data Sheet H. Epoxy Adhesive Technical Data Sheet 2

7 1.4 INFORMATIONAL SUBMITTALS A. Welding Certificates: Copies of certificates for Welding Procedure Specifications (WPS) with the supporting Procedure Qualification Record (PQR)( if required by AWS), and the appropriate AWS Welder Certifications. B. Fabricator Qualifications C. Concrete Break Test results shall be submitted to Owner. D. Reinforcement Certifications 1.5 QUALITY ASSURANCE A. Fabricator Qualifications: A firm that complies with the following requirements and is experienced in producing precast structural concrete units similar to those indicated for this Project and with a record of successful in-service performance. 1. Assumes responsibility for engineering precast structural concrete units to comply with performance requirements. This responsibility includes preparation of Shop Drawings. 2. Participates in PC I' s Plant Certification program at the time of bidding and is designated a PCI-certified plant for Group B, Category Bl -Precast Bridge Products (No Prestressed Reinforcement) 3. Has sufficient production capacity to produce required members without delaying the Work. 4. Certification shall be maintained throughout the production of the precast structural concrete units. Production shall immediately stop if at any time the fabricator's certification is revoked, regardless of the status of completion of contracted work. Production will not be allowed to re-start until the necessary corrections are made and certification has been re-established. In the event certification(s) can not be reestablished in a timely manner, causing project delays, the fabricator, at no additional cost, will contract out the remainder of the units to be manufactured at a PCI certified plant. B. Design Standards: Comply with ACI 318 (ACI 318M) and the design recommendations of PCI MNL 120, "PCI Design Handbook- Precast and Prestressed Concrete," applicable to types of structural precast concrete members indicated. C. Quality-Control Standard: For manufacturing procedures and testing requirements and quality control recommendations for types of members required, comply with PCI MNL 116, "Manual for Quality Control for Plants and Production of Structural Concrete Products." 3

8 H. Welding: Qualify procedures and personnel according to A WS D 1.1/D 1.1M, "Structural Welding Code - Steel" and A WS D 1.5/D 1.5M, "Bridge Welding Code". I. Preinstallation Conference: Conduct conference to comply with requirements in Section "Coordination." 1.6 DELIVERY, STORAGE, AND HANDLING A. Deliver all structural precast concrete members in such quantities and at such times to assure compliance with the agreed upon project schedule and setting sequence to ensure continuity of installation. B. Handle and transport members in a manner to avoid excessive stresses that could cause cracking or other damage. C. Store units with adequate dunnage and bracing, and protect units to prevent contact with soil, staining, and to control cracking, distortion, warping or other physical damage. D. Unless otherwise specified or shown on Shop Drawings, store members with dunnage across full width of each bearing point. E. Place stored members so identification marks are clearly visible, and units can be inspected. F. Place dunnage of even thickness between each member. G. Lift and support members only at designated points indicated on the Shop Drawings. 1.7 SEQUENCING A. Furnish loose connection hardware and anchorage items to be embedded in or attached to other construction without delaying the Work. Provide locations, setting diagrams, templates, instructions, and directions, as required, for installation. PART 2- PRODUCTS 2.1 FORM MATERIALS A. Forms: Rigid, dimensionally stable, nonabsorptive material, warp and buckle free, that will provide precast concrete surfaces within fabrication tolerances indicated; nonreactive with concrete and suitable for producing required surface finishes. 4

9 B. Form-Release Agent: Commercially produced form-release agent that will not bond with, stain or affect hardening of precast concrete surfaces and will not impair subsequent surface or joint treatments of precast concrete. 2.2 STEEL REINFORCEMENT MATERIALS A. Reinforcment shall be in accordance with section of the MoDOT standard Spec. All reinforcement shall be uncoated except as follows: a. Bridge 3153 reinforcing bar shall be epoxy coated in accordance with section of the MoDOT Standard Spec. B. Supports: Use bolsters, chairs, spacers, and other devices for spacing, supporting, and fastening reinforcing bars in place according to PCI MNL CONCRETE MATERIALS A. Concrete shall be in accordance with section and 501 of the MoDOT standard Spec. B. Concrete shall be Class A-1. C. Compressive Strength (28 Days): 6000 psi minimum. 2.4 EPOXY ADHESIVE A. Epoxy Adhesive for bonding Neoprene to Deck Panels: 1. Shall meet specification ASTM C-881 Types I and IV Class B. 2. Shall possess a minimum slant shear bond strength at 2 days of 1700 psi per ASTM C Shall be a two component epoxy approved by the manufacturer for bonding concrete to neoprene smfaces. 4. Shall be one of the following or an approved equal meeting the requirements of sections 1 through 3 directly above: A. Sikadur 31, Hi-Mod Gel Sika Corporation 201 Polito A venue B. Rezi-Weld Gel Paste State Lyndhurst, NJ W.R. Meadows, Inc. C. Pro-Poxy 200 P.O. Box 338 Hampshire, IL Dayton Superior Corporation 1125 Byers Road Miamisburg, OH

10 2.5 NEOPRENE AND OTHER ACCESSORIES A. Provide the neoprene pads between the precast deck panels and steel surface meeting the requirements of Shore A- 50 Durometer and in accordance with Section of the MoDOT Standard Spec. B. Erection Accessories: Provide clips, hangers, high density plastic or steel shims, and other accessories required to install structural precast concrete members. C. Welding Electrodes: E8018C3 Electrodes and comply with AWS standards for steel type and/or alloy being welded. 2.6 GROUTMATERIALS A. Nonshrink Grout: Premixed, prepackaged, non-ferrous aggregate grout containing selected silica sands, portland cement, shrinkage-compensating agents, plasticizing and water-reducing agents, complying with ASTM C 1107, Grade A for drypack and Grades B and C for flowable grout and of consistency suitable for application with a 30-minute working time. Water-soluable chloride ion content of grout less than 0.06 percent chloride ion by weight of cement when tested in accordance with ASTM C1218/C1218M. Non-shrink Grout shall be mixed with water and Water Reactive Crystalline Admixture in the dosage prescribed by the Water Reactive Crystalline Admixture manufacturer. 2.7 WATER REACTIVE CRYSTALLINE ADMIXTURE A. Shall be a hydrophilic crystalline permeability reducing admixture for concrete exposed to hydrostatic pressure (PRAH) in accordance with ACI212.3R-10. B. Shall have no leakage after 14 days when pressure tested at 150 psi (350ft. water head) in accordance with U.S. Almy Corp of Engineers CRD-C C. Shall be one of the following or an approved equal: 1. AQUAFIN-IC ADMIX Aquafin Inc. 505 Blue Ball Rd. #160 Elkton, MD XYPEX ADMIX C-500NF Xypex Chemical Corporation Mayfield Place Richmond, British Columbia V6V 2G9 Canada 3. Krystol Internal Membrane (KIM) KRYTON International Inc East Kent Avenue Vancouver, British Columbia, V5P 2S8 Canada 6

11 2.8 PENETRATING CRYSTALLINE CEMENTITIOUS COATING A. Shall be a hydrophilic crystalline cementitious surface applied waterproofing which reacts with un-hydrated cement particles in the base concrete to produce crystals that grow into capillary voids and minor cracks within the base concrete. B. Shall seal static cracks up to 1/64" in width that occur after application of the coating and when exposed to water. C. Shall resist hydrostatic pressure of at least 71 psi (164ft. water head) when tested to DIN 1048 Part-5 direct water penetration test. D. Shall be one of the following or an approved equal: 1. AQUAFIN-IC Aquafin Inc. 505 Blue Ball Rd. #160 Elkton, MD XYPEX CONCENTRATE Xypex Chemical Corporation Mayfield Place Richmond, British Columbia V 6V 2G9 Canada 3. Krystol T1 & T2 KRYTON International Inc East Kent A venue Vancouver, British Columbia, V5P 2S8 Canada 2.9 FORM FABRICATION A. Form: Accurately construct forms, mortar tight, of sufficient strength to withstand pressures due to concrete placement, vibration operations, and temperature changes. Coat contact smfaces of forms with release agent before reinforcement is placed. Avoid contamination of reinforcement by release agent. B. Maintain forms to provide completed structural precast concrete members of shapes, lines, and dimensions indicated in Contract Documents, within fabrication tolerances specified. 1. Edge and Corner Treatment: Uniformly chamfered or as built-in on standard forms FABRICATION A. Cast-in Anchors, Inserts, Plates, Angles, and Other Anchorage Hardware: Fabricate anchorage hardware with sufficient anchorage and embedment to comply with design requirements. Accurately position for attachment of loose hardware and secure in place during precasting operations. Locate anchorage hardware where it does not affect position of main reinforcement or concrete placement. Do not relocate embeds in members unless approved by Engineer. 7

12 1. Weld headed stud anchors used for anchorage according to AWS Dl.l/Dl.lM and AWS C5.4, "Recommended Practices for Stud Welding." B. Furnish loose hardware items including steel plates, clip angles, seat angles, anchors, dowels, hangers, and other hardware shapes for securing precast concrete members to supporting and adjacent construction. C. Cast-in reglets, slots, and other accessories in structural precast concrete members as indicated on Contract Drawings. D. Reinforcement: Comply with recommendations in PCI MNL 116 for fabricating, placing, and supporting reinforcement. 1. Clean reinforcement of loose rust and mill scale, earth, and other materials that reduce or destroy the bond with concrete. When damage to epoxy coated reinforcing exceeds limits specified in ASTM A 775/A 775M, repair with patching material compatible with coating material and epoxy coat bar ends after cutting. 2. Accurately position, support, and secure reinforcement against displacement during concrete-placement and consolidation operations. Locate and support reinforcement by plastic tipped or corrosion resistant metal or plastic chairs, runners, bolsters, spacers, hangers, and other devices for spacing, supporting, and fastening reinforcing bars and welded wire reinforcement in place according to PCI MNL Place reinforcing steel to maintain at least% in. (19 mm) minimum concrete cover, or minimum cover as shown on the plans. Provide cover requirements in accordance with ACI 318 (ACI 318M) when units are exposed to corrosive environment or severe exposure conditions. Arrange, space, and securely tie bars and bar supports to hold reinforcement in position while placing concrete. E. Comply with requirements in PCI MNL 116 and in this Section for measuring, mixing, transporting, and placing concrete. After concrete hatching, no additional water may be added. F. Place concrete in a continuous operation to prevent cold joints or planes of weakness from forming in precast concrete members. G. Thoroughly consolidate placed concrete by vibration without dislocating or damaging reinforcement and built-in items, and minimize pour lines, honeycombing or entrapped air voids on surfaces. Use equipment and procedures complying with PCI MNL 116. H. Comply with PCI MNL 116 procedures for hot and cold-weather concrete placement. I. Identify pickup points of precast concrete members and orientation in structure with permanent markings, complying with markings indicated on Shop Drawings. Imprint or permanently mark casting date on each precast concrete member on a surface that will not show in finished structure. 8

13 J. Cure concrete, according to requirements in PCI MNL 116, by moisture retention without heat or by accelerated heat curing using live steam or radiant heat and moisture. Cure members until compressive strength is high enough to ensure that stripping does not have an effect on the performance or appearance of final product FABRICATION TOLERANCES A. Fabricate structural precast concrete members of shapes, lines and dimensions indicated, so each finished member complies with PCI MNL 135 product tolerances as well as position tolerances for cast-in items. Dimensional tolerances shall be according to "Bridge Deck Units" except as modified below: 1. b =Width (measured longitudinal to bridge) ±Ys" 2. c = Depth ±W' 3. Location of embed Bottom Plate Assembly ±W' longitudinal and transverse 4. Location of Side Plate and Embedded Rod Hf' longitudinal and vertical 5. Concrete Blackouts ± 1.4" transverse B. Panels will be rejected at the job site if found to be out of tolerance by the inspector FINISHES A. Concrete shall be struck off and thoroughly vibrated until concrete of a uniform and satisfactory density is attained. B. After surface irregularities have been removed, top surface of panels shall be tined transversely to bridge with a wire comb. Wire comb and texturing shall be in accordance with sections and of the MoDOT Standard Spec SOURCE QUALITY CONTROL A. Quality-Control Testing: Test and inspect precast concrete according to PCI MNL 116 requirements. B. Concrete Break Test results shall be submitted to Owner. PART 3- EXECUTION 3.1 PREPARATION A. Furnish loose connection hardware and anchorage devices for precast concrete members to be embedded in or attached to the structural steel before starting that Work. Provide locations, setting diagrams, templates and instructions for the proper installation of each anchorage device. 9

14 3.2 EXAMINATION A. Examine supporting structural steel and conditions for compliance with requirements for installation tolerances, bearing surface tolerances, and other conditions affecting precast concrete performance. B. Proceed with precast concrete installation only after unsatisfactory conditions have been corrected. 3.3 ERECTION A. Install loose clips, hangers, bearing pads, and other accessories required for connecting structural precast concrete members to supporting members and backup materials. B. Erect precast structural concrete level, plumb and square within the specified allowable erection tolerances. Provide temporary structural framing, shoring and bracing as required to maintain position, stability, and alignment of members until permanent connections are completed. 1. Install temporary steel or plastic spacing shims or bearing pads as precast concrete members are being erected. Surface weld steel shims to each other to prevent shims from separating. 2. Maintain horizontal and vertical joint alignment and uniform joint width as erection progresses. 3. Remove projecting lifting devices and use plastic patchcaps or sand-cement grout to fill voids within recessed lifting devices flush with surface of adjacent precast concrete surfaces when recess is exposed. C. Connect structural precast concrete members in position by bolting, welding, grouting, or as otherwise indicated on approved Shop (Erection) Drawings. Remove temporary shims, wedges, and spacers as soon as practical after connecting and/or grouting activities are completed. D. Welding: Comply with applicable A WS D 1.5/D 1.5M requirements for welding, welding electrodes, appearance of welds, quality of welds, and methods used in correcting welding work. 1. Protect structural precast concrete members and bearing pads from damage during field welding or cutting operations and provide noncombustible shields as required. 2. Welds not specified shall be continuous fillet welds, using not less than the minimum fillet as specified by A WS D 1.5/D 1.5M. 3. Visually inspect all welds critical to precast structural concrete connections. Visually check all welds for completion and remove, reweld or repair all defective welds, if services of A WS-certified welding inspector are not furnished by Owner. 10

15 E. At bolted connections, use upset threads, thread locking compound or other approved means to prevent loosening of nuts after final adjustment. 1. Where slotted connections are used, verify bolt position and tightness at installation. For sliding connections, properly secure bolt but allow bolt to move within connection slot. 2. Grouting or Dry-Packing Connections and Joints: Indicate joints to be grouted and any critical grouting sequences on Shop (Erection) Drawings. Grout open spaces at keyways, connections and joints where required or indicated. Provide reinforcing steel where indicated. Retain flowable grout in place until it gains sufficient strength to support itself. Fill joints completely without seepage to other surfaces. Alternatively, pack spaces with stiff dry pack grout material, tamping until voids are completely filled. Place grout and finish smooth, level, and plumb with adjacent concrete surfaces. Promptly remove grout material from exposed surfaces before it affects finishes or hardens. Keep grouted joints damp for at least 24 hours after initial set. F. Field cutting of precast, prestressed concrete members is not permitted without approval of the Engineer. G. Fasteners: Do not use drilled or power-actuated fasteners for attaching accessory items to precast, prestressed concrete members unless approved by Precast Engineer and Engineer of Record. 3.4 ERECTION TOLERANCES A. Erect structural precast concrete members level, plumb, square, and in alignment without exceeding the noncumulative erection tolerances ofpci MNL 135 except as modified below: d =Joint Width 1 /.t" ± W' 3.5 REPAIRS A. Repairs will be permitted provided structural adequacy, serviceability and durability of members and appearance are not impaired. B. Remove and replace damaged precast structural concrete members when repairs do not comply with specified requirements. 11

16 3.6 CLEANING A. Clean exposed smfaces of precast concrete members after erection and completion of joint treatment to remove weld marks, other markings, dirt, and stains. 1. Perform cleaning procedures, if necessary, according to precast concrete fabricator's recommendations. Protect adjacent work from staining or damage due to cleaning operations. 2. Do not use cleaning materials or processes that could change the appearance of exposed concrete finishes or damage adjacent materials. END OF SECTION