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03410 STRUCTURAL PRECAST CONCRETE *************************************************************************************************************** SPECIFIER: CSI MasterFormat 2004 number 03 41 00 *************************************************************************************************************** PART 1 GENERAL 1.1 SUMMARY A. Provide labor, materials, necessary equipment, services and included, but not limited to, related work to complete the structural precast concrete work, as indicated on the drawings and as specified. B. Related Sections: 1. 03100 - Concrete Formwork 2. 03200 - Concrete Reinforcement 3. 03300 - Cast-in-Place Concrete 4. 05805 - Expansion Joint Covers 1.2 REFERENCES A. American Society for Testing and Materials (ASTM), latest edition: 1. A36 Specification for Carbon Structural Steel. 2. A153 Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware. A307 Specification for Carbon Steel Bolts, Studs, and Threaded Rod 60,000 PSI Tensile Strength. 3. A416 Specification for Steel Strand, Uncoated Seven-Wire for Prestressed Concrete. 4. C42 Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete. 1.3 QUALITY ASSURANCE A. Comply with provisions of latest edition of the following codes, specifications, and standards, except as otherwise indicated. 1. Prestressed Concrete Institute MNL 116: Manual for Quality Control for Plants and Production of Precast Concrete Products. 2. ACI 318/318R: Building Code Requirements for Reinforced Concrete and Commentary. 3. AWS Dl.4: Structural Welding Code - Reinforcing Steel. 4. AWS Dl.1: Structural Welding Code - Steel. 5. Applicable codes, specifications, and standards referenced in Sections 03100, 03200, and 03300. B. Fabricator Qualifications: Firms with 5 years of successful experience in fabrication of precast concrete units similar to units required for this project. Fabricator shall have sufficient production capacity to produce required units without causing delay in work. Project No. SPECIFICATION GUIDELINES 03410-1

C. Fire-resistance Rated Precast Units: Where precast concrete units are shown or scheduled as requiring a fire-resistance classification, provide units: 1. Tested and listed by UL or other OSHA approved Nationally Recognize Testing Laboratory (NRTL). Testing shall be conducted according to appropriate standards and each unit shall bear appropriate label and marking. 2. Complying with the requirements of the applicable building codes. 1.4 DESIGN A. Prestressed units shall be designed to comply with the latest requirements of ACI 318-95. B. Systems shall provide fire ratings as scheduled on the drawings. C. Design for horizontal shear requirements in beams with precast soffits and in joists shall be the responsibility of the manufacturer. D. Stirrups in beams with precast soffits subject to torsion shall meet the minimum requirements of ACI 318, paragraph 11.6.3. E. Design loads, moments, shears, and torsions shall be as scheduled in the drawings. In joist design, add the dead load of masonry partitions to given uniform loads unless other specific provisions have been stated. F. Any soffit beam supporting joists from one side only or from both sides with ratio of spans greater than 2.0 shall be designed for the smaller of: 1. Cracking torsion at the critical section for shear, reduced rationally based on the shear envelope of the beam. 2. Torsion based on the joist reactions applied 1 inch inside the face of the beam. G. Design shears scheduled in the drawings are at the face of support. Shear envelope shall vary rationally from the values at supports to value at mid-span, based on applied uniform or concentrated loads. H. Formwork, shoring, and reshoring shall comply with requirements of Section 03100. 1.5 SUBMITTALS A. Product Data: Submittals shall comply with applicable requirements of Sections 03100, 03200, 03300, and 05805. B. Mix designs in compliance with Section 03300 for classes of concrete, including provisions for control of total chloride ion content for prestressed members. C. Shop Drawings: 1. Shop drawings and manufacturer's complete design calculations shall be signed and sealed by a current Florida registered professional engineer. See construction notes in the structural working drawings for additional requirements. 2. Submit shop drawings showing complete information for fabrication and installation of structural precast concrete units. Indicate: Project No. SPECIFICATION GUIDELINES 03410-2

a. Member dimensions and cross-section. b. Location, size, and type of reinforcement, including special reinforcement and lifting devices necessary for handling and erection. c. Required strength at release, initial and in-service camber. d. Shoring requirements. e. Detail inserts, connections, and joints, including accessories and construction at openings in precast units. 3. Provide layout, dimensions, and identification mark of each precast unit. Indicate welded connections by AWS standard symbols. Include erection procedure for precast units and sequence of erection. 4. Provide location, details, and instructions of anchorage devices to be embedded in other construction. Furnish templates if required for accurate placement. 1.6 DELIVERY, STORAGE, AND HANDLING A. Deliver structural precast concrete units to project site in such quantities and at such times to assure continuity of installation. Store units at project site to insure against cracking, distortion, staining, or other physical damage, and so that markings are visible. Lift and support units at designated lift points. B. Deliver anchorage items to be embedded in other construction before start of such work. PART 2 PRODUCTS 2.1 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 required finish surfaces. B. Accurately construct forms, mortar tight, of sufficient strength to withstand pressures due to concrete placing operations, temperature changes, and when prestressed, pretensioning and detensioning operations. Maintain formwork to provide completed precast concrete units of shapes, sizes, and dimensions indicated, within specified fabrication tolerances. C. Unless forms for plant-manufactured prestressed concrete units are stripped before detensioning, design forms so that stresses are not induced in precast units due to deformation of concrete under pre-stress or to movement during detensioning. D. Comply with ACI 347. 2.2 REINFORCING MATERIALS A. Comply with applicable requirements of Section 03200, Concrete Reinforcement. 2.3 PRE-STRESSING TENDONS A. Uncoated, 7-wire stress-relieved strand complying with ASTM A416, Grade 270, Low- Relaxation. Project No. SPECIFICATION GUIDELINES 03410-3

2.4 CONCRETE MATERIALS A. Comply with applicable requirements of Section 03300, Cast-In-Place Concrete. 2.5 CURING AND SEALING COMPOUNDS A. Comply with applicable requirements of Section 03300, Cast-In-Place Concrete. 2.6 CONNECTION MATERIALS A. Steel Shapes, Plates, and Bars: ASTM A36. B. Anchor Bolts: ASTM A307, Grade A, or ASTM A36, low-carbon steel bolts, regular hexagon nuts and carbon steel washers. C. Finish of Steel Units: Units exposed to non air-conditioned atmosphere in service shall be galvanized according to ASTM A153. Units exposed in air-conditioned atmosphere shall be painted with rust-inhibitive primer. D. Bearing Pads: Comply with requirements of Section 05820, Expansion and Isolation Bearings. E. Accessories: Provide clips, hangers, and other accessories required for installation of project units and for support of subsequent construction of finishes. 2.7 PROPORTIONING AND DESIGN OF MIXES A. Comply with applicable requirements at Section 03300, Cast-In-Place Concrete. B. Minimum 28 day strength shall be 6,000 psi, except soffit slab units may have a minimum strength of 4,000 psi at 28 days. 2.8 FABRICATION A. Fabricate precast concrete units complying with manufacturing and testing procedures and quality control recommendations of PCI MNL-116, and as specified for types of units required. B. Built-in Anchorages: Accurately position built-in anchorage devices and secure to formwork. Locate anchorages where they do not affect position of main reinforcement of placing of concrete. Do not relocate bearing plates in units unless acceptable to A/E. C. Coat surfaces of forms with bond-breaking compound before reinforcements 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 according to manufacturer's instructions. D. Clean reinforcement of loose rust and mill scale, dirt, and other materials that may reduce or destroy bond with concrete. E. Accurately position, support, and secure reinforcement against displacement by formwork, construction, or concrete placement operation. Locate and support reinforcing by metal chairs, runners, bolsters, spacers and hangers, as required. Project No. SPECIFICATION GUIDELINES 03410-4

F. Place reinforcement to obtain at least the minimum coverages for concrete protection. Arrange, space, and securely tie bars and bar supports to hold reinforcement in position during concrete placement operation. Set wire ties so ends are directed into concrete, not toward exposed concrete surfaces. G. Use single strand tensioning method or multiple-strand tensioning method requirements for pretensioning of tendons for prestressed concrete. Comply with PCI MNL-116. H. Comply with plastic shrinkage requirements of Section 03300, Cast-in-Place Concrete during concrete placing operations. I. Place concrete in a continuous operation to prevent formation of seams or planes of weakness in precast units, Comply with ACI 304. Thoroughly consolidate concrete by internal and external vibration without dislocation or damage to reinforcement and built-in items. J. Identification: Provide permanent markings to identify pickup points and orientation in structure, complying with markings indicated on final shop drawings. Imprint date of casting on each precast unit on a surface not showing in finished structure. 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 curing time. L. Delay detensioning of prestressed units until concrete has attained at design strength consistent with the design, as established by test cylinders. 1. If concrete has been heat-cured, perform detensioning while concrete is still warm and moist, to avoid dimensional changes that may cause cracking or undesirable stresses in concrete. 2. Detensioning of pretensioned tendons may be accomplished either by gradual release of tensioning jacks or by heat cutting tendons, using a sequence and pattern to prevent shock or unbalanced loading. M. 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 produced in forms that impart a smooth finish to concrete. Small surface holes caused by air bubbles, normal form joint marks, and minor chips and spalls will be tolerated. Major or unsightly imperfections, honeycomb, or structural defects are not allowed. 2. Commercial Finish: Remove fins and large protrusions and fill large holes. Rub or grind ragged edges. Faces shall be true, well-defined surfaces. 3. Architectural Grade B Finish: Air holes and pockets over 1/4" diameter filled with sand-cement paste, with form offsets or fins over 1/8" ground smooth. 4. Architectural Grade A Finish: In addition to Architectural Grade B Finish requirements, float coat exposed surfaces, with neat cement paste. After thin paste coat has dried, rub surfaces vigorously with burlap to remove loose particles. N. Finish of Unformed Surfaces: Apply trowel finish to unformed surfaces unless otherwise indicated. Consolidate concrete, bring to proper level with a straightedge, float, and trowel to a smooth, uniform finish. Project No. SPECIFICATION GUIDELINES 03410-5

1. Apply scratch finish to precast units receiving concrete topping after installation. Following initial strike-off, transversely scarify surface to provide ridges approximately 1/4" deep. 2.9 STRUCTURAL FRAMING UNITS A. Type: Precast prestressed concrete units including soffit beams, keystone joists, columns, beams, and inverted tee beams. B. Units shall be free of voids or honeycomb, with straight true edges and surfaces. C. Provide "Standard Finish" units as specified. 1. Where ends of strands will not be enclosed or covered, cut flush and cover with a high strength mortar bonded with an epoxy resin bonding agent. D. Adequately reinforce units to resist transporting and handling stresses. E. Include cast-in weld plates as required for anchorage or lateral bracing to other supporting members. F. Cooperate with other trades for the installation of items to be cast in precast structural framing units. Notify contractor of items not received in ample time so as to not delay work. G. Precast beam soffits shall have not less than 4 strands. Precast joists shall have not less than 2 strands. H. Manufacturer's production record of initial and final tension in pre-stressing strands and induced tension due to strand elongation during deflection (harping) shall be submitted to the A/E upon request. PART 3 EXECUTION 3.1 EXAMINATION A. Erector shall examine supporting structure and conditions under which precast concrete work is to be erected, and notify contractor in writing of conditions detrimental to proper and timely completion of work. Do not proceed with installation until unsatisfactory conditions have been corrected in a manner acceptable to erector. 3.2 INSTALLATION A. Joists and beam soffits shall be installed as soon after casting as is practicable. Joists with camber in excess of that shown on approved design calculations shall be subject to rejection by the A/E. Camber shall be managed by the manufacturer or under the direct supervision of the manufacturer, without scoring or other modification of the members. B. Bearing Pads: Install flexible bearing pads where indicated, as precast units are being erected. Set pads on level, on uniform bearing surfaces and maintain in correct position until precast units are placed. C. Welding: Perform welding according to AWS Dl.1-86 and AWS Dl.4-79. Project No. SPECIFICATION GUIDELINES 03410-6

D. Protect units from damage by field welding or cutting operations and provide noncontestable shield as required. E. Repair damaged metal surfaces by cleaning and applying a coat of liquid galvanizing repair compound to galvanized surfaces and compatible primer to painted surfaces. F. Powder and pneumatic actuated (shot-type) fasteners shall not be used for attachment of accessory items to precast and prestressed unit. G. Any drilling into precast and prestressed units shall be performed only with prior written approval by the A/E.Installation Tolerances: Install precast units without exceeding following tolerance limits: 1. Variations from Plumb or Design Slope: a. 1/4" at any 20 foot run or story height. b. 1/2" total at any 40 foot run or longer run. 2. Variations from Level: a. 1/4" at any 20 foot run. b. 1/2" at any 40 foot run. c. Total + 1/2" at any location. 3. Variation from Position in Plan: a. + 1/2" maximum at any location. 4. Offsets in Alignment of Adjacent Members at Any Joint: a. 1/4" maximum. H. Grouting Connections and Joints: After precast concrete units have been placed and secured, grout open spaces at connections and joints with cement grout. 3.3 PLANT QUALITY CONTROL EVALUATIONS A. The precast manufacturer shall allow the Board s testing facility access to materials storage areas, concrete production equipment, and concrete placement and curing facilities. Cooperate with the Board s testing laboratory and provide samples of materials and concrete mixes requested for additional testing and evaluation. B. Dimensional Tolerances: Units having dimensions smaller or greater than required, and outside specified tolerance limits, will be subject to additional testing as specified. 1. Precast units having dimensions greater than required will be rejected if appearance of function or the structure is adversely affected, or if larger dimensions interfere with other construction. Repair, or remove and replace rejected units as required to meet construction conditions. Project No. SPECIFICATION GUIDELINES 03410-7

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 affecting the strength of the precast units, including the following conditions: 1. Failure to meet compressive strength tests requirements. 2. Reinforcement and pretensioning and detensioning of tendons of prestressed concrete not complying with specified fabrication requirements. 3. Concrete curing and protection of precast units against extremes in temperature, not as specified. D. Testing Precast Units: When there is evidence that strength of precast concrete units does not meet specification requirements, the concrete testing service, with costs born by the manufacturer, shall take cores drilled from hardened concrete for compressive strength determination, complying with ASTM C42 and as follows: 1. Take at least 3 representative cores from precast units of suspect strength, from locations selected by A/E. 2. Test cores according to ACI 304 as follows: a. In a saturated-surface-dry condition if concrete will be wet during use of completed structure. b. In an air-dry condition if concrete will be dry during use of completed structure. 3. Strength of concrete for each series of cores will be considered satisfactory if their average compressive strength is at least 85 percent of 28-day design compressive strength. 4. Tests results will be made in writing on same day that tests are made, with copies to A/E, 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 of members represented by core tests, design compressive strength, compression breaking strength, and type of break (corrected for length-diameter ratio), direction of applied load to core with respect to horizontal plan of concrete as placed, and moisture condition of core at time of testing. E. Patching: 1. Where core test results in satisfactory and precast units are acceptable for use in work, fill core holes solid in compliance with Section 03600 - Grout. 2. Finish to match color and texture of adjacent concrete surfaces if exposed to view in completed structure. F. Defective Work: 1. Precast concrete units not complying with specified requirements, including strength, tolerances, and finishes,, shall be replaced with precast concrete units that meet requirements of this section. 2. The contractor shall also be responsible for the cost of corrections to any other work affected by or resulting from corrections to precast concrete work. END OF SECTION Project No. SPECIFICATION GUIDELINES 03410-8