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Plant-Precast Architectural Concrete

Standard Specification Section 03450

Plant-Precast Architectural Concrete PDF

Plant-Precast Architectural Concrete DOC

PART 1 - GENERAL

1.1 SECTION INCLUDES

Architectural precast concrete wall panels.
Architectural precast concrete lintels, sills, copings, and trim.
Architectural precast concrete pavers
Supports, anchors, and attachments.
Perimeter and intermediate joint seals.
Grouting under panels.Manufacturer shall furnish Cast Stone covered by this specification.
Installing contractor shall unload, store, furnish all anchors, set, patch, clean and seal (optional) the Cast Stone as required.

1.2. RELATED SECTIONS

Section 03300 - Cast-in-Place Concrete: Building structural frame.
Section 03380 - Post Tensioned Concrete: Building structural frame.
Section 03410 - Plant-Precast Structural Concrete: Building structural frame.
Section 03470 - Tilt-Up Precast Concrete: Building structural frame.
Section 03415 - Precast Concrete Hollow Core Planks: Building structural floor.
Section 05120 - Structural Steel: Building structural frame.
Section 07620 - Flashing and Sheet Metal.
Section 07900 - Joint Sealers.
Section 04720 – Architectural Cast Stone

1.3 REFERENCES

American Concrete Institute.

ACI 211.1 - Normal, Heavy Weight, and Mass Concrete, Practice for Selecting Proportions; 1991.
ACI 318 - Building Code Requirements for Reinforced Concrete; 2002.
ACI 533R - Guide for Precast Concrete Wall Panels; 1993.

ASTM International.

ASTM A 36/A 36M - Standard Specification for Carbon Structural Steel; 2001
ASTM A 47/A 47M - Standard Specification for Ferritic Malleable Iron Castings; 1999.
ASTM A 123/A 123M - Standard Specification for Zinc (Hot-Dipped Galvanized) Coatings on Iron and Steel Products; 2002.
ASTM A 153/A 153M - Standard Specification for Zinc Coating (Hot Dip) on iron and Steel Hardware; 2002.
ASTM A 185 - Standard Specification for Steel Welded Wire, Fabric, Plain, for Concrete Reinforcement; 2001.
ASTM A 283/A 283M - Standard Specification for Low and Intermediate Tensile Strength Carbon Steel Plates; 2000.
ASTM A 307 - Standard Specification for Carbon Steel Bolts and Studs, 60,000 PSI Tensile Strength; 2002.
ASTM A 325 - Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength; 2002.
ASTM A 325M - Standard Specification for High Strength Bolts for Structural Steel Joints; 2000
ASTM A 416/A 416M - Standard Specification for Steel Strand, Uncoated Seven-Wire for Prestressed Concrete; 1999.
ASTM A 496 - Standard Specification for Steel Wire, Deformed, for Concrete; 2001.
ASTM A 500 - Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes; 2001a.
ASTM A 563 - Standard Specification for Carbon and Alloy Nuts; 2000.
ASTM A 572/A 572M - Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel; 2001.
ASTM A 615/A 615M - Standard Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcement; 2001b.
ASTM A 767/A 767M - Standard Specification for Zinc-Coated (Galvanized) Bars for Concrete Reinforcement; 2000b.
ASTM A 934/A 934M - Standard Specification for Epoxy-Coated Prefabricated Steel Reinforcing Bars; 2001.
ASTM C 33 - Standard Specification for Concrete Aggregates; 2002a.
ASTM C 39/C 39M - Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens; 2001.
ASTM C 150 - Standard Specification for Portland Cement; 2002a.
ASTM C 260 - Standard Specification for Air-Entraining Admixtures for Concrete; 2001.
ASTM C 330 - Standard Specification for Lightweight Aggregates for Structural Concrete; 2002b.
ASTM C 404 - Standard Specification for Aggregates for Masonry Grout; 1997.
ASTM C 494/C 494M - Standard Specification for Chemical Admixtures for Concrete; 1999a.
ASTM C 642- Standard Test Method for Density, Absorption, and Voids in Hardened Concrete; 1997.
ASTM C 979 - Standard Specification for Pigments for Integrally Colored Concrete; 1999.
ASTM C 1107 - Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Nonshrink); 2002.
ASTM C 1240 - Standard Specification for Use of Silica Fume as a Mineral Admixture in Hydraulic-Cement Concrete, Mortar and Grout; 2003.
ASTM D 412 - Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers-Tension; 1998a.
ASTM F 593 - Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs; 2002.

American Welding Society.

AWS D1.1/D1.3M - Structural Welding Code; 2003.
AWS D1.4 - Structural Welding Code - Reinforcing Steel; 1998.

Cement and Concrete Reference Laboratory (CCRL).
Concrete Reinforcing Steel Institute (CRSI).

CRSI - Manual of Standard Practice; 2001.

Department of Defense (DOD).

DOD P-21035A - Galvanizing Repair Specification.

Precast/Prestressed Concrete Institute.

PCI MNL-117 - Manual for Quality Control for Plants and Production of Architectural Precast Concrete Products; 1996.

Steel Structures Painting Council (SSPC).

SSPC Paint 20 - Zinc-Rich Primers (Type I, Inorganic, and Type II, Organic); 2002.
SSPC Paint 25 - Zinc Oxide, Alkyd, Linseed Oil Primer for Use Over Hand Cleaned Steel, Type I and Type II; 1997.

American Institute of Steel Construction (AISC).

1.4 SUBMITTALS

Submit under provisions of Section 01300.
Product Data: Submit product data for manufactured materials and products.
Shop Drawing:

Show in-place location, manufacturing details, plans, elevations, anchorages, reinforcement, connection details and methods, dimensions, finishes, relationships to adjacent materials, and erection and placement.
Show identification marks, coordinated to Shop Drawings, and date of manufacture on all units to facilitate hauling and erection.
Setting diagrams, templates, instructions and directions as required for installation.

Engineering Calculations: Engineering calculations as required sealed by an engineer licensed to practice in (project state).
Mix Design(s): Proposed concrete mix design for each type and color of concrete mix required including backup mix.
Material Test Reports: Submit material certificates signed by manufacturer for concrete materials, reinforcing materials, admixtures, and similar items.
Certifications:

Manufacturer’s certification from APA, PCI, or applicable municipal certifications.
Welder’s AWS certification. Submit for each welder.

Selection Samples: For each finish product specified, two complete sets of color chips representing manufacturer's full range of available colors, textures, and patterns.
Verification Samples: For each finish product specified, two samples, approximately 12 inches (300 mm) square, representing actual product, color, texture, and patterns.

1.5 QUALITY ASSURANCE

Manufacturer’s Qualifications.

Firm shall have a minimum of five years experience in producing units similar to those required for this Project, with sufficient production capacity to produce and deliver required units without causing delay in Work.
Fabricating plant shall be certified by one of the following:

Architectural Precast Association (APA).
Precast/Prestressed Concrete Institute (PCI), Group A1.
Or Equal Certification Program.

Installer’s Qualifications: Installer shall have a record of at least five years of successful installation of units similar to those required for this Project.
Welder’s Qualifications: Provide certification that welders to be employed in the Work are certified by AWS and applicable local building officials, and have been re-certified in the last 12 months.
Mock-Up: Provide a mock-up for evaluation of surface finishes and workmanship.

Provide initial production units for job-site assembly with other materials for approval. Coordinate type and location of mock-ups with project requirements. Accepted units will be used as the standard for acceptance of production units. Remove and replace units which are not accepted.
Do not proceed with remaining work until workmanship, color, and finish are approved by Architect.
Refinish mock-up area as required to produce acceptable work.
Incorporate accepted mockup as part of Work.

1.6 DELIVERY, STORAGE, AND HANDLING

Deliver, store and handle precast in strict compliance with manufacturer's instructions and recommendations and industry standards Protect from damage. Lift and support units only at designated lifting points as shown on approved Shop Drawings.
Deliver units to the Project site in such quantities and at such times to ensure continuity of installation.
Handle precast units to position, consistent with their shape and design. Lift and support only from support points.
Provide anchorage items to be embedded in or attached to other construction without delaying the Work. Provide setting diagrams, templates, instructions and directions as required for installation.
Blocking and Lateral Support During Transport and Storage: Clean, non-staining, without causing harm to exposed surfaces. Provide temporary lateral support to prevent bowing and warping.
Protect units to prevent staining, chipping, or spalling of concrete.
Mark units with date of production in location not visible to view when in final position in structure.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

Acceptable Manufacturer:

Pedroni's Cast Stone; 5169 Edgewood Court, Jacksonville, FL, 32569. Tel: (904) 783-1690. Fax: (904) 783-0143. Email: sales@pedroniscaststone.com Web: www.pedroniscaststone.com

Substitutions: Not permitted.
Requests for substitutions will be considered in accordance with provisions of Section 01600.

2.2 APPLICATIONS/SCOPE

Design units to withstand design loads as calculated in accordance with applicable code, and erection forces. Calculate structural properties of units in accordance with ACI 318.

Wind Loads.
Seismic forces.
Building dynamics, thermal, live, impact or concentrated loads, structural deflection, story drift.

2.3 MATERIALS

Concrete Materials:

Portland Cement: Complying with ASTM C 150, Type I or III, white or gray colors to achieve desired finish colors. Use only one brand, type, and color from the same mill. Gray cement may be used for non-exposed backup mixes.
Aggregates: Complying with ASTM C 33, gradation may differ to achieve desired finish characteristics. Select coarse and fine aggregate colors and screen sizes to match approved sample(s). Verify that adequate supply, from one pit or quarry, for each type of aggregate is available for the entire Project. If possible obtain entire aggregate supply prior to starting Work, or have aggregate supply held in reserve by aggregate supplier.
Lightweight aggregate: Complying with ASTM C 330.
Water: Potable. Clean, clear, and free from deleterious amounts of salts, acids, alkalies, organic materials, oils, detergents, or other matter that may interfere with color, curing, or strength of concrete.
Admixtures: Select to be compatible in specified mix.

Air Entraining: Complying with ASTM C 260.
Water Reducing: Complying with ASTM C 494, Type A, B, C, For G.
Silica Fume: Complying with ASTM C 1240, for cement replacement for high performance concrete.
Coloring Agent: Complying with ASTM C 979, compatible with other concrete materials.
Other constituents: Integral water repellents and other chemicals for which no ASTM standard exists, shall be previously established as suitable for use in concrete or shall be shown by test or experience not to be detrimental to the concrete.

Formwork:

Provide forms with acceptable form facing materials that are non-reactive with concrete or form release agents and will produce required finish surfaces.
Construct and maintain forms to produce precast concrete units of shapes, lines, and dimensions indicated, within specified tolerances.

Reinforcing Materials:

Reinforcing Bars: Complying with ASTM A 615/A 615M, Grade 40 or 60, unless otherwise required to meet structural requirements.
Galvanized Reinforcing Bars: Complying with ASTM A 767/A 767M, hot-dip galvanized; use where concrete cover is less than 1-1/2 inches.
Epoxy Coated Reinforcing Bars: Complying with ASTM A 934; use in special applications where indicated.
Steel Welded Wire Fabric: Complying with ASTM A 185, plain, cold drawn.
Pre-Stressing Tendons: Complying with ASTM A 416/A 416M, Grade 250 or 270, uncoated, 7 wire, low relaxation strand.

Connection Materials:

Steel Shapes and Plates: Complying with ASTM A 36/A 36M.
Malleable Iron Castings: Complying with ASTM A 47/A.47M.
Carbon Steel Plates: Complying with ASTM A 283/A 283M.
High Strength, Low Alloy Structural Steel: Complying with ASTM A 572.
Carbon Steel Structural Tubing: Complying with ASTM A 500, Grade B.
Anchor Bolts: Complying with ASTM A 307, carbon steel or ASTM A 325 (ASTM A325M), high strength; bolts nuts, and washers.
Welded Headed Studs: Complying with AWS D1.1/D1.3M, Type B.
Deformed Steel Wire Bar Anchors: Complying with ASTM A 496.
Stainless Steel Plate: Complying with ASTM F 593, Type 304 or Type 316; bolts and studs, nuts and washers. Note that selection of stainless steel will result in increased costs.
Finish for Steel Connection Materials:

Hot-dip galvanize steel exposed to weather in final assembly complying with ASTM A 123/A 123M or ASTM A 153/A 153M.
Shop Prime Remaining Steel Shapes: Complying with SSPC Paint 25.
Anchor Bolts, Nuts, Washers, Cadmium Plated: Complying with ASTM A 563, Grade C.
Hot-dip galvanize setting bolts or projecting steel in masonry applications complying with ASTM A 153/A 153M.
Galvanizing Repair Paint: Complying with DOD P-21035A or SSPC Paint 20.
Welding Electrodes: Comply with AWS Standards.

Bearing Pads: Elastomeric pads, complying with ASTM D 412.
Grout Materials:

Cement Grout: Cement complying with ASTM C 150; sand complying with ASTM C 404; proportions 1:2.5 by volume, minimum water for placement and hydration.
Non-Shrink Grout: Complying with ASTM C 1107.
Epoxy Grout: Consult Suppliers.

2.4 MIXES

Design mixes for each type of concrete specified shall be prepared by an independent testing agency or by an architectural precast manufacturing plant at precast manufacturer’s option. Proportion mixes by either testing agency trial batch or field test data methods in accordance with ACI 211.1, using materials to be used on the Project, to provide concrete with properties as follows:

Concrete Density: Normal weight.
Concrete Density: Lightweight.
Compressive Strength: 5,000 psi (35 MPa) when tested in accordance with ASTM C 39/C 39M.
Maximum water cement ratio 0.40 at point of placement.
Add air-entrainment admixture to result in air content at point of placement complying with ACI 533R requirements.
Water absorption maximum 6% (by weight) when tested in accordance with ASTM C 642.

2.5 MANUFACTURING

General:

Fabricate precast concrete units with manufacturing and testing procedures, quality control recommendations, and dimensional tolerances as specified in PCI MNL-117 or ACI 533R, unless more stringent requirements are shown or specified.
Fabricate units straight, smooth and true to size and shape, with exposed edges and corners precise and square, unless otherwise indicated.

Cast openings larger than 10 inches (254 mm) in any dimension according to locations shown on Shop Drawings. Smaller holes may be field cut when approved by Architect.
Reinforcement: Comply with CRSI Manual of Standard Practice, PCI MNL-117, or ACI 533R recommendations. Reinforce architectural precast concrete units to resist handling, transportation, and erection stresses, and to comply with specified performance criteria.
Pretension tendons for units in compliance with PCI MNL-117 or ACI 533R.
Cast-in Items: Provide embedded anchors, inserts, steel shapes, and lifting devices as shown on reviewed Shop Drawings. Window connections are best made by field drilled inserts. Firmly hold cast items in place by jigs, strongbacks, or other approved means.
Comply with PCI MNL-117 or ACI 533R requirements for measuring, mixing, transporting, and placing concrete. Place facing mix to a thickness of the greater of 1 inch (26 mm) or 1.5 times the maximum aggregate size. Place back-up concrete to ensure bond with face concrete.
Consolidate concrete using equipment and procedures complying with PCI MNL-117 or ACI 533R.
Permanently mark units with pick-up points as shown on reviewed Shop Drawings. Imprint casting date and piece mark on a surface to be concealed from view in the finished structure.
Cure concrete in accordance with PCI MNL-117 or ACI 533R requirements.
Discard units that are warped, cracked, broken, spalled, stained, or otherwise defective unless repairs are approved by the Architect and meet specified requirements. Refer to ACI-533R for product finish requirements unless otherwise shown or specified.
Manufacturing Tolerances: Fabricate to tolerances listed in PCI MNL-117 or ACI 533R.

2.6 FINISHES

Finish exposed surfaces or units to match Architect’s design reference sample.
Finish exposed surfaces or units to match APA and PCI “Architectural Precast Concrete-Color and Texture Selection Guide” of Plate Numbers Indicated.
Finish exposed surfaces or units in accordance with the following:

Smooth surface finish free from pockets, sand streaks, honeycomb, with uniform color and texture. State whether bugholes less than 5/8 inch (16 mm) in diameter are acceptable.
Textured surface finish from form liners or inserts.
Machine textured finish, using power or hand tools to remove matrix and fracture coarse aggregate.
Retarded finish, using chemical retarding agents applied to forms, with washing and brushing procedures to expose aggregate and surrounding matrix.
Abrasive blast finish, using abrasive grit, equipment, application and cleaning procedures to expose aggregate and surrounding matrix.
Acid etched finish using acid solution and application techniques to expose aggregate and surrounding matrix.
Honed or Polished finish using mechanical abrasion, followed by filling and rubbing procedures.
Sand embedment finish, using selected coarse aggregate placed in a sand bed in the bottom of the mold, with sand removed after removal from the mold.
Applied material finish, using selected ceramic or natural stone materials, specified in Section 04400.

Finish Exposed Back Surface of Units:

To match face surface of units.
By smooth, steel trowel finish.

Finish unexposed surfaces of units by float finish or as-cast form finish.

2.7 SOURCE QUALITY CONTROL

Inspect and test architectural precast concrete in accordance with PCI MNL-117 or ACI 533R.
The Owner may retain an independent Testing Laboratory to evaluate manufacturer’s quality control and testing methods. Testing Laboratory shall be certified by CCRL or similar National authority. Manufacturer shall allow Testing Laboratory access to all operations pertinent to the Project.
Defective Work: Discard units that do not conform to requirements as shown or specified. Replace with units which meet requirements.

PART 3 - EXECUTION

3.1 EXAMINATION

Do not begin installation until substrates have been properly prepared.
Field Dimensions: Furnish field dimensions to manufacturer as required.
Examine substrates and conditions for compliance with requirements for installation, tolerances, true and level bearing surfaces, and other conditions affecting performance of architectural precast concrete units.
If substrate preparation is the responsibility of another installer, notify Architect of unsatisfactory preparation before proceeding.
Do not install units until supporting structure has been completed and has attained minimum allowable design compressive strength.

3.2 ERECTION

Erect units using personnel experienced and trained in placement and securing of precast concrete units.
Lift and handle precast using lift points and embeds as shown on approved shop drawings.
Erect level, plumb, and true to line. Do not allow cumulative dimensional errors to develop.

Adjustments such as shimming which would place additional stress on units shall not be permitted.
Adhere to dimensional tolerances in accordance with PCI recommendations.

Erect and secure in a manner to prevent damage to units or units in place.
Erection Tolerances. Erect within tolerances listed in PCI MNL-117 Appendix I or ACI 533R.
Joint Sealants: As specified in Section 07900.
Where two stage joint seal is required, sequence with sealant application to ensure that sealant, gaskets, and similar items required for interior side seal are installed concurrently with installation of precast units.

3.3 CLEANING

Clean exposed surfaces of units after erection if soiled or stained.

Wash and rinse according to architectural precast concrete manufacturer’s recommendations. Protect other work from damage while cleaning.
Do not use cleaning materials or methods that change the appearance of architectural precast concrete finishes. Test clean a small area to verify adequacy and safety of materials and methods.
Leave in condition for application of water repellents specified in Section 07190.

3.4 PROTECTION

Subsequent trades to Protect finished surfaces from soiling or damage.
Touch-up, repair or replace damaged products before Substantial Completion.

Repair exposed surfaces of units to match color, texture, and uniformity of surrounding units.
Remove and replace damaged units when repairs do not meet requirements.

3.5 SCHEDULE

Item: