2519Cellular Concrete

2519.1DESCRIPTION

This Work consists of using cellular concrete to fill the annular space between existing pipe Culvert and a new liner, fill embankments, backfill structures and fill abandoned pipe in accordance with 2104, “Removing Pavement and Miscellaneous Structures,” 2112, “Subgrade Preparation,” and 2461, “Structural Concrete.” A Definitions For the purpose of the Work specified in 2519,”Cellular Concrete” the Department defines: Cellular Concrete: A lightweight and flowable mixture of cement, water, and foaming agent. Segregated Areas: Areas where the surface exhibits a crunchy foamy top.

2519.2MATERIALS

Use base mix (slurry) from a Certified Ready-mix Plant in accordance with 2461.3F, “Certified Ready-mix Concrete.” Use mix 3G52 for concrete bulkheads. Use Type I or Type I/II cement.

Use Type IL cement. F Admixtures .............................................................................................................. 3113 and APL Anti-Washout Admixtures U.S. Army Corps of Engineers CRD-C661-06 G Foaming Agent ........................................................................................................... ASTM C869

2519.3CONSTRUCTION REQUIREMENTS

A Mix Design

A.1 Cellular Concrete Mix Design Design the cellular concrete mix to an absolute volume of 27 cubic feet in accordance with Table 2519.3-1. Table 2519.3-1 Cellular Concrete Mix Design Requirements Mix Number Maximum Designed Cast Density ASTM C796 (pounds/cubic foot) Maximum W/C Ratio Minimum 28-Calendar Day Compressive Strength ASTM C495 LCCF 30 0.55 40 psi CLSM LOW DENSITY 45 0.55 100 psi CLSM HIGH DENSITY 75 0.55 120 psi

B Submittals B.1 Cellular Concrete Mix Design Submit form CONC-208, Cellular Concrete Mix Design to the Concrete Engineer a minimum of 21 Calendar days before the initial cellular concrete placement. The Department will review the Contractor’s proposed concrete mix design solely for compliance with the applicable mix design properties in Table 2519.3-1. The Department makes no guaranty or warranty, either express or implied, that compliance with mix design properties ensures compliance with any other requirements. B.2 Placement Work Plan Submit a written placement work plan detailing the specific application methods to complete the placement of cellular concrete a minimum of 15 Calendar Days before placing cellular concrete. The plan must include the following, where applicable:

shoring.

exceeding the lift height of 4 feet.

certification and approval for Anti-washout product.

B.3 Cellular Concrete Density at point of placement Submit form CONC-701, Cellular Concrete Density Worksheet a maximum of 24 hours after placement. C Placing Cellular Concrete Incorporate foaming agent in accordance with the manufacturer’s recommended foam generating equipment for the mixing and production of the cellular concrete. Monitor pumping pressure during placement. Remove standing water from the subgrade surface. Temporarily suspend the mixing and placing operations and implement the Hot or Cold Weather Protection Plan if the National Weather Service forecast for the construction area predicts temperatures less than 33° F or greater than 100° F. Temporarily suspend placing cellular concrete and protect the work area if the National Weather Service forecast predicts rain in the construction area within 24 hours or as approved by the Engineer. C.1 CLSM Low Density and CLSM High Density Secure the pipe liner to the invert of the existing pipe Culvert. Install concrete bulkheads on both ends of the pipe Culvert. Finish the inlet end with a 45-degree mitered fillet-transition between the in-place pipe Culvert and the inside of the liner. Utilize a method of venting through the bulkheads or grouting ports at the crown to allow air to escape and to allow verification by the Engineer that the annular space has been filled. Place CLSM Low Density when minimal to no water is present in the annular space, otherwise use CLSM High Density. Place CLSM to grout the annular space between the existing pipe Culvert and pipe liner, including breaks or holes in the existing pipe Culvert . Completely fill the annular space along the entire length of the liner and pipe Culvert. Use cylindrical wooden plugs to plug CLSM entry holes. After the CLSM has set, remove the plugs, and fill with Mix No. 3G52 concrete or an approved non-shrink grout listed on the APL. C.2 Lightweight Cellular Concrete Fill (LCCF) C.2.a Embankment Fill Prepare the subgrade as shown in the Plans and in accordance with 2112, “Subgrade Preparation.” Provide temporary shoring to support the placement of the LCCF. Place LCCF in maximum lifts of 4 feet. Move the discharge hose sufficiently to ensure level filling though the specified area. Avoid excessive handling of the LCCF to prevent segregation. Place subsequent LCCF lifts 12 hours after prior LCCF placement. Finish the final LCCF surface to within 0.05 feet above to 0.10 feet below the cross - section shown on the plans.

Protect the final LCCF surface from backfilling or construction loading a minimum of 24 hours after placement or until the LCCF reaches a compressive strength of 20 pounds per square inch. Obtain Engineer acceptance of LCCF prior to backfilling or applying load on the final surface. Temporarily cover the LCCF with polyethylene plastic sheet if the final LCCF surface is not backfilled within 36 hours of LCCF placement. Remove and replace segregated areas. C.2.b Backfilling Structure Provide temporary shoring to support the placement of the LCCF, when required. Place LCCF in maximum lifts of 4 feet. Move the discharge hose sufficiently to ensure level filling though the specified area. Avoid excessive handling of the LCCF to prevent segregation. Place subsequent LCCF lifts 12 hours after prior LCCF placement. Finish the final LCCF surface to within 0.05 feet above to 0.10 feet below the cross - section shown on the plans. Protect the final LCCF surface from backfilling or construction loading a minimum of 24 hours after placement or until the LCCF reaches a compressive strength of 20 pounds per square inch. Obtain Engineer acceptance of LCCF prior to backfilling or applying load on the final surface. Temporarily cover the LCCF with polyethylene plastic sheet if the final LCCF surface is not backfilled within 36 hours of LCCF placement. C.2.c Filling Abandoned Pipes Remove and dispose of debris from the pipe in accordance with 2104.3D.3, Disposal Outside Rightofway.” Place LCCF when minimal to no water is present in the pipe, otherwise place CLSM High Density. Install concrete bulkheads with injection points capable of withstanding the required pumping pressure. Locate injection points at intervals to allow adequate inspection ports. D Quality Control Sample and test cellular concrete in accordance with the Schedule of Materials Control. Measure the density at the point of placement in accordance with ASTM C796, Standard Test Method for Foaming Agents for Use in Producing Cellular Concrete Using Preformed Foam. Record the density on form CONC-701 Cellular Concrete Density Worksheet and adjust the mix as required to obtain the specified cast density during placement. Maintain the cellular cast density within 3 pounds per cubic foot of the cast density design. Cast cylinders in accordance with ASTM C495, Standard Test Method for Compressive Strength of Lightweight Insulating Concrete. Cure cylinders in accordance with 2461.3G.5.b , “Standard Strength Cylinders.” The Department will transport the cylinders in accordance with 2461.3G.5.b(3), “Transporting Cylinders,” and test the cylinders at the Office of Materials and Road Research in accordance with ASTM C495, Standard Test Method for Compressive Strength of Lightweight Insulating Concrete (do not oven dry before testing).

2519.4METHOD OF MEASUREMENT

The Engineer will measure cellular concrete by the volume as verified from the computerized Ready-mix Certificate of Compliances multiplied by the expansion factor of the cellular concrete identified on the MnDOT reviewed Cellular Concrete mix design with consideration of any waste as agreed upon with the Engineer.

2519.5BASIS OF PAYMENT

The Contract Unit Price for cellular concrete is compensation in full for Equipment, Materials and labor required to complete the Work. The Engineer will reject damaged cellular concrete in accordance with 1503, “Conformity with Contract Documents” and 1512, “Unacceptable and Unauthorized Work.” Use of CLSM High Density in place of CLSM Low Density or LCCF will be paid for as Extra Work in accordance with 1402.2, “Differing Site Conditions.” The Department will pay for cellular concrete on the basis of the following schedule : Item No. Item Unit

2519.507 CLSM Low Density cubic yard

CLSM High Density Lightweight Cellular Concrete Fill cubic yard cubic yard