499Concrete — General

499.01Description. This specification consists of proportioning requirements for portland

cement concrete mix designs, mixing, adjustments and controls, and batch plant requirements for portland cement concrete.

499.02Materials. Furnish materials conforming to:

Portland cement ..... 701.01, 701.02, 701.04

701.05, 701.09, 701.15, 701.16, 701.17 or blended cement[1]

Micro-silica ...................................... 701.10 Slag cement ...................................... 701.11 Fly ash or natural pozzolan .............. 701.13 Fine aggregate [2][3] ........................... 703.02 Coarse aggregate[3] ........... 703.02, 703.13[4] Recycled Concrete Aggregate (RCA)Supplement 1117 Air-entraining admixture ................. 705.10 Chemical admixture for concrete[5] .. 705.12 Carbonate micro-fines ...................... 705.27 Macro-fibers[6] ................................. 705.29 [1] If blended cement is used, provide mill certification of all the cement and pozzolanic components and final product for approval by the Office of Materials Management [2] 703.02 natural sand or sand manufactured from stone as specified in Item 703.02.A.3 is required in 255, 256, 451, 452, 526, and 511 deck slabs. [3] Aggregates may be standard gradation sizes from 703.02 and Table 703.01-1 or they may be a modified gradation defined with the mix design submittal and certified by the Office of Materials Management under Supplement 1069. [4] Applies only to 305, 451 and 452 concrete. [5] Admixtures shall contain no more than 50 parts per million chlorideions by weight of cement except for Type C accelerating admixtures or calcium chloride for QC RS only. [6] Applies only to Class QC RS. Use water for concrete mixing free from sewage, oil, acid, strong alkalis, vegetable matter, clay, and loam. Potable water is satisfactory for use in concrete. Non -potable water will meet the requirements of ASTM C1602. Water from a reclaiming system will contain no more than 0.06% chlorides. Test the non-potable water monthly and maintain data verifying that the water meets the requirements. Provide the data at the Engineer’s request.

499.03Concrete Mix Designs. Develop concrete mix designs with 1 -inch maximum nominal

size coarse aggregate according to ACI 301, Section 4 meeting the requirements of Table 499.03-1. Limit the pozzolan and carbonate micro-fines content of any mix design according to Table 499.03-2 and Table 499.03-3. The design air for concrete with 1 -inch nominal maximum size aggregate is 7%. Develop concrete mix designs per this specification and Supplement 1126. Only use mix designs accepted by the Department and issued a JMF number. 287 TABLE 499.03-1 CONCRETE MIX DESIGN REQUIREMENTS Quantities per Cubic Yard Provide Concrete with 7±2% Air Content Class Design Strength psi (MPa) Permeability [1] Maximum (Coulombs) Surface Resistivity [2] Minimum (kΩ-cm, α = 1.5) Paste Volume Maximum [11] Shrinkage Maximum [11] Aggregate Requirements QC 1 4,000 (28.0) at 28 days 2,000 21 N/A N/A Well-Graded QC 1P[8] [9] 4,000 (28.0) at 28 days 2,000 21 28% 0.050% Well-Graded QC 2 4,500 (31.0) at 28 days 1,500 29 28% 0.050% Well-Graded QC 3 Special As per plan 1,500 or as per plan 29 or as per plan 28% or as per plan 0.050% or as per plan Well-Graded or as per plan QC 4 Mass Concrete [4] [5] 4,000 (28.0) or as per plan [3] 2,000 or as per plan 21 or as per plan N/A N/A Well-Graded or as per plan QC 5 [7] 4500 (31.0) at 28 days N/A N/A N/A N/A 1 inch or 3/8- inch nominal maximum size QC SCC [7] 4500 (31.0) at 28 days 1,500 or as per plan 29 or as per plan N/A N/A Well-Graded, 1 inch or 3/8-inch nominal size or as per plan QC MS See Supplement 1126 N/A N/A N/A N/A 1-inch nominal maximum size QC RS[10] See Supplement 1126 2,000 21 N/A N/A Well-Graded QC Misc. [6] 4,000 (28.0) at 28 days N/A N/A N/A N/A 1-inch nominal maximum size [1] AASHTO T277 Modified. Mix design must meet either permeability or resistivity requirement. [2] AASHTO T358 Modified. Mix design must meet either permeability or resistivity requirement. [3] Strength for Mass Concrete (QC 4) may be tested at either 28 or 56 days. [4] Do not use Type III cement or accelerating admixtures in mass concrete. [5] The maximum fly ash, natural pozzolan, or slag cement content may be increased up to 50%. [6] For QC Misc. mixes only –Water/Cementitious ratio limited to 0.50 maximum. [7] For QC 5 and QC SCC mixes with 3/8-inch nominal size, provide an air content of 8±2%. [8] Portland cement concrete pavement mix design. [9] QC 1P may be used in lieu of QC 1. QC 1 may not be used in lieu of QC 1P. [10] Provide QC RS with 6±2% air content. [11] Mix design must meet either Paste Volume or Shrinkage requirement. Shrinkage is determined per ASTM C157 Modified. 288 Determine the permeability by testing according to AASHTO T277 except moist cure the permeability samples for 7 days at 73 °F (23 °C) followed by 21 days of moist curing at 100 °F (38 °C). Perform permeability testing at 28 days. Determine the resistivity by testing according to AASHTO T358 except test 4” x 8” cylinders cured in lime-water. Perform resistivity testing at 28 days. Paste volume is the sum of the liquid and total cementitious material volume expressed as a percentage of the total volume per cubic yard of concrete. Determine the shrinkage by testing according to ASTM C157 except in section 10.3 replace 28 day storage in lime-water with 7 days and test in accordance with 11.1.2 Air Storage with readings at 4, 7, 14, and 28 days. Limit pozzolan materials as a percent of total cementitious content according to Table 499.03-2: TABLE 499.03-2 POZZOLAN MATERIALS Materials Maximum Content (%) Fly Ash 25 Natural pozzolan 25 Slag Cement 30 Micro-Silica 10 When using multiple pozzolan materials, do not exceed the individual maximum contents above for each material. A combination of pozzolan materials may not exceed 50% of the total cementitious content by weight. Limit carbonate micro-fines as a percent of total cementitious content according to Table 499.03- 3: TABLE 499.03-3 CARBONATE MICRO-FINES MATERIALS Material Maximum Content (%) Carbonate Micro-Fines 20 Do not use carbonate micro-fines in Class QC 2 or QC 3 concrete.

of water to meet slump requirements. Water -reducing admixtures conforming to the requirements of

705.12may also be used or adjusted to meet slump requirements. Do not use concrete with a slump

greater than the maximum shown in Table 499.03-4. Conduct tests on the plastic concrete for pavement at the point of placement or at an Engineer-designated location. 289 TABLE 499.03-4 CONCRETE SLUMP Type of Work Nominal Slump inch (mm)[1] Maximum Slump inch (mm)[2] Concrete pavement (305, 451, 452, 615) 1 to 3 (25 to 75) 4 (100) Structural Concrete (511, 622) 1 to 4 (25 to 100) 5 (125) Superstructure concrete (511, 526) 2 to 4 (50 to 100) 4 (100) Non-reinforced concrete (601, 602, 611, 608, 609, 622) 1 to 4 (25 to 100) 5 (125) [1] This nominal slump may be increased to 6 inches (150 mm), provided the increase in slump is achieved by adding a chemical admixture conforming to the requirements of

, Type F or G

[2] This maximum slump may be increased to 7 inches (180 mm), provided the increase in slump is achieved by adding a chemical admixture conforming to the requirements of

, Type F or G

Maintain slump flow within the nominal slump flow range in Table 499.03-5. Do not use concrete with a slump flow greater than the specified maximum for the SCC Class shown in Table 499.03-5. Test for slump flow and Visual Stability Index (VSI) according to ASTM C1611. Provide a VSI of zero (0) or one (1) according to the Appendix in ASTM C1611. TABLE 499.03-5 CONCRETE SLUMP FLOW SCC Class Minimum Slump Flow inch (mm) Nominal Slump Flow inch (mm) Maximum Slump Flow inch (mm) Class I 18 (460) 20 (508) 22 (560) Class II 22 (560) 24 (600) 26 (660) Class III 26 (660) 28 (710) 30 (760)

percentage range specified in Table 499.03-1.

499.04Adjustments and Controls. Provide the following adjustments and controls during batching

and placement of the concrete:

Adjustments to the JMF’s aggregate proportions up to 100 lbs (44 kg) for workability may be made. Adjustments greater than 100 lbs (44 kg) may be made if appr oved by the Engineer . Maintain an absolute volume of 27.0 cubic feet/cubic yard for the adjusted concrete mix. For Well Graded JMF adjustments, maintain the combined aggregate gradation within the optimal zone II requirements and the Tarantula Curve limits for well-graded mixes as defined in Supplement 1126. If outside the optimal zone II of the Coarseness Factor Chart or the Tarantula Curve limits of the Tarantula Curve adjust the JMF’s proportions to maintain the combined gradation within Zone II and the Tarantula Curve limits and report the JMF changes to the Engineer.

uniform grading within the specified gradation. Do not combine aggregates from different sources or 290 of different gradings in the same stockpile. Do not use segregated or contaminated aggregates. Keep aggregate stockpiles at or above SSD condition prior to batching.

the aggregates. Perform moisture burn offs on all aggregates prior to concrete production. For bridge deck concrete, perform a moisture burn off 2 hours prior to the start of concrete placement. Provide moisture burn off calculations showing the free moisture of each aggregate prior to batching concrete.

manufacturer’s recommendations. Furnish a volumetric dispenser for the Type F or G admixture or ensure that there is a gage on each truck -mounted Type F or G admixtur e dispensing tank. If any admixture is added at the job site, mix the load for a minimum of 5 minutes.

accepted JMF. Use a water -reducing admixture conforming to 705.12 or develop and submit for acceptance a new JMF.

with further mixing. If after corrective action, balling continues, reject the load. Revise the mixing process and/or loading sequence to prevent further balling.

adjusted to restore plasticity with a Type F or G chemical admixture conforming to 705.12, additional water, or both, only if the maximum water -cementitious ratio of the accepted JMF is not exceeded. Mix for a minimum of 30 revolutions at mixing speed after addition of admixture, water, or both. Inform the Inspector, record all adjustments, and confirm compliance with 499.03.A. The Engineer will recheck the slump and air content to ensure conformance to the specification. If after any adjustment the components of the load are segregated, the Department will reject the load.

499.08

project requirements.

temperature exceeds a nominal temperature of 75 F (24 C).

499.05Equipment. Use a Department approved batch plant and trucks. Provide batching and mixing

equipment meeting the following requirements:

no intermingling of the materials before batching. Use weighing mechanisms that allow a visible means of checking weights and produce a printed record. Use dispensing mechanisms for water and admixtures that allow a visible means of checking quantities and produce a printed record. Use cement and aggregate weighing mechanisms that are accurate to within 0.5 percent of the correct weight. Ensure that devices for weighing or metering water are accurate to 1.0 percent throughout the range used. Maintain a certification from a Sealer of Weights and Measures or a scale servicing company attesting to the accuracy of the weighing and metering devices. A Certificate of Performance issued by the National Ready Mixed Concrete Association may be used instead of the Sealer of Weights and 291 Measures or a scale servicing company. Do not use plants with a certification or certificate older than 12 months Maintain the services of a scale servicing company or ten standard test weights to reach a capacity of 500 pounds (227 kg) for testing the weighing devices at the batch plant. Ensure all device -testing weights are sealed by the Ohio Department of Agriculture every 3 years. The Engineer may test weighing and dispensing devices as often as necessary to ensure continued accuracy.

and 11.6, except that the Department will allow mechanical counters. For bodies of non -agitating concrete hauling equipment, provide smooth, mortar -tight, metal containers capable of discharging the concrete at a satisfactory controlled rate without segregation. Provide covers when required by the Engineer . The Engineer will allow trucks having dump bodies with rounded corners and no internal ribs or projections for non-agitating hauling.

equipment in accordance with ACI 304.2R and ACI 304.4R . Conduct a pre -placement meeting to discuss concrete pumping and conveying procedures to maintain air content within specified limits per Table 499.03-1.

C685, Sections 7, 8, 9, 10, 11, 13, and 14. Mixers must have rating plates indicating that the performance of the mixer is in accordance with the Volumetric Mixer Manufacturer Bureau or equivalent. Mix concrete in accordance with the manufacturer’s recommended procedures. The volumetric mixer must be capable of carrying sufficient unmixed dry bulk cement, supplementary cementitious materials, coarse and fine aggregate, admixtures and water, in separate compartments and accurately proportion the approved JMF. E ach volumetric mixer shall be equipped with an onboard ticketing system that will electronically produce a record of all material used and their respective weights and the total volume of concrete placed. Place no more than 30 cubic yards (23 m 3) per unit per day. Limit the use of volumetric truck mixers to QC Misc., QC MS, QC RS, Item 613, and QC 1 when used for residential driveways, Item 606, Item 608, Item 609, Item 611 concrete collars or encasements, and Item 623. Provide a process control plan, product quality control plan, and manufacturer’s recommended procedures to the OMM Cement and Concrete Engineer. Calibrate the proportioning devices before the start of a project and at intervals recommended by the manufacturer. Perform calibrations in the presence of the Engineer. Calibrate the cement and aggregate proportioning devices by weighing (determining the mass of) each component. Calibrate the admixture and water proportioning device(s) by weight (mass) or volume. Batch each material to ensure weights are within the tolerances listed in Table 499.06-2, based on the amount specified in the accepted JMF. Furnish batch tickets in accordance with Item 499.07. Verify yield daily based on the cement meter count (number of revolutions per 94 pounds (42.5 kg) of cement), for each volumetric truck mixer.

499.06Handling, Measuring, and Batching Materials. Do not stockpile aggregates from different

sources or different gradations together. Do not use aggregates that have become segregated or mixed with foreign material. The Engineer may direct reworking or cleaning, or may reject aggregates that have become segregated or mixed with earth or foreign material. Prior to and during batching, maintain all coarse and fine aggregates at a uniform moisture content, at or above, an SSD condition. 292 For all slag aggregates or other aggregates with a reported absorption above 3.0 percent, maintain the moisture contents at or above the ODOT-reported SSD for that aggregate as follows:

at or above SSD. Test the moisture content of the watered aggregate stockpiles at least five (5) locations to assure the stockpile is at or above SSD.

consistency has begun. Twenty-four (24) hours before batching concrete with the aggregate, shut down the stockpile watering process to allow drainage and to establish a uniform moisture content.

concrete production. If the moisture content varies between tests by more than 1 percent increase the moisture testing frequency to assure correct batching information.

Separately weigh the amounts of fine aggregate and coarse aggregate. Use a separate weighing device for cementitious materials. Batch each material to ensure weights are within the tolerance specified in Table 499.06-1, based on the amount specified in the approved JMF including any proportion adjustments according to Item

TABLE 499.06-1 CONCRETE BATCHING TOLERANCES Material Batching Tolerance (%) Cement ±1.0 Pozzolan[1] ±1.0 Carbonate Micro-fines[2] ±2.0 Aggregates[2] ±2.0 Water[3][4] ±1.0 Chemical Admixtures ±3.0 Macro-fibers ±3.0 [1] Tolerance is on cumulative target weight when weighing together with cement [2] Tolerance is on cumulative target weight when weighing together with more than one aggregate [3] Measured by weight or volume [4] Tolerance based on target water quantity, not water quantity allowed at maximum water- cementitious ratio TABLE 499.06-2 VOLUMETRIC TRUCK BATCHING TOLERANCES Material Batching Tolerance (%) Cement 0.0 to +4.0 Pozzolan 0.0 to +4.0 Carbonate Micro-fines 0.0 to +4.0 Aggregates ±2.0 Water ±1.0 Chemical Admixtures ±3.0 Macro-fibers ±3.0 293

499.07Batch Plant Tickets. Furnish a concrete batch plant ticket to the Engineer for each load of

concrete incorporated into the project. Provide computer generated batch tickets. At a minimum, include the information listed in Table 499.07-1 on each ticket: 294 TABLE 499.07-1 EVERY BATCH TICKET Name of ready-mix batch plant Batch plant No. Batch plant location Facility ID Serial number of ticket Date Truck number Class of concrete JMF Number Batch time Batch size yd3 (m3) Actual weights and batch tolerance of cementitious material: Cement lb (kg) Fly ash lb (kg) Natural pozzolan lb (kg) Slag cement lb (kg) Micro-silica lb (kg) Other lb (kg) Actual weights and % variance of aggregates: Coarse lb (kg) Intermediate lb (kg) Fine lb (kg) Carbonate Micro-Fines lb (kg) Other lb (kg) Actual weight of water and % variance lb (kg) Actual volume of admixtures: Air-entrainer fl oz (mL) Superplasticizer fl oz (mL) Water-reducer fl oz (mL) Retarder fl oz (mL) Macro-fibers lb (kg) Other fl oz (mL) Aggregate moisture contents: Coarse aggregate % Intermediate aggregate % Fine aggregate % Water-cementitious ratio, leaving the plant Allowable additional water gallons 295 Provide the information in Table 499.07-2 with batch tickets for each day’s first load of concrete and for each JMF. Include Table 499.07-2 information on the batch ticket or furnish the information on a separate computer -generated or handwritten form attached to the batch ticket. Provide moisture adjustment calculations for all coarse and fine aggregate according to 499.06.C. If during the concrete manufacturing process any of the information listed in Table 499.07-2 changes, resubmit Table 499.07-2 information with the first batch ticket supplied with the changed concrete. TABLE 499.07-2 FIRST TICKET EACH DAY, EACH JMF Cementitious Materials: Source: Grade or Type: Cement Fly ash Natural pozzolan Slag cement Micro-silica Aggregates Other Admixtures Brand: Type: Air-entrainer Retarder Superplasticizer Water-reducer Macro-fibers Other The provided concrete batch ticket information is according to ASTM C94/C 94M, Section 14. Provide a copy of the moisture burn off calculation sheet with the first ticket of the day, or when there is an updated moisture burn off performed.

Mixing Concrete. Use a central mix plant or in truck mixers to mix the concrete

When using a central mix plant, mix the concrete not less than 60 seconds Begin the mixing time when all materials are in the drum and end the mixing time when discharge begins. Include transfer time in multiple drum mixers in the mixing time. Remove the c ontents of an individual mixer drum before a succeeding batch is emptied into the drum. When concrete is mixed using a truck mixer for complete mixing, mix each batch of concrete at the rotation rate designated on the mixer as mixing speed for not less than 70 revolutions of the drum. Transport mixed concrete from the central mixers in truck mixers, truck agitators, or trucks having non- agitating bodies. Within 90 minutes after cement and water are combined, deliver and completely discharge concrete. Use admixtures containing more than 50 parts per million chloride by weight of cement only when specified in the Contract Documents, the accepted JMF, or with the Engineer’s written permission. Ensure that the temperature of all concrete does not exceed 95 F (35 C) until incorporated into the work. For bridge deck concrete, ensure the temperature of the concrete does not exceed 85 F (30 C). 296 500 STRUCTURES ITEM 501 STRUCTURES—GENERAL