542HIGH PERFORMANCE CONCRETE, RAPID SET

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5-316SECTION 542 – HIGH PERFORMANCE CONCRETE, RAPID SET

542.01DESCRIPTION . This work shall consist of designing, furnishing, and placing a high early

strength, high performance, Portland cement concrete for structures and incidental construction . The Portland cement concre te may consist of a homogeneous mixture of cement, fine aggregate, coarse aggregate, water, admixtures, and pozzolans, proportioned and mixed according to these specifications.

542.02MATERIALS . Materials shall meet the material requirements specified in Subsection 501.02 and

the following subsections: High Early -Strength Portland Cement ................................ ................................ ........ 701.0 3

542.03CLASSIFICATION AND PROPORTIONING . Concrete shall meet the requirements specified in

Table 542.03A and shall be used as shown on the Plans. TABLE 542.03A – HIGH PERFORMANCE CONCRETE, RAPID SET PROPERTIES Min. 28 -Day Compressive Strength (psi) Max. W/CM Ratio 1 Max. VSI 2 Slump Limit Spread Limit Air Content Limits Max. Free Shrinkage Max. 56 -Day Surface Resistivity 3 5,000 TBD 1 N/A 4 TBD 5 7.0% ± 1.5% 0.040% Low 1 The maximum W/CM ratio shall be determined by the Contractor as established by mix qualification testing. During production, the W/CM ratio shall be less than or equal to the W/CM ratio from the approved qualification mix. See Subsection 542.03(b) . The W/CM ratio shall be rounded to two decimal places in accordance with ASTM E29 . 2 For SCC mixes, visual stabi lity index (VSI) as determined in accordance with ASTM C1611 . 3 The Contractor shall determine the surface resistivity in accordance with Subsection 542.03( b)(3). 4 The mix shall not exhibit segregation. If the mix does exhibit segregation, the load shall be rejected . If the spread is equal to or exceeds 20 inches, the mix shall be classified as SCC mix. 5 For SCC mixes, the Contractor shall determine the spread target and limits in accordance with Subsection 542.03(b)( 4). The spread shall be maintai ned within the determined spread limits for the placement. The mix shall not exhibit segregation. If the mix does exhibit segregation or exceeds the upper spread limit, the load shall be rejected . and subsequent loads shall be tested by the Contractor until the mix meets the allowable limits. The Engineer may perform a J -ring test at the time of placement if blocking is a concern.

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5-317If a nominal maximum aggregate size is not specified, the Contractor shall determine the nominal

maximum aggregate size using guidance from ACI 211.1 . In no case shall the maximum aggregate size exceed 1/5 of the narrowest dimension between sides of the fo rms, 1/3 the depth of slabs, or 3/4 of the minimum clear spacing between individual reinforcing bars, bundles of bars, or pre -tensioning strands unless approved by the Engineer. The Contractor may use industry methods to develop gradations not specified in Section 704 that are better optimized to satisfy the required concrete performance characteristics. If the Contractor is using a combined gradation, they shall provide the method or methods of how they will monitor gradation, the limits of the gradation r anges, and the frequency of monitoring. Lightweight fine aggregate may be used to replace up to 30% of the volume of normal weight sand. The gradation of the lightweight fine aggregate shall conform to the requirements of AASHTO M 195 . The lightweight fine aggregate shall be conditioned for enough time to fully saturate the material. The stockpile shall be constructed so that the moisture content is uniform throughout the pile. The stockpile will be allowed to drain for 12 hours to 15 hours immediately prio r to use, unless an alternate procedure is approved by the Structural Concrete Engineer. The Contractor shall state the method, duration and procedure used to confirm that the material is at or above its saturated surface dry (SSD) value, by weight, throug hout the pile. The use of chlorides or admixtures containing chlorides is prohibited. All admixtures will be considered incidental to the work and included in the Contract unit price of the concrete. The concrete materials may be proportioned using the abs olute volumes method in accordance with the specified requirements. The volumetric proportioning method , such as that outlined in ACI 211.1 or other approved volumetric proportioning methods, shall be employed in the mix design. Prior to placing concrete on the project (or prior to the trial pour, whichever occurs first), the Contractor shall submit for approval the single mix design formulation that satisfies all mix design qualification requirements and testing for the class of concrete specified. The mi x designs shall be submitted to the Structural Concrete Engineer at the Agency’s Materials Testing and Certification Section Central Laboratory. The Structural Concrete Engineer may require a minimum of 8 weeks for testing, review, and approval of new mix designs. No class of concrete shall be placed on a project, including the trial pour, until the mix design is approved. If the proposed performance concrete mix design fails to meet the qualification requirements, the Contractor shall submit a revised mix design formula in writing to address the mix qualification deficiencies of the original failed mix design. Review of the revised mix design formula by the Structural Concrete Engineer will be completed within 14 calendar days.

542 5-318 (a) Mix Design Information. The mix design shall contain the following information:

Concrete test mix or mixes shall be used to obtain the test results where applicable. All wet testing shall be done by personnel with current ACI Concrete Field Testing Technician Grade I certifications. All other tests shall be performed by a laboratory t hat is accredited by AASHTO re:source or the Concrete and Cement Reference Laboratory (CCRL) in the particular test method, or as allowed by the Engineer.

air content value and the maximum water/cementitious materials ratio of the material used to pass the mix qualification tests shall become the minimum air content value and the maximum water/cementitious materials ratio allowed during production.

542 5-319 (1) The free shrinkage rate of the concrete shall be tested in accordance with Subsection

501.03(b)(1)

AASHTO T 22 for 3, 7, 14, and 28 day standard cured cylinders.

(b)(4)

accordance with Subsection 501.03(b)(5) .

measured in accordance with Subsection 501.03(c) . Test results shall be submitted with the mix design.

reviewed and approved by the Structural Concrete Engineer, no changes to the mix design will be allowed. If a source change is requested due to a change in product or material name that does not include any significant change in product formulation or material characteristic, and this is substantiated by the product or material supplier in writing, re -testing is not required. No new materials shall be incorporated without prior written approval of the Engineer. In no case shall concrete from mor e than one mix design be permitted to be used during the same pour without prior written approval of the Engineer. The approved mix design will be allowed consecutive re -approval if no material proportioning or material sources have changed from the previo us year’s approved mix design and the mix design is submitted with updated aggregate properties and volumes adjusted accordingly. The aggregate properties shall be tested annually. Aggregate property values will be valid for 14 months from the date tested. The properties to be tested include, but are not limited to, specific gravity and absorption. The mix design shall be accompanied by the previously completed and accepted mix qualification test data and any applicable updated test information. The submittal shall also include all applicable quality control test results and all requests for variance from the material requirements of these specifications.

requirements may also be considered for use.

542 5-320 542.04 BATCHING . Batching shall meet the requirements of Subsection 501.04 .

542.05MIXING AND DELIVERY . Mixing and delivery shall meet the requirements of Subsection

501.05

542.06QUALITY CONTROL . The Contractor shall provide assistance, equipment, materials, and

curing for field sampling and testing as required by the Engineer. All costs shall be included in the Contract unit prices under Section 631 . The Engineer shall per form all acceptance sampling and testing in accordance with the Agency’s Quality Assurance Program . The Contractor shall perform all on -site quality control (QC) sampling and testing. The person performing the QC sampling and testing shall have, as a minim um, current ACI Concrete Field Testing Technician Grade I Certification.

produce and place a 2 cubic yard trial batch, at a location agreed upon by the Contr actor and the Engineer. The purpose of this trial batch is to demonstrate that the mix is capable of producing the wet test results within the specified ranges. The Engineer shall be given a minimum notice of 7 calendar days prior to the trial batch pour. The trial batch shall be poured in the presence of the Engineer and the Structural Concrete Engineer. The trial batch shall be produced and poured in the same manner, estimated concrete temperature, and time frames that will occur during construction. For SCC the spread shall be within ± 3 inches of the target spread, but still be within the established spread range limits for SCC. The J -ring test will be performed for SCC mix, and the difference between the J -ring and spread test shall not be greater than 2 inches. The Contractor shall provide qualified personnel to test spread, air content, and temperature of the trial batch. A trial batch will be required for each mix design used on the project. If SCC will be used in work with a sloped finished surface, the Contractor shall produce a mock - up during the trial batch to demonstrate that the mix can be finished with the sloped surface.

R 60 or other procedures approved by the Agency. Sampling shall be done at the point of placement or as close to it as practical. .

tolerances, whether modified at the batch plant or at the site, additional QC sampling and

testing shall be performed on the modified load prior to incorporating the concrete into the

work.

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purposes that is taken before 15% of the load has been discharged. Beginning of load

sampling shall be performed as required by the Engineer, or as needed to ensure that the

concrete meets the Contract requirements at the point of placement. The QC personnel

shall monitor the placement operation and adjust the mix accordingly to ensure that the

material being incorporated into the work meets Contract requirements.

Procedure B. The concrete inside the cone shall not be tamped.

ASTM C1611, Appendix X.1 and shall be performed on each completed spread test.

in AASHTO T 152.

For SCC mixes, the specimens shall be fabricated in accordance with ASTM C1758.

will be as specified in the Materials Sampling Manual. The Engineer may order additional

tests as deemed necessary.

Compressive test cylinders shall be made in accordance with the requirements of AASHTO

R 100 and tested for compressive strength in accordance with the requirements of AASHTO

T 22.

For SCC mixes, the specimens shall be fabricated in accordance with ASTM C1758.

compliance with requirements for the project. All test cylinders used for quality

acceptance testing shall be stored in an approved curing box until they are shipped

to the Agency’s Materials Testing and Certification Section Central Laboratory.

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adequate curing procedures are being followed and for early form removal or early

loading of structure.

the same curing and protection from the elements as the concrete that they

represent up until 24 hours before anticipated testing of specimens.

testing for estimating the concrete strength. The procedures of ASTM C1074

shall be followed for the maturity method except as noted below:

cylinders cast. Two of the 17 shall have temperature sensors

embedded in them to be used for monitoring.

ii. For ASTM C1074, Section 8.4, there shall be 3 cylinders tested for

each test age.

iii. For ASTM C1074, Section 8.4, for rapid set concrete mixes the test

ages shall be 12 hours, 1 day, 2 days, 7 days, and 28 days. The

Contractor may adjust or add test ages if approved by the Engineer.

All temperature measuring devices shall be verified or calibrated on a 12

month basis, or sooner if there are questions about their accuracy. The

devices shall have an accuracy of ± 2° F.

At least two temperature sensors shall be embedded each day in each pour.

One sensor shall be placed where maturity is expected to develop the

slowest at, or near, an exposed outer edge, and a second sensor shall be

placed in the concrete poured from the last load of the day. Sensors shall be

placed 2 inches to 4 inches from any existing concrete or an exposed outer

edge. The temperature sensing end of the monitor shall not be placed in

direct contact with reinforcing materials or other elements that will protrude

through the surface of the concrete. The Contractor shall submit the

proposed locations to the Engineer for review and approval.

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in the specifications or as directed by the Engineer. If not specifically stated, the

curing shall be as specified in Table 542.06A.

TABLE 542.06A – CONCRETE SPECIMEN CURING REQUIREMENTS

Testing Category Number of Specimens Curing Location

Acceptance See the Materials

Sampling Manual Curing box

Job control 2 per test On structure

C1064.

542.07WEATHER AND TEMPERATURE LIMITATIONS. Weather and temperature limitations shall

be as specified in Subsection 501.07.

542.08FORMS. Forms shall meet the requirements of Subsection 501.08

542.09PLACING CONCRETE. Placing concrete shall be performed as specified in Subsection 501.09

542.10PUMPING. Pumping shall meet the requirements of Subsection 501.11

542.11CONSTRUCTION JOINTS. Construction joints shall meet the requirements of Subsection

501.12

542.12EXPANSION JOINTS. Expansion joints shall meet the requirements of Subsection 501.13

542.13CONCRETE FINISHING. Concrete finishing shall meet the requirements of Subsection 501.14

542.14CURING CONCRETE

Subsection 745.01. The effective cure time shall be only the time that the concrete has been

maintained in a wet condition with the concrete surface temperature above 50°F. If the concrete is

not maintained in a wet condition or the concrete surface temperature drops below 50°F, it shall

not be counted as effective cure time. The cure period will be extended 4 hours for every 1 hour

the concrete is below 50°F, beginning when the concrete temperature is raised to or exceeds the

minimum curing temperature.

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Regardless of the curing medium specified, the entire surface of the newly placed concrete shall

be kept damp. This shall be achieved by applying water with a nozzle that atomizes the flow so

that a mist and not a spray is formed. The moisture shall not be applied under pressure directly

upon the concrete and shall not be allowed to accumulate in a quantity sufficient to cause a flow

or washing of the surface.

The atomized flow shall be applied continuously until the surfaces can be covered by the specified

curing mediums. The curing method shall be applied within 15 minutes of the completion of the

finishing process.

Unless otherwise specified in the Contract, concrete shall be wet cured until it has reached the

minimum 28-day compressive strength, verified by testing of job control specimens.

following specified methods:

of approved burlap that has been pre-soaked with water. The burlap shall then be covered

with a lapped layer of white polyethylene sheeting. Once the concrete superstructure has

hardened sufficiently, a stream of water, applied with a soaker hose or similar device, shall

be run continuously under the polyethylene sheeting until the cure period is complete.

with a blanket of cotton mats that has been pre-dampened with water. The mats shall be

maintained in a damp condition until the curing period is complete.

542.15LOADING OF CONCRETE. After the concrete has been placed and the finishing operations

concluded, it shall not be walked on or disturbed in any manner, including the removal of forms, until

curing is complete as specified in the Contract.

A portable compression testing machine calibrated in accordance with ASTM C39, Section 5 shall be

provided by the Contractor and available on-site for cylinder testing of field-cured cylinders for

construction progress. There shall also be a hand-held grinding stone included with the compression

testing machine. The hand-held grinding stone will be used to grind the top of the cylinders to relieve any

sharp projections on the cylinder surface. All testing and equipment shall conform to ASTM C39. Testing

will be performed, and equipment operated by, qualified Agency personnel. The individual shall be trained

in the operation of the machine by the owner or representative of the machine who is proficient in the

operations and functions of the machine.

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If an independent lab is proposed to be used to test the field-cured cylinders instead of a portable

compression testing machine, the Contractor shall submit the following documentation:

The Agency at any time reserves the right to perform an independent proficiency test of the technician for

the test methods used and a review of the testing facility.

542.16METHOD OF MEASUREMENT. The quantity of High Performance Concrete, Rapid Set to be

measured for payment will be the number of cubic yards of concrete placed in the complete and accepted

work, as determined by the prismoidal method using dimensions shown on the Plans or as directed by the

Engineer.

The quantity of concrete will exclude the volume of steel or other stay-in-place forms and form filling

materials. No deductions will be made for the volume of concrete displaced by steel reinforcement,

structural steel, expansion joint material, scuppers, weep holes, conduits, tops of piles, scoring, chamfers,

or corners, inset panels of 1-1/2 inches or less in depth, or any pipe less than 8 inches in diameter.

542.17BASIS OF PAYMENT. The accepted quantity of High Performance Concrete, Rapid Set will be

paid for at the Contract unit price per cubic yard. Payment will be full compensation for performing the

work specified, including designing the mix, performance of trial pours, satisfactory finishing and curing.

Payment will also be full compensation for furnishing all forms, materials, including joint filler and bond

breaker, labor, tools, admixtures, and equipment, including automatic temperature recording units, trial

batches, and incidentals necessary to complete the work.

The cost of heating materials and protecting the concrete against cold weather, and any additional cost for

cement, will not be paid for separately but will be considered incidental to High Performance Concrete,

Rapid Set.

The cost of furnishing testing facilities and supplies at the batch plant and the setting of inserts,

benchmarks, and bridge plaques furnished by the Agency will not be paid for separately but will be

considered incidental to High Performance Concrete, Rapid Set.

Costs for all materials, labor, and incidentals for steel or other stay-in-place forms and form filling

materials will not be paid for separately, but will be considered incidental to High Performance Concrete,

Rapid Set.

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Payment will be made under:

Pay Item Pay Unit

00 High Performance Concrete, Rapid Set ....................................................Cubic Yard

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5-327SECTIO N 543 – CONTRACTOR -FABRICATE D PRECAS T CONCRET E STRUCTURE

543.0 1 DESCRIPTION . This work shall consist of manufacturing, transporting, handling, and erecting precast concrete structure components fabricated by the Contractor at a location other than a PCI or NPCA certified precast concrete facility. 543.0 2 MATERIALS . Materials sh all meet the material requirements specified in Subsection 501.02 , Subsection 507.02 , and Subsection 540.02 . Concrete shall meet the material requirements specified in Subsection 540.05 . 543.0 3 GENERA L FABRICATIO N REQUIREMENTS . Unless noted otherwise her ein, Contractor - fabricated precast concrete (CFPC) shall meet the requirements of Section 501 , Section 507 , and Section 540. 543.0 4 SUBMITTALS . As soon as practical after award of the Contract, all required information shall be prepared and submitted. Fa brication drawings and erection plans shall be submitted as separate submittals. If the Contractor proposes a different configuration than what is provided in the Plans then a complete copy of the structural design calculations for the CFPC shall be submitted accompanying the construction drawings in accordance with Subsection 105.06 . The design calculations shall substantiate that the proposed precast concrete satisfies the design parameters of the Contract. The applicable design code will be the AASHTO LRFD Bridge Design Specifications unless indicated otherwise in the Contract . Fabrication drawings for the precast concrete shall be submitted in accordance with Subsection 105.06 . In addition to the requirements for fabrication drawings in Subsection 105.06 , the following shall also be included:

inserts. Reinforcing steel material lists, material designations, and bending details shall also be included.