SPECIFICATIONS

H O L L O W CO R E
P RECAST /P RESTRESSED CONCRETE
SECTION 03410 - HOLLOWCORE PRECAST / PRESTRESSED CONCRETE
1.0 General 2.0 Description 3.0 .1 The General conditions of the Contract and Supplementary General Conditions apply to this Division, except as qualified herein and / or excluded. .2 Refer to drawings and specifications 4.0 5.0 Related Work .1 Cast-in-Place Concrete: Section 03300 Reference Standards Spec Note: List latest standards. Specifier to update specifications to latest edition. .1 Do precast / prestressed concrete work in accordance with CSA A23.3 and CSA A23.4 / ACI 318-99 and PCI MNL-116. .2 Do welding in accordance with CSA W59 / AWS D1.1 for welding to steel structures and CSA W186 / AWS D1.4 for welding reinforcement. Qualifications of Manufacturer .1 Manufacturers of precast / prestressed concrete elements to be certified by CSA /PCI in accordance with CSA A23.4 / PCI MNL-116 Precast Concrete - Materials and Construction. Design Criteria .1 Design precast / prestressed concrete units to CSA A23.3 / ACI 318-99 and to carry handling stresses. .2 Design loads in accordance with applicable codes for use and occupancy, wind, temperature and earthquake. .3 Consider vibration characteristics in accordance with NBC / The BOCA National Building Code 1996. .4 Design prestressed units to meet one (1) or two (2) hour fire resistance rating (specify). Allowable Tolerances .1 Conform with requirements of CSA A23. 4-Section 10 / PCI MNL-116 - PCI Design Handbook, Fifth Edition (Section 8-1) .2 Refer to related Sections of this specification and fabricate work to accommodate the specified tolerances. 9.0 Source Quality Control .1 Upon request, provide Engineer with certified copies of quality control tests and inspections related to project as specified in CSA A23.4 and CSA G279 / PCI MNL-116. .2 Inspection of prestressed concrete tendons is required in accordance with CSA G279 / ASTM A416. .3 Upon request, provide Engineer with certified copies of mill test report of reinforcing steel supplied, showing physical and chemical analysis. Shop Drawings Spec Note: It is not the Precast Manufacturers responsibility to confirm and correlate dimensions at the job site. Precast concrete is a prefabricated material. Site dimensioning would require the foundation / structure to be complete before fabrication could commence. .1 Submit shop drawings in accordance with the appropriate section. .2 Submit shop drawings in accordance with CSA A23.3 and CSA A23.4. Upon request, the following items shall be provided: 1) Design calculations for items designed by manufacturer. 2) Estimated camber / deflection. 3) Finishing Schedules. 4) Methods of handling and erection. 5) Openings, inserts and related reinforcement. 6) Each drawing submitted to bear stamp of qualified Professional Engineer registered in the State / Province of _________________. Warranty .1 This Contractor hereby warrants that the pre cast / prestressed elements will not spall or show visible evidence of cracking, except for normal hairline shrinkage cracks, in accordance with the General Conditions warranty clause, for a one year period.

10.0

6.0

7.0

11.0

8.0

12.0

Materials .1 Cement, aggregates, water, admixtures: To CSA A23.1 and CSA A23.4 / PCI MNL-116. .2 Prestressing steel: Uncoated 7 wire strands conforming to CSA G279 / ASTM A416. .3 Reinforcing steel: To CSA G30.18 / ASTM A615-94. .4 Anchorages and couplings: To CSA A23.1 / ASTM A615-94 .5 Embedded steel: To CSA G40.21, Type M300W / ASTM A615-94. .6 Welding materials: To CSA W48.1. .7 Bearing pads: 3mm x 75 mm masonite smooth one side / 3mm x 50mm korolath. .8 Air entrainment admixtures: To CSA A266.1 / ASTM C 260. .9 Chemical Admixtures: To CSA A266.2 / ACI 318-99.

.5 Fasten precast/prestressed units in place as indicated on approved shop drawings. .6 Level differential elevation of horizontal joints with grout to slope not more than 1:12. .7 Clean field welds with wire brush and touch up with primer. .8 Field cut holes and openings up to 254mm (10) diameter for mechanical trades. Openings larger than 254mm (10) to be located on shop drawings at the time of approval and to be either cast in the manufacturing facility or cut in the field at the manufacturers sole discretion. Do not cut reinforcing without approval of precast hollowcore slab manufacturer and Engineer.

17.0

Topping

13.0

Concrete Mixes

.1 Use concrete mix designed to produce 41 Mpa (6000 psi) compressive strength at 28 days with maximum water/cement ratio to CSA A23.1, Table 7 for Class D Exposure / PCI MNL-116 & ACI 318-99. .2 Admixtures: To CSA A266.4, CSA A266.5 / ASTMC 494 or C 1017. .3 Do not use calcium chloride or products containing calcium chloride.

.1 This contractor shall provide a suitable top finish to accept direct application of finished flooring as per the room finish schedule. .2 Where concrete topping (minimum 37mm 1 1/2) is to be applied, refer to the appropriate specifications. The top surface of the precast / prestressed slabs is to be raked (roughened) for bonding of topping.

18.0

Exposed Ceilings

14.0

Grout Mix

.1 Cement grout: One part type 10 Portland Cement 2 1/2 parts sand, sufficient water for placement and hydration. Grout strength to be 20 Mpa / 3000 psi minimum at 28 days.

.1 Caulk exposed longitudinal ceiling joints, using caulking as recommended by this contractor. .2 The underside of precast shall be finished as per CSA A23.4 (clause 24.2.2) STANDARD FINISH as per the specifications.

19.0

Clean-Up

15.0

Manufacture

.1 Manufacture units in accordance with CSA A23.4 / PCI MNL-116. .2 Mark each precast unit to correspond to identification mark on shop drawings for location on part of unit which will not be exposed. .3 Provide hardware suitable for handling elements.

.1 Upon completion of the work of this section, all surplus materials and debris shall be removed from the site.

16.0

Execution / Erection

.1 Erect elements within allowable tolerances indicated or specified. .2 Non-cumulative erection tolerances in accordance with CSA A23.4, Section 10 /PCI Design handbook fifth edition 8-3 / PSI Hollowcore Design Handbook. .3 Install 3mm masonite / korolath bearing pads, smooth side up on concrete or masonry bearing surfaces. .4 Set units in a tight, level position on true level bearing surface provided by others. Minimum bearing 90mm (3 1/2) on masonry and 75mm (3) on structural steel.

Spec Note:*Items relating to precast / prestressed slabs to be carried out by other trades, and covered in their respective specifications; (1) Drypacking of gap between precast / prestressed slabs at all locations where load bearing walls are parallel and/or perpendicular to length of slab. (2) Perimeter caulking. (3) Electrical holes. (4) Concrete topping.

SPECIFICATIONS

STRUCTURAL
P RECAST /P RESTRESSED CONCRETE
SECTION 03420 - STRUCTURAL PRECAST / PRESTRESSED CONCRETE
1.0 General
.1 The General conditions of the Contract and Supplementary General Conditions apply to this Division, except as qualified herein and / or excluded. .2 Refer to drawings and specifications.

1.3
.1 .2 .3 .4 .5 .6 .7

Reference Standards
Spec Note: Latest standards are listed. Specifier to update specifications to latest edition. CSA A23.1-94 / ACI 318-99, Concrete Materials and Methods of Concrete Construction. CSA A23.3-94 / ACI 318-99, Methods for Test for Concrete CSA A23.3-94 / ACI 318-99, Design of Concrete Structures CSA A23.4-94 / ACI 318-99, Precast ConcreteMaterials and Construction CSA A266.4-M78 / ACI 318-99, Guidelines for the Use of Admixtures in Concrete CSA A266.5-M1981 / ASTMC 494 / ASTM C1017, Guidelines for the Use of Superplasticizing Admixtures in Concrete. CSA A283-1980 / Qualification Code for Concrete Testing Laboratories. CSA G30.5-M / ASTM A185 / ACI 318-99 Weld Steel Wire Fabric for Concrete Reinforcement. CSA G30.15-M / ASTM A497/ ACI 318-99, Welded Deformed Steel Wire Fabric for Concrete Reinforcement CAN / CSA G30.18 / ASTM A615-94, Billet Steel Bars for Concrete Reinforcement CAN / CSA G40.21 / ASTM A36, Structural Quality Steel. CSA W186-M1997/ AWS D1.4, Welding of Reinforcing Bars in Reinforced Concrete Construction W47.1-97/ XNA, Certification of Companies for Fusion Welding of Steel Structures ASTM A775/A 775M [94d] / ASTM A934-95, Specification for Epoxy-Coated Reinforcing Steel Bars.

1.1

Work included
.1 Design, supply, delivery and installation of: Spec Note: This section includes structural precast / prestressed concrete units including the following: - Double tee slab units - Structural framing units - Parking / Building Structures - Structural precast/prestressed concrete

Spec Note: This section specifies products of standard or special shapes that are reinforced using steel reinforcement, pre-tensioning or post-tensioning and through application become an integral structural part of the object. .a The specifications cover precast / prestressed structural concrete construction. .b This section includes product design, manufacture, transportation, erection and other related items such as anchorage, bearing pads, inserts and similar accessories required for work under this contract. .c Take delivery and cast into precast work boxes/inserts/openings required and supplied by other trades only if supplied prior to casting. .d Supply information required for the installation of bracing, supports, inserts and similar accessories required for the work under this contract supplied and to be installed by others.

.8 .9 .10 .11 .12 .13 .14

1.2 Related Work

.1 Section 03300 - Cast-in-Place Concrete .2 Section 03410 - Hollowcore Precast / Prestressed Concrete .3 Section 03450 - Architectural Precast Concrete and / or Insulated Precast Concrete Wall Panels .4 Section 05100 - Structural Metal Framing Spec Note: For parking structures add reference to concrete topping and deck waterproofing, traffic topping, sealants, and expansion joints.

1.4 Qualifications of Manufacturer

.1 Fabricate precast / prestressed concrete elements certified by the Canadian Standards Association and MNL130 in the appropriate category(ies) according to CSA Standard A23.4-94 Precast Concrete-Materials and Construction and the Prestressed Concrete Institute (PCI) according to PCI/MNL-116, MNL-117 Manual for Quality Control for Plants and Production of Precast Prestressed Products. The precast concrete manufacturer shall be certified in accordance with the CSA / PCI Certification program for Structural Precast / Prestressed Concrete prior to submitting a tender and must specifically verify as part of their tender that they are currently certified in the appropriate category(ies): Spec Note: Delete the categories which do not apply.

(A) Precast Concrete Products - Architectural (I) Non-Prestressed or (II) Prestressed (B) Precast Concrete Products - Structural (I) Non-Prestressed or (II) Prestressed (C) Precast Concrete Products - Specialty (I) Non-Prestressed or (II) Prestressed Only precast concrete elements fabricated by certified manufacturers are acceptable to the Owner. Certification must be maintained for the duration of the fabrication and erection for the project. Fabricate precast concrete elements in accordance with the applicable state/provincial Building Code requirements. .2 The structural precast/ prestressed concrete manufacturer shall have a proven record and satisfactory experience in the design, manufacture and erection of the structural units specified. The company shall have adequate financing, equipment, plant and skilled personnel to detail, fabricate and erect the work of this Section as required by the Specifications and Drawings. The size of the plant shall be adequate to maintain the required delivery schedule.

1.8 Shop Drawings

Spec Note: It is not the Precast Manufacturers responsibility to confirm and correlate dimensions at the job site. Precast concrete is a prefabricated material. Site dimensioning would require the foundation / structure to be complete before fabrication could commence. .1 Prepare and submit shop drawings of precast/ prestressed structural concrete elements in accordance with the General Conditions of the contract, the appropriate specification section and as specified below. 1) Submit fully detailed and dimensioned drawings showing and including but not limited to the following: 2) Design calculations for items designed by manufacturer. 3) Typical details of prestressed and nonprestressed members, reinforcement and connections. 4) Estimated camber / deflection. 5) Finishing Schedules 6) Methods of handling and erection. 7) Openings, sleeves, inserts and related reinforcement. 8) Show the exact location of inserts and anchors required to be cast into precast / prestressed units for interface elements. 9) Show the system of identifying units for erection purposes on shop drawings and apply a similar mark on all units at the time of manufacture. 10) Provide the Shop Drawings to obtain approvals from the Authorities having jurisdiction prior to fabrication of structural precast / prestressed units. 11) If requested provide drawings of all precast members.

1.5

By-Laws and Codes

.1 Conform with applicable requirements of the local Building Code, the National Building Code and local authorities having jurisdiction. .2 Design and provide reinforcement, anchors and supports as required by codes and to Consultants approval. Submit relevant design data prepared by a professional engineer registered in the state/province where the project is located for approval if so requested by the Consultant.

1.6

Allowable Tolerances
.1 Conform with requirements of CSA A23.4Section 10 / PCI MNL-116 - PCI Design Handbook, Fifth Edition (Section 8-1) .2 Refer to related Sections of this specification and fabricate work to accommodate the specified tolerances.

1.9

Finishes of Formed Surfaces

1.7

Source Quality Control

.1 Make available copies of quality control tests related to this project as specified in CSA 3A23.4 /PCI MNL-116. .2 Inspect prestressed concrete tendons in accordance with CSA-A23.4 / PCI MNL-116. .3 Make available records from in-house quality control program based upon plant certification requirements for inspection and review. .4 Make available certified copies of mill test reports of steel reinforcement supplied, showing physical and chemical analysis. .5 In addition to quality control, an independent inspection and testing company may be appointed by the owner to verify compliance with this Specification. .6 Cooperate with inspector to facilitate their work. .7 Cost of an independent inspection is paid for by the owner.

.1 Finish formed surfaces of precast structural concrete as indicated for each type of unit, and as follows: A) Standard Finish: Normal plant-run finish produced in forms that impart a smooth finish to concrete. Small surface holes caused by air bubbles, normal color variations, form joint marks, and minor chips and spalls will be tolerated. Major or unsightly imperfections, honeycombs, or structural defects are not permitted. B) Commercial Finish: Remove fins and large protrusions and fill large holes. Rub or grind ragged edges. Faces are to be true, well-defined surfaces. C) Grade B Finish: Fill air pockets and holes larger than 1/4 inch (6mm) in diameter with sand-cement pastel matching color of adjacent surfaces. Grind smooth form offsets or fins larger than 1/8 inch (3mm). D) Grade A Finish: Fill air pockets and holes larger than 1/4 inch (6mm) in diameter with sand-cement paste matching color of precast concrete. Grind smooth form offsets or fins larger than 1/8 inch (3mm). Float-apply a neat cement-paste coating to exposed surfaces. Rub dried paste coat with burlap to remove loose particles.

1.10

Warranty
.1 Provide standard warranty with a duration of one (1) year in accordance with the General Conditions. Warranty shall be in writing and shall warrant work under this Section to be free from defects for the period stipulated.

1.11

Delivery, Storage and Protection

.1 Accept full responsibility for delivery, handling and storage of units. .2 Deliver, handle and store precast/prestressed units using methods approved by the manufacturer. Do not permit units to contact earth or staining influences or to rest on corners.

.8 Bearing pads: neoprene, [60] durometer hardness to ASTM D2240, and [17] Mpa minimum tensile strength to ASTM D412, moulded to size or cut from moulded sheet. (Random oriented fiber reinforced neoprene.) .9 Shims: [plastic] [steel]. .10 Zinc-rich primer: to CGSB 1-GP-181M / ASTM D412 .11 Surface retardant: to CSA A266.2/ASTM D4146

1.15

Concrete Mixes
.1 Unless otherwise noted or specified, use concrete mix designed to produce a minimum of 35 MPa / 5000 PSI compressive strength at 28 days, with a maximum water/cement ratio to CSA A23.4 / ACI 318-99. .2 Use cement and supplementary cementing materials which conform to CSA A23.1 / ASTM C150 Type I or III. .3 Air entrainment of Concrete Mix: Refer to CSA A23.1 / ASTM C260. .4 Use of calcium chloride not permitted.

1.12

Design
.1 Requirements: Design and fabricate precast / prestressed structural concrete elements, brackets and anchorage devices so that when installed they will: 1) Compensate for allowable construction tolerances in the structure to which they are secured. 2) Tolerate a structural deflection of span/360 due to live load (or otherwise specified). 3) Adequately sustain themselves, and the super imposed loads, specified by the engineer, without exceeding deflection of span/360 (unless otherwise specified). 4) Design loads shall be specified by the local Building Code where the project is to be constructed. Spec Note: 1.12 applies to specifications for parking structures. Edit accordingly.

1.16

Reinforcement and Anchors

.1 Attach anchors securely in accordance with CSA W.186.70 / ASTM A36. .2 Galvanize anchors after fabrication and touch up anchors with zinc rich primer after welding. .3 Reinforcing Steel: To CSA G30.16, CSA G30.12, CSA G30.18 [epoxy coated] / ASTM A615

1.17

Manufacture

1.13

Special Surface Treatments

.1 All anchors, plates etc. exposed to the elements to be hot dipped galvanized, except for inserts and treated items which shall be electro zinc plated (or approved equivalent). .2 Hardware protected from exposure to the elements or by a minimum of 1 1/2 concrete shall be shop coated with grey oxide primer. .3 Double tee shear connectors, where exposed to the elements, shall be stainless steel.

1.14

Materials
.1 Reinforcing Steel: to CSA-A23.1 / ASTM A615 .2 Forms: to CSA3-A23.4 / PCI MNL-116. .3 Hardware and miscellaneous materials: to CSAA23.1 / PCI MNL-116 Spec Note: Re 2.1 .4: Type 400W is weldable structural grade steel having a yield strength of 400 Mpa. Refer to CSA-G40.21 for other grades and yield strengths available. .4 Anchors and supports: to CSA-G40.21, Type [400] [(epoxy coated)(galvanized)(primed after fabrication)]. .5 Welding materials: to CSA W47.1-97 / AWS D1.1 and CSA W186-[M1997]. .6 Steel primer:to CGSB 1-GP-40M / PCI MNL-116. .7 Air entrainment admixture: to CSA-A266.4 / ASTM C-260.

.1 Fabricate precast / prestressed concrete units to CSA A23.4 / PCI MNL-116. .2 Mark each precast / prestressed unit to correspond to identification mark on shop drawings for location. .3 Mark each precast/prestressed unit with date cast. .4 Cast members in accurate rigid moulds designed to withstand high frequency vibration. Set reinforcing anchors and auxillary items to detail. Cast in anchors, blocking and inserts supplied by other sections as required to accommodate their work. Vibrate concrete during casting until full thickness is reached. Provide necessary holes and sinkages for flashings, anchors, etc. as indicated. Separately and accurately batch cement and aggregates uniformly by weight to ensure maintenance of even and uniform appearance. .5 Anchors, lifting hooks, shear bars, spacers and other inserts or fittings required shall be as recommended and /or designed by the manufacturer for a complete and rigid installation. Each shall conform to requirements of local building By-Laws. Lift hooks shall be adequately sized to safely handle panels according to member dimension and weight.Anchors/ inserts shall be concealed where practical. .6 Burn off lift cables and fill in recesses if required. Spec Note: If special architectural finish is required for exposed structural precast import the appropriate paragraph from section 03450 Architectural Precast Concrete.

Identify surfaces requiring these specific finishes.

1.18

Parking Structures

.1 Precast / prestressed floor and roof units shall be double tee components with prestressed reinforcement as required by design. The finish of the underside of the double tees shall be a standard form finish. .2 Precast beams and columns shall be of the dimensions shown on the drawings with prestressed and/or non-prestressed reinforcement at the manufacturers discretion. Architectural finish and colour: (specify) -A grey cement, standard form finish .3 Precast spandrel panels shall have a profile and thickness as shown on the drawings (and as required by design). Architectural finish and colour (specify) -A grey cement, light sandblast finish for the exterior surfaces exposed to view. -The exposed interior surface of spandrel panel shall have a standard wood float finish or a vertical light broom finish. .4 All other structural components shown on drawings shall have a grey cement, standard form finish. .5 Prestressing tendons shall be uncoated 7 wire strands conforming with CSA Standard A23.4 / ASTM A416 Grade 270, low relaxation. 1.19 Structural Framing Units .1 Type: Precast / Prestressed concrete structural framing units. .2 Furnish units free of voids or honeycombs. .3 Provide standard finish to precast units. .4 Where ends of strands will not be enclosed or covered, recess and cover with a highstrength mortar bonded to unit with an epoxyresin bonding agent. .5 Reinforce units to resist transportation and erection stresses. .6 Include cast-in weld plates where required. Execution / Erection .1 Erect precast /prestressed work in accordance with CSA-A23.4 / PCI MNL-127 .2 Supply anchors for precast units required to be cast into cast-in-place concrete frame to General Contractor for installation. Provide such items in ample time to meet the construction schedule. Supply layout drawings accurately locating the position of all cast in items to be installed by other sections. Installation .1 Set precast/ prestressed concrete units, straight, level and square. .2 Do welding in accordance with CSA-W59 / AWS D1.1 for welding to steel structures and CSA A23.4, Section[10] / PCI MNL-116 - PCI handbook, 5th Edition, Section 8-1. Spec Note: Select one only of the two following paragraphs. .3 Erect precast / prestressed elements within allowable tolerances as [indicated][specified]. .4 Non-cumulative erection tolerances to be in accordance with CSA A23.4, Section

[10]. / PCI MNL-116, PCI handbook, 5th Edition, Section 8-1. Spec Note: Where bearing pads are required, specify locations if not clearly indicated on drawings. .5 Set elevations and alignment between units to within allowable tolerances before connecting units. .6 Grout underside of precast units with nonshrinkage grout where indicated on approved shop drawings. .7 Secure with bolts using [lockwashers] [or] [tack-weld nut to bolt]. .8 Do not weld or secure bearing plates at sliding joints. .9 Use grout to align elevations at surface of joints in situations where allowable tolerances have been exceeded or as noted on consultants drawings in critical locations. .10 Clean field welds with wire brush and touch-up [shop primed materials with primer] [galvanized finish with zinc rich primer]. .11 Fasten units in place as per the approved connection detail shop drawings. Protect work from damage by weld splatter. 1.22 Handling .1 Precast / prestressed components shall be handled and erected in accordance with CSA Standard A23.4 / PCI Design handbook, 5th Edition and as per the manufacturers instructions. .2 Precast / prestressed components shall be delivered and handled in such a manner as to avoid warpage. .3 Holes and reglets shall be protected from forming of ice during freezing weather. .4 Lifting devices shall be protected from rusting at all times. .5 All precast / prestressed components shall be erected by experienced workmen under the supervision of a qualified superintendent with a minimum of five (5) years of precast installation experience. .6 Welding of the precast units shall be performed by certified welders in accordance with CSA Standard A23.4, Clause 32 / AWS D1.1. .7 Units shall be set plumb and true with joints parallel and uniform. .8 All necessary precautions shall be taken to prevent weld burn or splatter on to exposed surfaces. .9 Patch damaged, or chipped components as required. Cleaning .1 If required, clean exposed face work by washing and brushing only. Use approved masonry cleaner if washing and brushing fails to achieve required finish. Remove immediately materials which may set up or harden. This section is not responsible for soiling or damage by others.

1.20

1.21

1.23