DIVISION 3
SECTION 03 30 00
CAST-IN-PLACE CONCRETE
Concrete Resistant to High Heat and High Thermal Cycling
PART 1
1.1
1.2
1.3
GENERAL
(Areas in red are to be adjusted to fit necessary job requirements)
SUMMARY
A.
Section Includes:
1.
Cast-in-place concrete exposed to high heat (HH) and/or high thermal cycling (HTC)
environments in, but not limited to: [industrial infrastructure], [vertical takeoff aircraft slabs on ground], [foundry concretes] [high temperature equipment pads]
[containment structures*] [walls and vertical concrete structures] [sumps], {food
processing and ovens} [and] [agricultural concretes].
*Requires pre-approval by CERATECH based upon heat ranges and/or thermal exposures.
B.
Related Sections:
1. Division 01: Administrative, procedural, and temporary work requirements.
2. Section 03 11 00 - Concrete Forming.
3. Section 03 20 00 - Concrete Reinforcing.
4. Section 03 31 23 - High Performance Structural Concrete.
5. Section 03 35 00 - Concrete Finishing.
REFERENCES
A.
American Concrete Institute (ACI):
1.
301 - Specifications for Structural Concrete.
2.
305 - Hot Weather Concreting.
3.
306.1 - Standard Specification for Cold Weather Concreting.
4.
308.1 - Standard Specification for Curing Concrete.
5.
318 - Building Code Requirements for Structural Concrete.
B.
ASTM International (ASTM): Test Methods cited
C.
American Association of State Highway and Transportation Officials (AASHTO); Test methods cited.
SUBMITTALS
A.
Heat and Thermal Cycling Evaluation
1.
Identify minimum and maximum temperatures in project environment, as well as typical
thermal cycling in environment.
2.
Identify any additional exposures, including but not limited to steam, water, open flame,
hydraulic fluids, chemicals, etc. to verify product capacity and lifecycle expectations.
a. Submit relevant test data.
B.
Submittals for Review:
1.
Product Data:
a.
Submit product standards, physical and chemical characteristics, technical specifications, limitations, and general recommendations regarding each material.
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b.
1.4
1.5
1.6
Submit data on joint devices, attachment accessories [, and admixtures].
C.
Quality Control Submittals:
1.
Design data:
2.
Certificate of Compliance: Certify that Products furnished meet or exceed specified requirements.
D.
Sustainable Design Submittals:
1.
Recycled Content: Certify recycled material content for recycled content products.
2.
Regional Materials: Certify source for local and regional materials and distance from
project site.
3.
Rapidly Renewable Materials: Certify materials made from plants harvested within a
ten-year, or shorter, cycle.
4. Water consumption savings
5. Carbon reduction realized
QUALITY ASSURANCE
A.
Manufacturer Qualifications: Company specializing in manufacturing products specified in this
Section with minimum 3 years [documented] experience.
B.
Concrete Contractor Qualifications: Company specializing in placing and finishing cast-inplace high performance concretes with minimum 2 years [documented] experience.
1.
At least one ACI Certified Concrete Flatwork Finisher during concrete placement
and finishing.
C.
Mockup:
1.
Construct mockup for architectural concrete surfaces receiving special treatment or finish as result of formwork.
2.
Size: Sufficient to show special treatment or finish required.
3.
Locate [where directed.] [where indicated.]
4.
Approved mockup may [not] qualify as part of work.
5.
In cases where a mock-up is used to verify thermal capabilities, test
according to manufacturer’s instructions, in service environment only.
D.
Perform work in accordance with [ACI 301] [and] [ACI 318] for mixing, transportation, placing and consolidation of concrete.
E.
Perform work in accordance ACI 305.1 for hot weather concrete placement and protection.
F.
Perform work in accordance ACI 306.1 for cold weather concrete placement and protection
G.
Acquire cement and aggregate from one pre-qualified source throughout work.
PROJECT CONDITIONS
A.
Environmental Requirements: Maintain concrete temperature after installation per ACI
Standards.
B.
Follow ACI 301 Standard for effect of concrete and air temperatures, relative humidity, sun
exposure, and wind speed on the rate of evaporation of surface moisture from concrete.
COORDINATION
A.
Coordinate placement of joint devices with erection of concrete formwork and placement of
form accessories.
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PART 2 PRODUCTS
2.1
MANUFACTURERS
A.
Contract Documents are based on FIREROKTM by CeraTech USA
(www.ceratechinc.com/products/firerok)
B.
2.2
Substitutions: [0r equal per 2.2 A. ff.]
HIGH HEAT AND HIGH THERMAL CYCLE RESISTANT STRUCTURAL CONCRETE MATERIALS
A.
Structural Concrete to conform to: ASTM C1157, or ASTM C1600 Type VRH or URH as
manufactured by CERATECH Inc.. Material shall exhibit the following characteristics;
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
B.
2.3
Effectively placed in ambient temperatures ranging from 30° to 120° F following traditional post hydration curing practices.
Mixed and placed similar to traditional Portland concrete,.
1 to 5 hours working time or as specified.
Finished via standard concrete finishing practices.
Achieve compressive strengths per design specifications.
Realize >70% of 28 day strength in 7 days.
Moderate sulphate resistance.
ASR Resistant
Concrete to feature Very Low to Low permeability per ASTM C 1202
Recycled material content of binder to exceed 90%
Utilize a W/C ratio of <.25
Test data to verify resistance to designated thermal environment, providing multiple
times service life to Portland Cement Concrete in same environment
Aggregate:
1.
Only type recommended by cementitious concrete manufacturer; 3/8 inch (10 mm), 1/2
inch (13 mm), 3/4 inch (19 mm), or 1 inch (25 mm) clean washed fractured stone.
2.
Aggregates used in Firerok™ shall be siliceous types, either granite or trap rock (basalt/diabase). Granite shall have less than 5% quartz content where exposure temperatures of 900° F or higher are required. Alternate aggregates may be acceptable, contact CeraTech’s Field Engineering to discuss service requirements and aggregate options.
3.
Aggregates shall meet ASTM C-33 specifications and be certified to be clean and free
of any contamination, deleterious or organic material.
ADMIXTURES
A.
Air Entrainment: ASTM C260.
1.
MicroAir from BASF per manufacturer's instructions.
2.
Substitutions require approval by cement manufacturer.
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2.4
CAST-IN-PLACE, HIGH HEAT AND HIGH THERMAL CYCLING, STRUCTURAL CONCRETE MIX
A.
Provide concrete mix design to met or exceed the project criteria for Ceratech Inc. approval:
CHARACTERISTIC
TEST METHOD
Compressive Strength
ASTM C39
28 days
Flexural Strength
RESULTS-NET /
RESULTS EXTENDED
[_______] psi ([_______] MPa)
ASTM C78
28 days
[______] psi ([______] MPa)
Splitting Tensile Strength @ 28 days
ASTM C496
Modulus of Elasticity @ 28 days
ASTM C469
Coefficient of Thermal Expansion @ 28 days
AASHTO TP 60
Length Change, Percent of total length @ 28 ASTM C1600
days dry cure (Air Storage)
Set Times at 72 degrees F/ 22 degrees C
Initial (Work Time)
Mix Design Dependent
Final
Mix Design Dependent
Load Bearing Strengths
dependent upon mix design
Foot Traffic
Mix Design Dependent
Wheeled Traffic
Mix Design Dependent
Stripping Formwork
24 to 72 hours
Curing
Approved Curing Compound or Evaporative Retarder
B.
Admixtures: Include admixture types and quantities indicated in concrete mix designs only
when approved by C-USA and Architect/Engineer and in accordance with the cast-in-place
high performance structural concrete manufacturer's installation/mixing instructions.
C.
Transit Mixed Concrete: Mix and deliver concrete in accordance with manufacturer's instructions.
D.
Site Mixed Concrete: Mix concrete in accordance with manufacturer's instructions [and ACI
318].
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PART 3
3.1
3.2
EXECUTION
EXAMINATION
A.
Verify requirements for concrete cover over reinforcement.
B.
Verify anchors, seats, plates, reinforcement and other items to be cast into concrete are accurately placed, positioned securely, and will not interfere with placing concrete.
PREPARATION
A.
Site Preparation: Construction site should be prepared in accordance with ACI Guidelines for
placement of structural concrete.
B.
In locations where new concrete is doweled to existing work, drill holes in existing concrete;
insert steel dowels to ensure proper performance.
C.
Remove debris and ice from formwork, reinforcement, and concrete substrates.
D.
Remove water from areas receiving concrete before concrete is placed.
E.
When bonding to existing concrete;
1.
Prepare host concrete by cleaning with hydro blast, or mechanical means to ensure
removal of all laitance, coatings, chemical contamination, and unsound materials.
a.
Remove existing concrete until reaching sound concrete with a ph >9.0
b.
Prepare to SSD condition (Saturate Surface Dry) prior to material placement
3.3
MIXING INSTRUCTIONS
A.
Standard Mixing Procedures per C-USA Producer Guide, mix design to be determined and
verified prior to project start.
3.4
PLACING HIGH HEAT AND HIGH THERMAL CYCLING STRUCTURAL CONCRETE
A.
General: Working times based on ambient temperature, mix design, and total amount of
water.
1.
Working times are influenced by substrate, surface temperature, humidity, and repair
profile.
2.
Upon initial set, a broom finish can be applied. Upon final set, the material can be sawcut and/or drilled.
3.
Sanding and/or polishing to be done per manufacturer’s specifications.
4.
Do not re-temper. The addition of water to the surface of concrete will negatively affect
the materials final properties.
Clean all tools and equipment with water prior to the material reaching final set.
5.
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B.
3.5
3.6
3.7
Place concrete in accordance with [ACI 301] [ACI 318].
CONCRETE FINISHING
A.
Provide formed [concrete surfaces to be left exposed] concrete [walls] [columns]
[beams] [joists] [____]] with [smooth rubbed] [____] [sand float] [sack rubbed] finish
[as Scheduled in this section].
B.
Follow manufacturer’s (CeraTech USA) instructions for finishing materials and methods.
C.
Finish concrete floor surfaces in accordance with [ACI 301] [ACI 318].
D.
Steel trowel surfaces, which are indicated to be exposed.
E.
In areas with floor drains, maintain floor elevation at walls; pitch surfaces uniformly to drains
[at [1/8] [1/4] [____] inch per foot ([10] [20] [____] mm per m) nominal] [as indicated on
drawings].
CURING AND PROTECTION
A.
Immediately after placement, protect concrete from premature drying, excessively hot or cold
temperatures, and mechanical injury.
B.
Protect concrete from freezing for minimum one day.
C.
Maintain concrete with minimal moisture loss at relatively constant temperature for period
necessary for hydration of cement and hardening of concrete.
D.
Cure floor surfaces in accordance with manufacturer's installation instructions and [ACI
308.1] [ACI 301] [ACI 318].
E.
Consult with Manufacturer to determine required cure time prior to returning concrete to high
heat service environment.
FIELD QUALITY CONTROL
A.
Field inspection and testing will be performed by Owner’s testing laboratory in accordance
with [ACI 318] [[applicable] [____] code].
END OF SECTION
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