BASRAH SPORTS CITY

SECTION 03 41 20 – STRUCTURAL PRECAST HOLLOW-CORE PLANKS

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Construction Contract, including General Conditions and
Division 1 Specification Sections, apply to this Section.

1.2 SUMMARY

A. This work includes the requirements for the design, fabrication, delivery, and installation of precast,
reinforced and prestressed concrete elements. The Work includes, but is not limited to the following:

1. Concrete Materials
2. Hardware, Metal Inserts and Embedments
3. Formwork
4. Furnishing and Placement of Reinforcement
5. Mixing and Placing Concrete
6. Surface Finish
7. Precast Quality Control, Inspection and Testing
8. Handling and Transportation of Precast Components
9. Openings Indicated on Design Drawings
10. Reinforcement Steel Placement Drawings and Fabrication
11. Precast Erection
12. Grouting of Joints as Indicated on Drawings
13. Patching of Joints

B. Related Work

1. Concrete Formwork - Section 03 10 00

2. Concrete Reinforcement and Embedded Assemblies - Section 03 20 00
3. Concrete - Section 03 30 00
4. Unit Masonry - Section 04 20 00
5. Structural Steel - Section 05 12 00

1.3 REFERENCE STANDARDS

A. Requirements, abbreviations and acronyms for reference standards are defined in Section 01 09 50.

B. Prestressed Concrete Institute (PCI) - MNL 116 - Manual for Quality Control for Plants and
Production of Precast and Prestressed Concrete Products.

C. PCI MNL 127 – Recommended Practice for Erection of Precast Concrete.

D. AASHTO M 251 – Specification for Plain and Laminated Elastomeric Bridge Bearings.

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E. ACI 301 – Standard Specifications for Structural Concrete.

F. ACI 304R – Guide for Measuring, Mixing, Transporting, and Placing Concrete.

G. Aci 309R - Guide for Consolidation of Concrete.

H. ACI 318 - Building Code Requirements for Structural Concrete.

I. ASTM A 185 - Standard Specification for Steel Welded Wire Fabric, Plain, for Concrete
Reinforcement.

J. ASTM A 307 - Standard Specification for Carbon Steel Bolts and Studs, 60,000 PSI Tensile
Strength.

K. ASTM A 416 – Standard Specification for Steel Strand, Uncoated Seven-Wire for Prestressed
Concrete.

L. ASTM A 496 - Standard Specification for Steel Wire, Deformed, for Concrete Reinforcement.

M. ASTM A 615 - Standard Specification for Deformed and Plain Billet-Steel Bars for Concrete
Reinforcement.

N. ASTM C 33 – Standard Specification for Concrete Aggregates.

O. ASTM C 42 - Standard Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of
Concrete.

P. American Welding Society D1.1 - Structural Welding Code - Steel.

Q. American Welding Society D1.4 - Structural Welding Code - Reinforcing Steel.

R. BOCA - National Building Code.

S. SSPC-PA 1 - Paint Application Specification No. 1: Shop, Field, and Maintenance Painting.

T. SSPC-SP 3 – Surface Preparation Specification No. 3: Power Tool Cleaning.

1.4 DESIGN

A. The design of all precast structural concrete is the responsibility of the Precaster and shall be
performed under the supervision of a Licensed Structural Engineer.

B. The Structural Engineer responsible for the design of the precast structural concrete (see paragraph
1.4.A) shall be responsible for the implementation of his design by reviewing the fabrication process
to assure conformance with his design.

C. Precast structural concrete shall be designed for the loads indicated on the drawings and shall take
into account all stresses resulting from initial handling and erection.

D. The design shall properly account for the load distribution of concentrated and live loads and for
effect of openings.

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E. The precast structural elements will be designed to coordinate with the parameters set forth by the
architectural and structural drawings. Any changes required to the structural system, and/or
architectural drawings, if accepted by the Architect/Engineer and Owner, will be based on the
Precaster bearing all costs of such changes including the redesign costs of the Architect/Engineer.

F. Precast structural concrete components shall be designed for the fire ratings indicated on the
architectural drawings.

1.5 QUALITY ASSURANCE

A. For precast concrete furnished under this Section, quality control inspection and testing shall occur
during the manufacture of the components, and the components are subject to the approval of the
precast supplier's Quality Control Manager and Owner’s Testing Laboratory.

B. Testing and Inspection will be in accordance with PCI MNL-116 Requirements for all units and PCI
MNL-117 Requirements for architectural units only.

C. Concrete components shall be cast under controlled conditions. Forms shall be rigidly constructed,
straight, square, true and designed for close control of dimensions and details.

D. Before shipment, all precast components shall be inspected to make certain the materials and
workmanship conform to the requirements of these specifications. Copy of the written inspection
reports shall be provided to the Architect/Engineer for record.

E. The finished product shall be lifted and/or supported at the points shown on the shop drawings or at
the support points of the member when it is put into service.

F. Fabricator Qualifications - Firms which have a minimum of 5 years successful experience in the
fabrication of structural precast concrete units, similar to units required for this project, will be
acceptable. Fabricator must have sufficient production capacity to produce, transport, and deliver
required units without causing delay in the Work.

G. Produce precast concrete units only at fabricating plant engaged primarily in manufacturing of
similar units.

H. Design modifications may be made only as necessary to meet field conditions and to ensure proper
fitting of the Work, and only as acceptable to Architect/Engineer. Maintain general design concept
shown without increasing or decreasing sizes of members or altering profiles and alignment shown.
Submit for record complete design calculations and drawings prepared by a Structural Engineer
licensed in the state where project is located, if design modifications are anticipated.

I. Erector Qualifications - Minimum of 5 years successful experience in the erection of structural

precast concrete units, similar to units required for this project.

J. Welder qualifications shall be in accordance with AWS D1.1 requirements.

1.6 SUBMITTALS

A. Submit the following according to Conditions of the Construction Contract and Division 1
Specification Sections.

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B. Mix Designs: Submit Mix design reports for action, with all data as specified in Section
03300/Concrete.

C. Submit shop drawings for Architect/Engineer’s action. Show layout, dimensions, sections through
members and assemblies, joint and corner details, type and location of all inserts, reinforcing,
prestressing tendons, strength of concrete, fastening and anchoring details, including clearances,
and details of attachment to other work. Indicate finishes, form types and other pertinent
information.

D. Shop Drawings shall also indicate, erection schedules and sequences, assembly techniques, and
marking of members.

E. Review of Shop Drawings will be for the general arrangement of components. Errors in dimensions
shown on the Shop Drawings shall be responsibility of the Precaster. Check and coordinate precast
Work with Work of other trades prior to submitting Shop Drawings.

F. Shop Drawings shall include fabrication, bending and placement of concrete reinforcement. Include
all special reinforcement required and openings through concrete structures.

G. Shop drawings shall show the following:

1. Dimensions, size and location of openings.

2. Quantities, location of stressing force of prestressing tendons.
3. Locations and details of connections.
4. Inserts, attachments, and embedments.
5. Anticipated cambers at time of erection.
6. Strength of concrete at prestressing and at time of erection.
7. Elongation for prestressing and at erection.
8. Caulked joints.
9. Location, extent and reinforcing of any cast-in-place concrete on top of precast that is
designed to be composite with slab units.
10. All areas of connections, embedments, etc. required to be sealed or caulked.

H. Submit structural design calculations for record only with the seal and signature of the licensed
Structural Engineer. Each change of component configuration and design shall have its own set of
calculations.

I. Product data: submit for record only manufacturer's product data, including specifications and
installation instructions clearly marked to indicate all technical information, including load tables
where applicable, that specifies full compliance with requirements of this section and Contract
Documents for each type of insert, accessory and product specified.

J. Hazardous Materials Notification: In the event no product or material is available that does not
contain asbestos, PCB or other hazardous materials as determined by the Owner, a "Material Safety
Data Sheet" (MSDS) equivalent to OSHA Form 20 shall be submitted for that proposed product or
material prior to installation.

K. Asbestos and PCB Certification: After completion of installation, but prior to Substantial Completion,
Contractor shall certify in writing that products and materials installed, and processes used, do not
contain asbestos or polychlorinated biphenyls (PCB), using format in General Conditions.

1.7 DELIVERY, HANDLING, STORAGE

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A. Comply with General Conditions and Section 01 60 00/Materials and Equipment.

B. Storage:

1. Store all units off ground.

2. Place stored units so that identification marks are discernible.
3. Separate stacked members by battens across full width of each slab unit.
4. Stack so that lifting devices are accessible and undamaged.
5. Do not use upper member of stacked tier as storage area for shorter member or heavy
equipment.

C. Handling:

1. Units shall be lifted and supported during manufacturing, stockpiling, transporting, and
erection operations only at the lifting or supporting point, or both, as shown on the shop
drawings, and with approved lifting devices. Lifting inserts shall have a minimum safety
factor or 4. Exterior lifting hardware shall have a minimum safety factor of 5.
2. Transportation, site handling, and erection shall be performed with acceptable equipment and
methods, and by qualified personnel.
3. Exposed concrete units shall be adequately protected by padding or other means to prevent
staining, chipping, or spalling of concrete.

1.8 WARRANTY

1. Comply with General Conditions, agreeing to repair or replace specified materials or Work
that has failed within the warranty period.

PART 2 - PRODUCTS

2.1 HOLLOW-CORE PLANK UNITS

A. Slab Type: Precast, prestressed concrete units with open, hollow cores running the full length of the
slab units.

B. Furnish units free of voids or honeycombs.

C. Provide standard finish to precast units, as specified herein.

D. Reinforce units to resist transportation and erection stresses.

E. Include cast-in weld plates where required.

F. Coordinate with other trades for installation of cast-in items.

G. Provide headers of cast-in-place concrete or structural steel shapes for openings less than or equal
to one slab width according to hollow-core slab unit fabricator's recommendations.

2.2 CONCRETE

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A. Cement shall be Portland Cement as specified in Section 03 30 00/Concrete. For exposed surfaces
use same brand, type, and source supply throughout,

B. Concrete aggregates shall conform to ASTM C 33. The size of coarse aggregates in the concrete
shall meet the spacing requirements of prestressing steel and/or reinforcing steels. The size of the
coarse aggregate shall be no larger than 3/4" (19mm) (size No. 67 per ASTM C 33). For exposed
face mix aggregate provide fine and course aggregates for each type of exposed finish from a
single source for entire job.

C. Water and admixtures shall be as specified in Section 03 30 00.

D. Cement and aggregates shall be stored in such a manner as to prevent their deterioration or the
intrusion of foreign matter. Any materials which have deteriorated or which have been contaminated
shall not be used for concrete.

E. Use of calcium chloride, chloride ions or other salts is not permitted.

F. Concrete shall have a minimum 28-day compressive cube strength of 40 MPa, and a release
strength of 25 MPa. Precast concrete shall have a resistance of not less than 3000 coulombs as
per AASHTO-T277.

G. All precast concrete shall have a maximum water cement ratio of 0.40.

H. See Section 03 30 00 for air entraining requirements and admixtures.

I. Coloring Agent: Synthetic mineral oxide, harmless to concrete set and strength.

2.3 REINFORCING

A. Materials, fabrication, etc., for reinforcing shall meet applicable ASTM standards as specified in
Section 03200/Concrete Reinforcement and Embedded Assemblies.

B. Reinforcing Bars - ASTM A 615, Grade 60.

C. Welded Plain Wire Fabric - ASTM A 185.

D. Prestressing Strand – ASTM A 416, uncoated seven-wire stress-relieved strand, with a minimum
tensile strength of 270,000 psi.

2.4 CONNECTION MATERIALS AND EMBEDDED ITEMS

A. Steel Shapes and Plates: ASTM A 36.

B. Bolts and Studs: ASTM A 307, Grade A; carbon-steel, hex-head bolts and studs; carbon-steel nuts;
and flat, unhardened steel washers.

C. Welded Headed Studs: AWS D1.1, Type B headed studs, cold-finished carbon-steel bars.

D. Deformed-Steel Wire Bar Anchors: ASTM A 496.

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E. Welding Electrodes: Comply with AWS requirements.

F. Accessories: Provide clips, hangers, shims, and other accessories required to install precast
concrete units.

G. Shop-Primed Finish: Prepare surfaces of interior steel items, except those with galvanized finish or
those surfaces to be embedded in concrete, according to requirements of SSPC-SP 3 and shop-
apply primer according to SSPC-PA 1.

1. Primer: Fast-curing, lead- and chromate-free, VOC-conforming, universal modified-alkyd

primer with good resistance to normal atmospheric corrosion.

2.5 BEARING PADS

A. Provide bearing pads for precast concrete units as follows:

1. Elastomeric Pads: AASHTO M 251, plain, vulcanized, 100 percent polychloroprene

(neoprene) elastomer, molded to size or cut from a molded sheet, 50 to 70 shore A
durometer.
2. Random, Fiber-Reinforced Elastomeric Pads: Preformed, randomly oriented synthetic fibers
set in elastomer. Surface hardness of 70 to 90 shore A durometer.
3. Cotton-Duck-Fabric-Reinforced Elastomeric Pads: Preformed, horizontally layered cotton-
duck fabric, bonded in elastomer. Surface hardness of 80 to 100 shore A durometer.
4. High-Density Plastic: Multimonomer, nonleaching, plastic strip.

2.6 FORMWORK

A. Provide forms and, where required, form facing materials of metal, plastic, wood, or other
acceptable material that is non-reactive with concrete and will produce required finish surface.

2.7 SOURCE QUALITY CONTROL

A. The Owner’s Testing Laboratory will evaluate precast fabricator's quality control and testing
methods.

1. Allow Owner's Testing Laboratory access to material storage areas, concrete production
equipment, concrete placement, and curing facilities. Cooperate with Owner's Testing
Laboratory and provide samples of materials and concrete mixes as may be requested for
additional testing and evaluation.

B. Quality-Control Testing: Test and inspect precast concrete according to PCI MNL-116
requirements.

C. Strength of precast concrete units will be considered potentially deficient when precast concrete
units fail to comply with requirements, including the following:

1. Fail to meet compressive-strength test requirements.

2. Reinforcement, and pretensioning and detensioning tendons of prestressed concrete do not
conform to fabrication requirements.

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3. Concrete curing and protection of precast units against extremes in temperature fail to meet
requirements.
4. Precast units are damaged during handling and erecting.

D. Testing: When there is evidence that the strength of precast concrete units may be deficient or may
not meet requirements, the Owner’s Testing Laboratory will obtain, prepare, and test cores drilled
from hardened concrete to determine compressive strength according to ASTM C 42.

1. A minimum of 3 representative cores will be taken from precast concrete units of suspect
strength, from locations directed by Architect/Engineer.
2. Cores will be tested in an air-dry condition per ACI 301 when precast concrete units will be
dry under service conditions.
3. Strength of concrete for each series of 3 cores will be considered satisfactory if the average
compressive strength is at least 85 percent of the 28-day design compressive strength and
no core compressive strength is less than 75 percent of the 28-day design compressive
strength.
4. Test results will be made in writing on the same day that tests are made, with copies to
Architect/Engineer, Contractor, and precast fabricator. Test reports will include the Project
identification name and number, date, name of precast concrete fabricator, name of concrete
testing agency; identification letter, name, and type of precast concrete unit or units
represented by core tests; design compressive strength, compressive strength at break and
type of break, corrected for length-diameter ratio, and direction of applied load to core with
respect to horizontal plane of concrete as placed.

E. Patching: Where core test results are satisfactory and precast concrete units meet requirements,
solidly fill core holes with patching mortar and finish to match adjacent concrete surfaces.

F. Dimensional Tolerances: Units having dimensions smaller or greater than required and not meeting
tolerance limits may be subject to additional testing.

1. Precast units having dimensions greater than required will be rejected if the appearance or
function of the structure is adversely affected or if larger dimensions interfere with other
construction. Repair or remove and replace rejected units, as required, to meet construction
conditions.

G. Defective Work: Precast concrete units that do not conform to requirements, including strength,
manufacturing tolerances, and finishes, are unacceptable. Replace with precast concrete units that
meet requirements.

PART 3 - EXECUTION

3.1 FABRICATION TOLERANCES

A. Listed below are generalized tolerances taken from the referenced standards

1. Overall dimension - The numeral greater of +/- 1/16" (1.6mm) per 10 ft. (3.0m) or +/- 1/8"
(3mm) (PCI).
2. Cross-sectional dimensional (ACI):

a. Section less than 6" (150mm), +/- 1/8" (3mm).

b. Section over 6" (150mm) and less than 18" (450mm), +/- 3/16" (4.8mm).
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3. Squareness (PCI) - 1/8" (3mm) in 6 ft. (1.8m) out of square as measured on the diagonal.
4. Deviation from specified camber (ACI) - Precast, 1/16" (1.6mm) per 10 ft. (3.0m) of span;
Prestressed, 1/8" (3mm) per 10 ft. (3.0m) of span. Differential camber between adjacent
units shall not exceed 3/8"(10mm).
5. Deviation from straight line in long section (ACI) - Not more than 1/8" (3mm) per 10 ft. (3.0m)
6. Warpage (PCI) - 1/8" (3mm) per 6 ft. (1.8m) of length.
7. Variation in size and locations of sleeves and openings (ACI) - 1/4" (6mm).
8. Location of anchors and inserts (PCI) - 3/8" (10mm) off center line location shown on
drawings.

B. Shop drawings shall explicitly show tolerances on major dimensions, i.e., length, width, thickness
and diagonals. A note summarizing the other above mentioned tolerances shall also appear.

3.2 FABRICATION AND PLACEMENT OF REINFORCING

A. Formwork: Accurately construct forms, mortar-tight, and of sufficient strength to withstand pressure
due to concrete placing operations, temperature changes and, when pretressed, pretensioning and
detensioning operations. Maintain formwork to provide completed precast concrete units of shape,
lines and dimensions indicated, within specified fabrication tolerances.

B. Unless forms for plant-manufactured prestressed concrete units are stripped prior to detensioning,
design forms so that stresses are not induced in precast units due to deformation of concrete under
prestress or to movement during detensioning.

C. Placing, supporting, etc., of reinforcing steel shall be in accordance with Concrete Reinforcing Steel
Institute's "Recommended Practice for Placing Bar Supports Specifications and Nomenclature", and
with applicable sections of ACI 318.

D. Reinforcement to be welded shall conform with AWS D1.4.

E. The spacing of prestressing strands at the ends of the component shall be the largest of the
following:

1. The center to center distance of prestressing strands shall be not less than three times the
strand diameter.
2. The clear spacing between strands shall not be less than 1-1/3 times the maximum size of
coarse aggregates.

F. Pretensioning: Pretension tendons for precast, prestressed concrete either by single-strand

tensioning method or multiple-strand tensioning method. Comply with PCI MNL-116 requirements.

G. Built-In Anchorages: Accurately position built-in anchorage devices and secure to formwork.
Locate anchorages where they do not affect the position of the main reinforcement or placing of
concrete. Do not relocate bearing plates in units, unless acceptable to Architect/Engineer.

H. Cast-in openings larger than 6 inches (150mm) in diameter or 6 inches (150mm) square according
to final shop drawings. Other smaller holes may be field cut by trades requiring them through core
of slab only, as acceptable to Architect/Engineer.

I. The concrete cover shall be as shown on the drawings or as per ACI 318, Chapter 7.

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J. The surface condition of all reinforcement shall be clean and free of oil and substances harmful to
bond. Special care shall be exercised with prestressing strands.

3.3 CONCRETE PLACEMENT

A. Place concrete in a continuous operation to prevent seams or planes of weakness from forming in
precast units. Comply with requirements of ACI 304R for measuring, mixing, transporting, and
placing concrete.

B. Thoroughly consolidate placed concrete by internal and external vibration without dislocating or
damaging reinforcement and built-in items. Use equipment and procedures complying with
ACI 309R.

3.4 CURING

A. The unit must be cured by either a continuous moist curing method approved by the
Architect/Engineer or by using curing compound.

B. Wet curing - Wet cure by continuous fog spray or immersion in water. Do not use curing
compounds on surfaces to be wet cured.

3.5 PRESTRESSING STEEL

A. Prestressing steel shall be detensioned so that force in the prestressing steel shall be transferred to
the concrete by releasing all strands simultaneously or by cutting individual strands. If the force in
the strand is transferred individually, a sequence release and corresponding calculations prepared
by the Precaster’s Structural Engineer shall be submitted for record to avoid subjecting the member
to damaging stresses.

B. Transfer of prestressing force shall be done when the concrete has reached a cube strength of 25
MPa or greater as required by design. Prestressed strands shall be tensioned as follows:

1. Strands may be tensioned and anchored all at once or one or more at a time, at the
discretion of the manufacturer.
2. When two or more strands are tensioned simultaneously, means shall be provided to obtain
equal tension in each strand.
3. For stress-relieved strand, pretensioning force shall be determined by elongation based on
the load elongation curve of the strand.

3.6 FINISH

A. Hollow Core Plank Standard underside

1. Resulting from casting against approved forms using good industry practice in cleaning of
forms, design of concrete mix, placing and curing.
2. Small surface holes caused by air bubbles, normal color variations, normal form joint marks
and minor chips and spalls shall be tolerated, but no major or unsightly imperfections,
honeycomb, or other defects will be permitted.

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B. Hollow Core Plank Standard top

1. Finish unformed surfaces by trowel, unless otherwise indicated. Consolidate concrete, bring
to proper level with straightedge, float, and trowel to a smooth, uniform finish.

a. Apply scratch finish to precast concrete units that will receive concrete topping after
installation. Following initial strike-off, transversely scarify surface to provide ridges
approximately 1/4 inch deep.

C. Wall units and any exposed units – See architectural requirements for finish.

D. Blockouts shall be removed prior to shipment.

E. Inserts shall be free of contaminants and burrs.

3.7 PRE-INSTALLATION INSPECTION

A. Examine the areas and conditions where precast structural concrete is to be installed and notify the
Architect/Engineer of conditions detrimental to the proper and timely completion of the Work. Do
not proceed with the Work until unsatisfactory conditions have been corrected by the Precaster in a
manner acceptable to the Architect/Engineer.

3.8 ERECTION

A. All precast units shall be erected level, plumb, square and true so that no cumulative dimensional
errors occur.

B. The erector shall be responsible for any chipping, spalling, cracking or other damage to the units
after delivery to the job site and until installation is completed.

C. The erector shall be responsible for damage to Work and materials of other trades.

3.9 ERECTION TOLERANCES

A. Tolerances for Location of Precast Units - Fabricate and erect precast units so that joints between
panels meet the following:

1. Face width of joints - plus or minus 3/16" (4.8mm).

2. Joint taper - 1/40" (0.6mm) per foot length, with maximum length of tapering in one direction
of 10' (3m).
3. Step in face - 1/4" (6mm).
4. Jog in alignment of edge - 1/4" (6mm).
5. Alignment for exterior panels is outside face.
6. Variation from plumb - plus or minus 1/2" (13mm) in any 40' (12m) run.
7. Variation from level - plus or minus 1/2" (13mm) in any 40' (12m) run.
8. Differential camber of adjacent pieces after erection under 1/4" (6mm).

3.10 INSTALLATION

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A. Bearing Pads: Install bearing pads as precast concrete units are being erected. Set pads on true,
level, and uniform bearing surfaces and maintain in correct position until precast units are placed.

B. Alignment: Members shall be properly aligned and leveled. Variations between adjacent members
shall be reasonably leveled out by jacking, loading, or any other feasible method as recommended
by the manufacturer and accepted by the Architect/Engineer.

C. Welding: Perform welding in compliance with AWS D1.1 and AWS D1.4.

1. Protect precast concrete units and bearing pads from damage by field welding or cutting
operations and provide noncombustible shields as required.
2. Repair damaged metal surfaces by cleaning and repriming damaged painted surfaces.

D. Fasteners: Do not use drilled or powder-actuated fasteners for attaching accessory items to
precast, prestressed units, unless otherwise acceptable to Architect/Engineer.

E. Shore and brace precast concrete units to maintain location, stability, and alignment until permanent
connections are installed.

3.11 GROUTING

A. Grout open spaces at keyways, connections, and joints as indicated or required except for items
grouted by other trades.

B. Mix non-shrink grout with sufficient water to cause it to flow under its own weight.

C. Place fluid grout from one side and puddle for complete filling of voids; do not remove dams or
forms until grout attains initial set. Finish exposed surfaces smooth and cure with damp burlap at
least 3 days.

3.12 PATCHING

A. Patch and feather all joints to the satisfaction of the Architect/Engineer. First patch, approved by
Architect/Engineer, will be considered standard of quality for subsequent patching. Proposed
patching procedure shall be submitted to the Architect/Engineer for review.

END OF SECTION 03 41 20

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