pip sts03001 (plain & reinforced concrete specification)

COMPLETE REVISIONJuly 2001

Process Industry PracticesStructural

PIP STS03001Plain and Reinforced Concrete

Specification

PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice hasbeen prepared from the technical requirements in the existing standards of majorindustrial users, contractors, or standards organizations. By harmonizing thesetechnical requirements into a single set of Practices, administrative, application, andengineering costs to both the purchaser and the manufacturer should be reduced. Whilethis Practice is expected to incorporate the majority of requirements of most users,individual applications may involve requirements that will be appended to and takeprecedence over this Practice. Determinations concerning fitness for purpose andparticular matters or application of the Practice to particular project or engineeringsituations should not be made solely on information contained in these materials. Theuse of trade names from time to time should not be viewed as an expression ofpreference but rather recognized as normal usage in the trade. Other brands having thesame specifications are equally correct and may be substituted for those named. AllPractices or guidelines are intended to be consistent with applicable laws andregulations including OSHA requirements. To the extent these Practices or guidelinesshould conflict with OSHA or other applicable laws or regulations, such laws orregulations must be followed. Consult an appropriate professional before applying oracting on any material contained in or suggested by the Practice.

This Practice is subject to revision at any time by the responsible Function Teamand will be reviewed every 5 years. This Practice will be revised, reaffirmed, orwithdrawn. Information on whether this Practice has been revised may be found athttp://www.pip.org.

© Process Industry Practices (PIP), Construction Industry Institute, TheUniversity of Texas at Austin, 3208 Red River Street, Suite 300, Austin,Texas 78705. PIP member companies and subscribers may copy this Practicefor their internal use. Changes, overlays, addenda, or modifications of anykind are not permitted within any PIP Practice without the express writtenauthorization of PIP.

PRINTING HISTORY

December 1995 IssuedJuly 2001 Complete Revision

Not printed with State funds

COMPLETE REVISIONJuly 2001

Process Industry Practices Page 1 of 13

Process Industry PracticesStructural

PIP STS03001Plain and Reinforced Concrete

Specification

Table of Contents

1. Introduction..................................21.1 Purpose ............................................. 21.2 Scope................................................. 2

2. References ...................................22.1 Industry Codes and Standards .......... 22.2 Government Regulations ................... 3

3. Definitions ....................................3

4. General .........................................44.1 Quality Control ................................... 44.2 Submittals .......................................... 54.3 Safety................................................. 5

5. Materials .......................................65.1 General .............................................. 65.2 Cementitious Materials ...................... 65.3 Admixtures......................................... 65.4 Aggregates ........................................ 65.5 Reinforcement ................................... 65.6 Water ................................................. 65.7 Accessories ....................................... 6

6. Execution ..................................... 76.1 Formwork........................................... 76.2 Joints ................................................. 76.3 Waterstops ........................................ 86.4 Reinforcing and Embedments ........... 86.5 Proportioning and Mixing ................... 96.6 Placing Concrete ............................. 106.7 Curing and Protection ...................... 106.8 Surface Finishing and Tolerances ... 116.9 Repair of Surface Defects ............... 116.10 Hot and Cold Weather Concreting... 126.11 Architectural and Prestressed

Concrete .......................................... 12

Table 1Supplier Data Requirements.................... 13

PIP STS03001 COMPLETE REVISIONPlain and Reinforced Concrete Specification July 2001

Page 2 of 13 Process Industry Practices

1. Introduction

1.1 Purpose

This Practice provides the contractor with a specification for cast-in-placeconcrete construction.

1.2 Scope

This Practice describes the technical requirements for furnishing and installationof all materials, proportioning, mixing, placing, testing, and curing of plain andreinforced concrete.

This Practice is a supplement to ACI 301-99, Specifications for StructuralConcrete. Concrete supply and construction shall conform to all requirements ofACI 301-99, except as modified or supplemented herein or by the contractdocuments.

Any conflicts or inconsistencies between this Practice, the design drawings, orother contract documents shall be brought to the attention of the buyer forresolution.

2. References

When adopted in this Practice or in the contract documents, the latest edition of thefollowing codes, standards, specifications, and references in effect on the date ofcontract award shall be used, except as otherwise noted. Short titles will be used hereinwhen appropriate.

2.1 Industry Codes and Standards

• American Concrete Institute (ACI)

– ACI 117 - Standard Specifications for Tolerances for ConcreteConstruction and Materials

– ACI 301-99 - Specifications for Structural Concrete

Note: Standards referenced in ACI 301, Section 1.3, Reference Standardsand Cited Publications, are declared to be part of ACI 301 and this Practice,the same as if fully set forth herein.

– ACI 306.1 - Standard Specification for Cold Weather Concreting

– ACI SP-66 - ACI Detailing Manual

In meeting the requirements of this Practice and ACI 301, the following ACIdocuments shall be used as acceptable practice:

– ACI 211.1 - Standard Practice for Selecting Proportions for Normal,Heavyweight, and Mass Concrete

– ACI 211.2 - Standard Practice for Selecting Proportions for StructuralLightweight Concrete

COMPLETE REVISION PIP STS03001July 2001 Plain and Reinforced Concrete Specification


– ACI 302.1R - Guide for Concrete Floor and Slab Construction

– ACI 304R - Guide for Measuring, Mixing, Transporting, and PlacingConcrete

– ACI 304.2R - Placing Concrete by Pumping Methods

– ACI 305R - Hot Weather Concreting

– ACI 306R - Cold Weather Concreting

– ACI 308 - Standard Practice for Curing Concrete

– ACI 347R - Guide to Formwork for Concrete

– ACI 504R - Guide to Joint Sealants for Concrete Structures

• American Society for Testing and Materials (ASTM)

– ASTM A185 - Standard Specification for Steel Welded Wire Fabric,Plain, for Concrete Reinforcement

– ASTM A615/A615M - Standard Specification for Deformed and PlainBillet-Steel Bars for Concrete Reinforcement

– ASTM C33 - Standard Specification for Concrete Aggregates

– ASTM C94/C94M - Standard Specification for Ready Mixed Concrete

– ASTM C150 - Standard Specification for Portland Cement

– ASTM C618 - Standard Specification for Coal Fly Ash and Raw orCalcined Natural Pozzolan for Use as a Mineral Admixture in PortlandCement Concrete

• National Ready Mixed Concrete Association (NRMCA)

– Checklist for Ready Mixed Concrete Production Facilities, Sixth Edition

2.2 Government Regulations

Requirements of state or local agencies that have jurisdiction where the concreteis to be placed shall apply.

• U.S. Department of Labor, Occupational Safety and Health Administration(OSHA)

– OSHA 29 CFR 1926 - Safety and Health Regulations for Construction

3. Definitions

Buyer: The party who awards the contract. The buyer may be the owner or the owner’sauthorized agent.

Contractor: The party responsible for supplying the materials, equipment, tools,supervision, and labor for the installation of the concrete and embedded items inaccordance with the contract documents. Unless otherwise noted, the term contractorshall apply also to the contractor’s subcontractor(s) and vendors.

Contract Documents: Any and all documents, including design drawings, that the buyerhas transmitted or otherwise communicated, either by incorporation or reference, and



made part of the legal contract agreement or purchase order between the buyer and thecontractor.

Engineer: The buyer’s authorized representative with overall authority and responsibilityfor the structural design.

4. General

4.1 Quality Control

4.1.1 The contractor shall submit a written quality control program andinspection procedures document to the buyer for approval. These shallprovide details of how compliance with the requirements of this Practiceand contract documents will be achieved.

4.1.2 The buyer will be responsible for providing a testing agency to act as the“owner’s testing agency” as defined by ACI 301, unless otherwisespecified in the contract documents.

4.1.3 The buyer reserves the right to make inspections at any time at thesource of supply of materials, at the place of preparation of materials, atthe mixing plant if ready mixed concrete is used, and during execution ofall concrete work.

4.1.4 Samples for testing shall be obtained in accordance with ACI 301. Therate of sampling shall be per ACI 301 and the following:

4.1.4.1 Structures and Foundations

Obtain one sample per 100 cubic yards (76 cubic meters) ofconcrete. At least one sample shall be obtained for eachstructure or foundation, except when placing a number of itemseach smaller than 15 cubic yards (11 cubic meters), where onesample per 15 cubic yards (11 cubic meters) will suffice.

4.1.4.2 Paving and Slabs on Grade

Obtain one sample per 50 cubic yards (38 cubic meters) ofconcrete.

4.1.4.3 Underground Pipe or Electrical Encasements andFireproofing

Obtain one sample at the beginning of each day of concretingwork.

4.1.4.4 All Other Concrete

Obtain same samples as paragraph 4.1.4.1.

4.1.4.5 Take additional samples when observations on tests for slump,temperature, or air content indicate nonconformance with thespecifications.



4.1.5 For each concrete sample taken, the following tests shall be conducted inaccordance with ACI 301:

a. Strength tests

b. Slump

c. Temperature

d. Air content

4.1.6 Test cylinder sets shall be dated and numbered consecutively.

4.1.7 Concrete QA test reports shall be provided to the buyer on a weeklybasis, unless noted otherwise in the contract documents. Data to beincluded in the test report shall include, but not be limited to, thefollowing:

a. Location of concrete on the job and associated drawing numbersand structure/foundation identification

b. Specified strength (f ′c)

c. Date poured

d. Mix type

e. 7- and 28-day compressive strength

f. Slump, air and concrete temperatures at time of pour, time of dayconcrete was batched, and time of day concrete was poured

g. Air content

h. Name of inspector making cylinders and cylinder number

4.1.8 Ready mixed concrete suppliers shall hold a current NRMCA Certificateof Conformance for Concrete Production Facilities. Alternatively,certification from an independent testing agent stating conformance withNRMCA Certification of Ready Mixed Concrete Production Facilities isacceptable.

4.2 Submittals

Before the start of work, the contractor shall submit the documentation presentedin Table 1 in accordance with the requirements of ACI 301, as a minimum, to thebuyer for review and acceptance. Additional submittals noted in ACI 301, whichare not listed in Table 1, shall be provided by the contractor to the buyer forreview and acceptance, when required by the contract documents.

4.3 Safety

The contractor shall comply with all applicable federal, state, or local safetyrequirements, site specific requirements of the buyer, and all safety requirementsspecified in the contract documents.



5. Materials

5.1 General

5.1.1 Materials that do not conform to this Practice or the contract documentsshall not be used, unless authorized in writing by the buyer.

5.1.2 Materials shall conform to applicable local volatile organic compoundregulations.

5.2 Cementitious Materials

5.2.1 Portland cement shall conform to ASTM C150, Type I or Type II, unlessotherwise specified on the design drawings. Only one brand of cementshall be used.

5.2.2 Fly ash may be used in accordance with ACI 301 and shall conform toASTM C618, Class F, unless otherwise specified on the design drawings.

5.3 Admixtures

5.3.1 All admixtures, except air entrainment admixtures, require theengineer’s authorization for use.

5.3.2 Only one supplier for each admixture shall be used.

5.3.3 Calcium chloride and admixtures containing soluble chlorides are notpermitted.

5.4 Aggregates

Aggregates shall conform to ASTM C33 and shall be obtained from a singlesource.

5.5 Reinforcement

5.5.1 Reinforcing bars shall be deformed billet steel conforming toASTM A615/A615M, grade 60, unless noted otherwise on the drawings.

5.5.2 All reinforcing shall be uncoated, unless otherwise specified on thedrawings.

5.5.3 Welded wire fabric shall be plain wire fabric and conform toASTM A185.

5.5.4 Tie wire shall be black annealed wire, 16 gage minimum.

5.6 Water

Mixing water and water used to make ice shall be potable or otherwise tested forsuitability in accordance with ASTM C94/C94M.

5.7 Accessories

All accessories shall be specified in the contract documents.



6. Execution

6.1 Formwork

6.1.1 Unless otherwise indicated in the contract documents, 3/4-inch(20-millimeter) chamfer strips shall be provided at all corners onpermanently exposed surfaces.

6.1.2 Form-release agents shall not be applied where concrete surfaces willreceive special finishes or where the agent may affect applied coverings.Alternately, inside surfaces of untreated formwork shall be soaked withclean water and kept moist before placing concrete.

6.1.3 Form removal shall be in accordance with ACI 301 and the following:

a. For structures for which the forms do not provide vertical support(e.g., footings, piers, columns, walls, or sides of beams), the formsmay be removed 48 hours after completion of placement if theconcrete is sufficiently hard to prevent damage by form removal,and if curing starts immediately.

b. Forms for self-supporting members may be removed after 7 daysprovided the concrete strength is at least 80 percent of the 28-daystrength, unless otherwise specified in the contract documents. Nosuperimposed load shall be applied to self-supporting membersbefore the 28-day strength has been verified by field-curedcylinders.

c. Forms shall not be left permanently in place without approval fromthe buyer.

6.1.4 Form accessories that remain embedded in the concrete (e.g., ties andhangers) shall be a commercially manufactured type.

6.1.5 Formed concrete surfaces shall be constructed to conform with thetolerances shown in ACI 117, unless specified otherwise. Tolerances forconcrete surfaces not specifically mentioned in ACI 117 shall be inaccordance with ACI 117, Section 4.

6.2 Joints

6.2.1 All joints shall be located and constructed in accordance with the designdrawings. Any variation from the location shown shall be approved bythe buyer.

6.2.2 Control joints to be cut with a saw shall be cut as soon as the concrete ishard enough to prevent surface raveling and aggregate dislodging, andno later than 12 hours after concrete placement.

a. Control joints shall be cut in accordance with the sawmanufacturer’s written recommendations.

b. Sawing sequence shall be based on pour time and size of slab.



6.2.3 Control joints in slab toppings shall be located directly above and in linewith the control joints in the underlying concrete slab.

6.2.4 Isolation joints shall be placed where the pavement adjoins verticalsurfaces (e.g., walls, columns, catch basins, manholes, and equipmentfoundations). Isolation joints shall be in accordance with the drawings.

6.2.5 Construction joints in structures intended to be watertight shall havewater stops.

6.2.6 Expansion joints shall be constructed with preformed expansion jointfiller material or another approved device to allow for expansion. Jointsealer shall be provided. Dowels at expansion joints shall be properlyaligned to prevent any restraint on expansion movement at the joint.

6.3 Waterstops

Waterstops shall be installed as indicated in the contract documents and inaccordance with the manufacturer’s recommendations.

6.4 Reinforcing and Embedments

6.4.1 Detailing and Fabrication

6.4.1.1 Reinforcement placing drawings and bending schedules shall beprepared in accordance with ACI SP-66. Drawings andschedules shall show number, grade, size, length, mark, location,and bending diagrams for reinforcing bars.

6.4.1.2 Splices in reinforcement shall be detailed, fabricated, andlocated as shown on the drawings only.

6.4.1.3 Fabrication drawings shall indicate the related PO number,release number, and design drawing number.

6.4.1.4 Reinforcement shall be tagged with weather-resistant metal tags.

6.4.1.5 Each bundle of fabricated bars shall be tagged. Such tags shallindicate drawing number, release number, mark number, barquantity, and bar size.

6.4.1.6 Each bundle of stock-length straight bars shall be tagged toindicate bar quantity, bar size, and bar length.

6.4.2 Installation

6.4.2.1 Embedded aluminum items are not permitted.

6.4.2.2 Anchor bolts, anchors, inserts, sleeves, drains, curb and seatangles, nosing, and other embedded items shall be installedbefore placing concrete. Welding of these items to thereinforcing bars is not permitted.

6.4.2.3 Anchor bolt threads shall be protected against damage and keptfree of concrete.



6.4.2.4 Anchor bolt sleeves shall be capped or plugged to keep outwater, concrete, and debris.

6.4.2.5 Reinforcing bars shall be spliced as shown on the designdrawings only. Welded or mechanical splices are not allowed,unless approved by the engineer.

6.4.3 Tolerances

Embedments shall be installed to the following tolerances, unless notedotherwise on the design drawings:

Anchor bolt projection + 1/4 inch (6 mm), – 0.00 inch (0 mm)

Center to center of any two anchorbolts within a bolt group

+ or – 1/8 inch (3 mm), where a boltgroup is defined as the set of anchorbolts for a single fabricated steelshipping piece, or a single piece ofequipment or skid

Center to center between bolt groups + or – 1/4 inch (6 mm)

Anchor bolt plumbness 1/8 inch in 3 feet (4 mm in 1 meter)

Plate inserts + or – 1/4 inch (6 mm) horizontal and+ or – 1/32 inch (1 mm) vertical

6.5 Proportioning and Mixing

6.5.1 The minimum 28-day compressive strength f ′c shall be as specified inthe contract documents.

6.5.2 If high early-strength concrete is specified, compressive strength shall be7-day strength.

6.5.3 Unless otherwise specified in the contract documents, the maximum sizeof coarse aggregate in concrete shall be in accordance with ACI 301 andshall not exceed the following:

Slabs and walls less than 8 inches thick 3/4 inch (20 mm)

Lightweight concrete 3/4 inch (20mm)

Liquid retaining structures 3/4 inch (20 mm)

Underground pipe or electrical encasements 3/4 inch (20 mm)

Fireproofing or structural steel encasements 3/8 inch (10 mm)

All other items 1-1/2 inch (40 mm)

6.5.4 Maximum water-soluble chloride ion concentrations in hardenedconcrete shall be 0.30% by weight of cement, as indicated in ACI 301,Table 4.2.2.6, for “reinforced concrete exposed to chloride in service,”unless otherwise specified in the contract documents.

6.5.5 Air content at the point of delivery shall conform to ACI 301,Table 4.2.2.4, for moderate exposure, unless otherwise specified in thecontract documents.



6.5.6 The maximum water-cementitious materials ratio shall be 0.4 for liquid-retaining (hydraulic) structures and 0.5 for all other concrete, unlessotherwise specified in the contract documents.

6.5.7 All admixtures shall be added at the batch plant, unless otherwisedirected by the engineer.

6.5.8 Concrete envelopes for underground electrical ducts and cover slabs fordirect-buried cables shall be colored red by adding 15 pounds of redoxide powder per cubic yard (9 kilograms per cubic meter) of concrete.

6.5.9 Concrete envelopes for underground instrument air-line ducts shall becolored yellow by adding 15 pounds of yellow oxide powder per cubicyard (9 kilograms per cubic meter) of concrete.

6.5.10 Job-mixed concrete shall not be used unless approved by the buyer.

6.6 Placing Concrete

6.6.1 The contractor shall obtain inspection and authorization from the buyerbefore placing concrete.

6.6.2 The contractor shall maintain concrete delivery tickets as a record forready mixed concrete.

6.6.3 Concrete that has achieved initial set or has been contaminated byforeign matter shall not be deposited in the structure. Retempering oraddition of water after concrete is first mixed shall not be allowed.

6.6.4 The addition of ice at the construction site is permitted only if it hasbeen considered in the mix design. The concrete manufacturer shallprovide written instructions on the required amount of ice and themixing procedure.

6.6.5 Materials and equipment for protection and curing shall be operational atthe placement site before placement begins.

6.6.6 Slabs shall be placed in alternating strips.

6.7 Curing and Protection

6.7.1 Concrete shall be cured and protected in accordance with ACI 301,Section 5.3.6, unless noted otherwise herein or in the contractdocuments.

6.7.2 Concrete not in contact with forms may utilize any of the methodsindicated in ACI 301, Section 5.3.6.4, for the preservation of moisture.However, for interior concrete slabs, ponding, sprayed water, or wetsand shall not be used.

6.7.3 Liquid membrane curing compounds shall not be used on surfaces toreceive bonded treatments, tiles, paint or other adhered finishes, epoxytoppings, or additional concrete, unless specified in the contractdocuments.



6.7.4 Hydraulic structures shall be cured by a wet-cure procedure only. Thisincludes the use of ponding, sprinkling, or a moisture-retaining fabric.Moist wood forms in contact with concrete shall not be considered ascuring for hydraulic structures. Curing shall occur for a minimum of14 days. Wall forms shall be loosened and water continually sprinkledbetween the wall and forms. Any structure designated as a hydraulicstructure shall be noted on the design drawings.

6.8 Surface Finishing and Tolerances

6.8.1 All finished concrete shall be as stated below, unless otherwise specifiedin the contract documents. The specified surface finish and correlatingtolerance requirements shall be as defined in ACI 301, unless notedotherwise.

6.8.2 Equipment bases shall be finished with a floated finish. Stairs, steps,ramps, and walks shall be finished with a broom finish.

6.8.3 Interior floor slabs shall be finished with a trowel finish that will meetthe conventional flat tolerance requirements of ACI 117.

6.8.4 Roads, area paving, and exterior slabs shall be finished with a broom orbelt finish that will meet the conventional straightedged tolerancerequirements of ACI 117.

6.9 Repair of Surface Defects

6.9.1 Tie holes, honeycombs, and other concrete surface defects shall berepaired as soon as practicable after form removal at such times and insuch manner that shall not delay, interfere with, or impair the propercuring of the fresh concrete, unless otherwise specified or permitted bythe engineer. The engineer shall be notified before proceeding withrepair if the defect is greater than 3 inches (75 mm) deep (at themaximum point) and if the defect is larger than 150 square inches(100,000 square mm) in surface area, or if the depth is over 1/4 thethickness of the member and greater than 6 inches (150 mm) in any otherdirection.

6.9.2 Prepackaged grouts and patching compounds or a patching mortarsimilar to the concrete mix without coarse aggregate may be used withapproval from the engineer. The color shall match the surrounding area.

6.9.3 Out-of-tolerance slabs shall be repaired by grinding down high pointsand/or raising low points by using a specified underlayment compoundor repair topping if the areas are exposed.

6.9.4 Critical slab areas, as identified on the design drawings, must bereplaced if out-of-tolerance. In this situation, the contractor shall submita demolition and replacement plan to the engineer for review andapproval before proceeding.



6.10 Hot and Cold Weather Concreting

6.10.1 During hot and cold weather, concrete supply and construction shall bein accordance with ACI 305R and ACI 306.1, respectively.

6.10.1.1 Hot Weather

Where the combination of temperature, humidity, and windvelocity per ACI 305R, Figure 2.1.5, is expected to cause a rateof evaporation equal to or greater than 0.2 pounds per squarefoot per hour, the recommendations of ACI 305R shall befollowed.

6.10.1.2 Cold Weather

Where the minimum temperature criteria of ACI 301,Section 4.2.2.7, applies, ACI 306.1 shall be followed.

6.11 Architectural and Prestressed Concrete

Refer to the contract documents for architectural and prestressed concreterequirements that are in addition to ACI 301 and this Practice.



Table 1Supplier Data Requirements

Type of Submittal When Required Remarks

ForApproval

ForRecord

Weekly AfterNotice toProceed

BeforeFabrication

With RFQSubmittal

Contractor's QA Program X X

Batch Plant and TruckMixer Certification

X X

Mix Designs X X

Trial Batch QualificationTest Results

X X

Cement Certifications X X

Mineral AdditiveCertifications

X X If applicable

Fine and CoarseAggregate Certifications

X X

Admixture Certifications X X

Material Suppliers,Sources, andCertifications

X X

Manufacturer Spec's,certifications andInstallation Instructions

X X

Proposed Curing Methods X X

Reinforcing BendingSchedule and PlacingDrawings

X 7 days

Certified Mill Test Reportsfor each bar size and heatnumber

X 7 days If requested

Epoxy Coating InspectionReports

X X If applicable

Delivery Ticket X With delivery

Compression TestReports

X X

Compression Breaks500 psi (3500 KPa) ormore below required

X Same daysubmittal

Water Testing Reports X 10 days If applicable

pip sts03001 (plain & reinforced concrete specification)

Documents

process industry practices

pip sts03001 plain

reinforced concrete specification

ready mixed concrete

day compressive strength

standard specification

1 industry codes

concrete surfaces