3047: King Abdulaziz Road Project Package A
OMRANIA Project Specification
SECTION 03 41 00
PRECAST STRUCTURAL CONCRETE
PART 1 GENERAL
1.01 SECTION INCLUDES
A. Beams, spandrels, girders, purlins.
B. Floor single tees and double tees.
C. Grout packing.
D. Connection and supporting devices.
1.02 RELATED REQUIREMENTS
A. Section 03 30 00 - Cast-in-Place Concrete: For concrete topping and connection anchor
placement.
1.03 REFERENCE STANDARDS
A. ACI 318 - Building Code Requirements for Structural Concrete and Commentary; 2014
(Errata 2017).
B. ASTM A36/A36M - Standard Specification for Carbon Structural Steel; 2014.
C. ASTM A153/A153M - Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel
Hardware; 2016a.
D. ASTM A501/A501M - Standard Specification for Hot-Formed Welded and Seamless Carbon
Steel Structural Tubing; 2014.
E. ASTM A572/A572M - Standard Specification for High-Strength Low-Alloy Columbium-
Vanadium Structural Steel; 2015.
F. ASTM A416/A416M - Standard Specification for Steel Strand, Uncoated Seven-Wire for
Prestressed Concrete; 2012a.
G. ASTM A615/A615M - Standard Specification for Deformed and Plain Carbon-Steel Bars for
Concrete Reinforcement; 2016.
H. ASTM A666 - Standard Specification for Annealed or Cold-Worked Austenitic Stainless
Steel Sheet, Strip, Plate, and Flat Bar; 2015.
I. ASTM A1064/A1064M - Standard Specification for Carbon-Steel Wire and Welded Wire
Reinforcement, Plain and Deformed, for Concrete; 2017.
J. ASTM C150/C150M - Standard Specification for Portland Cement; 2017.
K. ASTM C618 - Standard Specification for Coal Fly Ash and Raw or Calcined Natural
Pozzolan for Use in Concrete; 2015.
L. ASTM C989/C989M - Standard Specification for Slag Cement for Use in Concrete and
Mortars; 2014.
M. ASTM C1240 - Standard Specification for Silica Fume Used in Cementitious Mixtures;
2015.
N. AWS D1.1/D1.1M - Structural Welding Code - Steel; 2015 (with March 2016 Errata).
O. AWS D1.4/D1.4M - Structural Welding Code - Reinforcing Steel; 2011.
P. IAS AC157 - Accreditation Criteria for Fabricator Inspection Programs for Reinforced and
Precast/Prestressed Concrete; 2010.
Q. PCI MNL-116 - Manual for Quality Control for Plants and Production of Structural Precast
Concrete Products; 1999, Fourth Edition.
R. PCI MNL-120 - PCI Design Handbook - Precast and Prestressed Concrete; 2010, Seventh
Edition.
S. PCI MNL-123 - Design and Typical Details of Connections for Precast and Prestressed
Concrete; 1988, Second Edition.
T. PCI MNL-124 - Design for Fire Resistance of Precast Prestressed Concrete; 1989, Second
Edition.
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U. PCI MNL-135 - Tolerance Manual for Precast and Prestressed Concrete Construction;
2000.
V. UL (FRD) - Fire Resistance Directory; current edition.
1.04 ADMINISTRATIVE REQUIREMENTS
A. Preinstallation Meeting: Convene a pre-installation conference one week prior to
commencing work of this section.
1. Discuss limitations, if any, on field cutting of openings.
1.05 SUBMITTALS
A. See Section 01 30 00 - Administrative Requirements, for submittal procedures.
B. Product Data: Indicate standard component configurations, design loads, deflections,
cambers, and bearing requirements.
C. Shop Drawings: Indicate layout, unit locations, fabrication details, unit identification marks,
reinforcement, connection details, support items, dimensions, openings, and relationship to
adjacent materials. Indicate design loads, deflections, cambers, bearing requirements, and
special conditions.
1. Submit shop drawings and design data to Engineer for review and approval.
D. Design Data: Submit design data reports indicating calculations for loadings and stresses
of fabricated, designed framing.
E. Designer's Qualification Statement.
F. Fabricator's Qualification Statement: Provide documentation showing precast concrete
fabricator is accredited under IAS AC157.
G. Include erection procedure and sequence of erection for precast units.
H. Check design of units for lifting and handling conditions. Provide additional reinforcement if
necessary. Submit calculations and details for approval by the Engineer.
I. Sustainable Design Reporting: If any fly ash, ground granulated blast furnace slag, silica
fume, rice hull ash, or other waste material is used in mix designs to replace Portland
cement, submit the total volume of concrete, mix design(s) used showing the quantity of
Portland cement replaced, reports showing successful cylinder testing, and temperature on
day of pour.
1.06 QUALITY ASSURANCE
A. Designer Qualifications: Design precast concrete members under direct supervision of a
Professional Structural Engineer experienced in design of precast concrete and licensed in
the Jurisdiction in which the Project is located.
B. Fabricator Qualifications: Company specializing in manufacturing products specified in this
section, with not less than five years of documented experience. Fabricator shall be
approved by the Engineer and be licensed to perform this type of work.
1. Fabricator shall have sufficient production capacity to produce required units without
causing delay in work.
2. Produce precast concrete units at fabricating plant engaged primarily in manufacturing
of similar units, unless plant fabrication or delivery to project site is impractical.
C. Erector Qualifications: Company specializing in erecting products of this section with not
less than five years documented experience and approved by precast manufacturer.
D. Welder Qualifications: All welders shall be certified by an approval body.
E. Where units are not produced at precast concrete fabricating plants, maintain procedures
and conditions for quality control which are equivalent to plant production.
F. Welder Qualifications: Qualified within previous 12 months in accordance with AWS
D1.1/D1.1M and AWS D1.4/D1.4M.
1.07 DELIVERY, STORAGE, AND HANDLING
A. Deliver single tees and double tees planks and pre-cast beams to the project site in such
quantities and at such time as will ensure continuity of installation.
B. Deliver anchorage items which are to be embedded in construction before the start of such
work. Provide setting diagrams, templates and instructions as required for installation.
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C. Handle precast members in position consistent with their shape and design. Lift and
support only from support points.
D. Lifting or Handling Devices: Capable of supporting member in positions anticipated during
manufacture, storage, transportation, and erection and by qualified personnel.
E. Store all units off the ground.
F. Protect members to prevent staining, chipping, or spalling of concrete.
G. Mark each member with date of production and final position in structure.
H. Separate stacked members by battens across the full width of each bearing point.
I. Stack so that lifting devices are accessible and undamaged.
J. Do not use upper member of stacked tier as storage area for shorter members or heavy
equipment.
PART 2 PRODUCTS
2.01 PRECAST UNITS
A. Precast Structural Concrete Units: Comply with PCI MNL-116, PCI MNL-120, PCI MNL-
123, PCI MNL-135, ACI 318 and applicable codes.
1. Design components to withstand design loads in the configuration indicated on the
drawings.
2. Calculate structural properties of framing members in accordance with ACI 318.
3. Design members exposed to the weather to provide for movement of components
without damage, failure of joint seals, undue stress on fasteners or other detrimental
effects, when subject to seasonal or cyclic day/night temperature ranges.
4. Design system to accommodate construction tolerances, deflection of other building
structural members and clearances of intended openings.
2.02 MATERIALS
A. Cement: Gray Portland type, conforming to ASTM C150/C150M, Type I.
B. Other Cementitious Materials:
1. Fly Ash or Natural Pozzolans: Comply with ASTM C618.
2. Ground Granulated Blast Furnace Slag: ASTM C989/C989M.
3. Silica Fume: Comply with ASTM C1240.
C. Aggregate, Sand, Water, Admixtures: Determined by precast fabricator as appropriate to
design requirements and PCI MNL-116.
2.03 REINFORCEMENT
A. Tensioning Steel Tendons: ASTM A416/A416M, Grade 250 (1725)
B. Reinforcing Steel: ASTM A615/A615M, Grade 420 MPa.
C. Steel Welded Wire Reinforcement: ASTM A1064/A1064M plain type or deformed type; in
flat sheets; unfinished.
D. When preformed cages are used, fabricate the cages on jigs to ensure dimensional
accuracy and carefully support them within the mould in such a way that they cannot move
when concrete is placed.
E. Provide cover to main reinforcement as shown on the Drawings. Space bars so that the
minimum clear distance between them is the maximum nominal aggregate size plus five
millimeters but in any case not less than the diameter of the bar.
F. Spacer blocks shall comply with the requirements of Section 03 20 00. In addition, the use
of concrete or plastic spacer blocks shall not be permitted against a concrete face which is
exposed in the finished works.
2.04 ACCESSORIES
A. Connecting and Supporting Devices; Anchors and Inserts: Plates, angles, items cast into
concrete, items connected to steel framing members, and inserts conforming to PCI MNL-
123, and as follows:
1. Material: Stainless steel conforming to ASTM A666.
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3047: King Abdulaziz Road Project Package A
OMRANIA Project Specification
B. Bearing Pads: High density plastic, Vulcanized elastomeric compound molded to size,
Neoprene (Chloroprene), or Tetrafluoroethylene(TFE); as recommended by the precast
fabricator for application ; coordinate the selection with the Strucrural Engineer if required
for bearing loads and rotation requirements; Shore A Durometer 50 to 70; smooth both
sides.
2.05 FABRICATION
A. Comply with fabrication procedures specified in PCI MNL-116.
B. Check the various individual units for all temporary stresses/loads imposed by fabrication,
handling, transporting and erecting, and provide all necessary reinforcing and inserts
required for successful fabrication, transporting and erecting and bracing each unit to its
final position in the work including all required connections.
C. Maintain plant records and quality control program during production of precast members.
Make records available upon request.
D. Ready-Mix Concrete: Comply with requirements of ASTM C 94, and as herein specified.
Delete references for allowing additional water to be added to batch for material with
insufficient slump. Addition of water to batch shall not be permitted.
E. During hot weather, or under conditions contributing to rapid setting of concrete, a shorter
mixing time than specified in ASTM C 94 may be required. When the air temperature is
between 30 degree, and 32 degree, reduce mixing and delivery time from 1-1/2 hours to 75
minutes, and when air temperature is above 32 degree, reduce mixing and delivery time to
60 minutes.
F. Built-in Anchorages: Accurately position built-in anchorage devices and secure to
framework. Locate anchorages without affecting position of main reinforcement or placing of
concrete. Do not relocate bearing plates in units without Engineer’s approval.
G. Coat surfaces of forms with bond-breaking compound before reinforcement is placed.
Provide commercial formulation form-coating compounds that will not bond with, stain nor
adversely affect concrete surfaces, and will not impair subsequent treatments of concrete
surfaces requiring bond or adhesion. Apply in compliance with manufacturer’s instructions.
H. Clean reinforcement of loose rust and mill scale, earth and other materials which reduce or
destroy bond with concrete.
I. Ensure reinforcing steel, anchors, inserts, plates, angles, and other cast-in items are
embedded and located as indicated on shop drawings.
J. Place reinforcement to obtain at least the minimum coverages for concrete protection.
Arrange, space and securely tie bars and bar supports to hold reinforcement in position
during concrete placement operations. Set wire ties so that ends are directed into concrete,
not toward exposed concrete surfaces.
K. Tension reinforcement tendons as required to achieve design load criteria.
L. Accomplish pretensioning of tendons for prestressed concrete units either by single strand
tensioning method or multiple-strand tensioning method. Comply with PCI MNL-116
requirements.
M. Provide required openings with a dimension larger than 150 mm and embed accessories
provided under other sections of the specifications, at indicated locations.
N. Exposed Ends at Stressing Tendons: Fill recess with non-shrink grout, trowel flush.
O. Place concrete in a continuous operation to prevent formation of seams or planes of
weakness in precast units, complying with requirements of ACI 304. Thoroughly
consolidate placed concrete by internal and external vibration without dislocation or damage
to reinforcement and cast-in items.
P. Identification: Provide permanent markings to identify pick-up points and orientation in
structure, complying with markings indicated on final shop drawings. Imprint date of casting
on each precast unit on a surface which will not show in finished structure.
Q. Curing by low-pressure steam, by steam vapor, by radiant heat and moisture, or other
similar process may be employed to accelerate concrete hardening and reduce curing time,
but in no case shall the temperature rise exceed 10 °C/hr until the maximum allowable
curing temperature of 65 °C is attained for a maximum 16 hr curing period.
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R. Delay detensioning of prestressed units till concrete has attained at least 70% of designed
stress, as established by test cubes.
S. Accomplish detensioning of pretensioned tendons either by gradual release of tensioning
jacks or by cutting tendons, using a sequence and pattern to prevent shock or unbalanced
loading.
2.06 FINISHES
A. Ensure exposed-to-view finish surfaces of precast concrete members are uniform in color
and appearance.
B. Cure members under identical conditions to develop required concrete quality, and
minimize appearance blemishes such as non-uniformity, staining, or surface cracking.
C. The formed faces of precast units shall be finished to class F3 and the unformed faces to
class U2, all as defined in Sections 03 11 00 and 03 30 00, unless another class of finish is
specified on the Drawings.
D. In cases where a special finish is required, construct a trial panel which, after acceptance of
the Engineer is kept available for inspection at the place of casting and production units
shall thereafter match the approved pattern.
E. Cast exterior cladding units using white cement.
F. Finish members to PCI MNL-116 as shown on Drawings.
G. Plant Finish: Normal plant finish; surface may contain small surface holes caused by air
bubbles, minor chips or spalling at edges or ends, without major discoloration.
H. Exposed-to-View Finish: Normal plant finish with fins and protrusions removed, ground
edges and ends, flat face surfaces.
I. Architectural Finish: Surface holes or bubbles over 6 mm filled with matching cementitious
paste, fins or protrusions removed and surface ground smooth.
J. Rubbed Finish: Surface holes or bubbles over 6 mm filled with matching cementitious
paste, fins or protrusions removed and surface ground smooth, surface then rubbed with
neat cementitious paste to smooth and even color and texture.
K. Sandblast Finish: Lightly sandblast to achieve partial exposure of aggregate.
2.07 FABRICATION TOLERANCES
A. Conform to fabrication tolerances specified in PCI MNL-116.
2.08 SOURCE QUALITY CONTROL
A. Section 01 40 00 - QUALITY REQUIREMENTS: Provide mix design for concrete.
B. Provide shop inspection and testing for precast units.
C. Test samples in accordance with applicable ASTM standard.
D. Employ a independent testing laboratory to evaluate precast manufacturer’s quality control
and testing methods.
E. The precast manufacturer shall allow Engineer access to the testing facility, material
storage areas, concrete production equipment, and concrete placement and curing
facilities. Cooperate with testing laboratory and provide samples of materials and concrete
mixes as may be requested for additional testing and evaluation.
F. Dimensional Tolerances: Units having dimensions smaller or greater than required, and
outside specified tolerance limits, shall be subject to additional testing as herein specified.
G. Precast units having dimensions greater than required will be rejected where appearance or
function of the structure is adversely affected, or when larger dimensions interfere with
other construction. Repair, or remove and replace rejected units as required to meet
construction conditions.
H. Strength of Units: The strength of precast concrete units shall be considered potentially
deficient when the manufacturing processes fail to comply with any of the requirements
which may affect the strength of the precast units, including the following conditions:
1. Failure to meet compressive strength test requirements.
2. Reinforcement, and pretensioning and detensioning of tendons of prestressed
concrete, not conforming to specified fabrication requirements.
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3. Concrete curing, and protection of precast units against extremes in temperature, not
as specified.
4. Precast units damaged during handling and erection.
I. Testing Precast Units: When there is evidence that strength of precast concrete units does
not meet specification requirements, the concrete testing service shall take cores drilled
from hardened concrete for compressive strength determination, complying with ASTM C
42 and as follows:
1. Take at least 3 representative cores from precast units of suspect strength, from
locations directed by Engineer.
2. Test cores in a saturated-surface-dry condition per ACI 318 if concrete will be wet
during use of completed structure.
3. Test cores in an air-dry condition per ACI 318 when concrete will be dry during use of
completed structure.
4. Strength of concrete for each series of cores will be considered satisfactory when their
average compressive strength is at least 85% of 28-day design compressive strength.
5. Tests results to be made available in writing on same day that tests are made, with
copies to Engineer. Include in test reports the project identification name and number,
date, name of precast concrete manufacturer, name of concrete testing service,
identification letter, number, and type of member or members represented by core
tests, design compressive strength, compression breaking strength and type of break
(corrected for length-diameter ratio), direction of applied load to core with respect to
horizontal plane of concrete as placed, and moisture condition of core at time of
testing.
J. Patching: Where core test results are satisfactory and precast units are acceptable for use
in work, fill core holes solid with patching mortar, and finish to match adjacent concrete
surfaces.
K. Defective Work: Replace precast concrete units which do not conform to specified
requirements, including strength, tolerances and finishes, with precast concrete units that
meet requirements of this Section. Make corrections to other works affected by or resulting
from corrections to pre-cast concrete work.
PART 3 EXECUTION
3.01 EXAMINATION
A. Verify that site conditions are ready to receive work and field measurements are as
indicated on shop drawings.
B. Provide suitable access to the building, proper drainage and firm level bearing area for
hauling and erection equipment to operate.
3.02 PREPARATION
A. Prepare support equipment for the erection procedure, temporary bracing, and induced
loads during erection.
B. Provide true level bearing surfaces on all field placed bearing walls and other field placed
supporting members.
C. Place and align accurate anchor bolts, plates or dowels in column footings, grade beams
and other field placed supporting members.
D. Provide shoring required for composite beams and slabs. Shoring shall have a minimum
load factor of 1.5 times (dead load plus construction loads).
3.03 ERECTION
A. Perform installation of precast, prestressed concrete by the manufacturer or a competent
erector. For temporary shoring and bracing, comply with manufacturer’s recommendations.
B. Erect members without damage to structural capacity, shape, or finish. Replace or repair
damaged members.
C. Align and maintain uniform horizontal and vertical joints, as erection progresses. Adjust the
variations between adjacent members by packing, loading, or any other feasible method as
recommended by the manufacturer and acceptable to the Engineer.
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D. Maintain temporary bracing in place until final support is provided. Protect members from
staining.
E. Provide temporary lateral support to prevent bowing, twisting, or warping of members.
F. Adjust differential camber between precast members to tolerance before final attachment.
G. Install bearing pads where indicated, as precast units are being erected. Set pads on level,
uniform bearing surfaces and maintain in correct position until precast units are placed.
H. Level differential elevation of adjoining horizontal members with grout to maximum slope of
1:12.
I. Set vertical units dry, without grout, attaining joint dimension with lead or plastic spacers.
J. Grout joints between members at roof locations, joints between members at floor locations,
and all sockets, bolt holes, etc.
K. Secure units in place. Perform welding in accordance with AWS D1.1/D1.1M.
L. Protect units from damage by field welding or cutting operations and provide non-
combustible shield as required.
M. Repair damaged metal surfaces by cleaning and applying a coat of liquid galvanizing repair
compound to galvanized surfaces and compatible primer to painted surfaces.
N. Power-Actuated Fasteners: Do not use power-actuated fasteners for surface attachment of
accessory items in precast, prestressed units unless otherwise accepted by precast
manufacturer.
3.04 TOLERANCES
A. Erect members level and plumb within allowable tolerances.
B. Conform to PCI MNL-135 for erection tolerances.
C. When members cannot be adjusted to comply with design or tolerance criteria, cease work
and advise Engineer. Execute modifications as directed.
3.05 PROTECTION
A. Protect members from damage caused by field welding or erection operations.
B. Provide non-combustible shields during welding operations.
3.06 CLEANING
A. Clean weld marks, dirt, or blemishes from surface of exposed members.
END OF SECTION
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