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CONCRETE STRUCTURES AND
FOUNDATIONS
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FOREWORD
The material in this chapter is written with regard to typical North American Railroad Concrete Structures and Foundations and other structures mentioned herein with
• Standard Gage Track,
• Normal North American passenger and freight equipment, and
• Speeds of freight trains up to 80 mph and passenger trains up to 90 mph.
Additional special provisions for speeds higher than those listed above may be added by the Engineer as necessary. This chapter is presented as a consensus document by a committee composed of railroad industry professionals having substantial and broad-based experience designing, evaluating, and investigating Concrete Structures and Foundations used by railroads. The recommendations contained herein are based upon past successful usage, advances in the state of knowledge, and current design and maintenance practices. These recommendations are intended for routine use and might not provide sufficient criteria for infrequently encountered conditions. Professional judgement must be exercised when applying the recommendations of this chapter as part of an overall solution to any particular issue.
This chapter is published annually, incorporating revisions made in the previous year. The latest published edition of the chapter should be used, regardless of the age of an existing structure. For purposes of determining historical recommendations under which an existing structure may have been built and maintained, it can prove useful to examine previous editions of the chapter. However, when historical recommendations differ from the recommendations contained in the latest published edition of the chapter, the recommendations of the latest published edition of the chapter should be used.
Part 8, Rigid Frame Concrete Bridges was deleted from the manual in 1975. Part 9, Reinforced Concrete Trestles was deleted from the manual in 1971. Part 15 is reserved for future use. Part 18, Elastomeric Bridge Bearings was moved to Chapter 15 in 2001.
1 The material in this and other chapters in the AREMA Manual for Railway Engineering is published as recommended practice to railroads and others concerned with the engineering, design and construction of railroad fixed properties (except signals and communications), and allied services and facilities. For the purpose of this Manual, RECOMMENDED PRACTICE is defined as a material, device, design, plan, specification, principle or practice recommended to the railways for use as required, either exactly as presented or with such modifications as may be necessary or desirable to meet the needs of individual railways, but in either event, with a view to promoting efficiency and economy in the location, construction, operation or maintenance of
Part/Section Description Page
1 Materials, Tests and Construction Requirements . . . 8-1-1
1.1 General . . . 8-1-6 1.2 Cement . . . 8-1-8 1.3 Other Cementitious Materials . . . 8-1-10 1.4 Aggregates. . . 8-1-11 1.5 Water . . . 8-1-16 1.6 Reinforcement . . . 8-1-16 1.7 Concrete Admixtures. . . 8-1-19 1.8 Storage of Materials . . . 8-1-20 1.9 Forms. . . 8-1-21 1.10 Details of Reinforcement . . . 8-1-24 1.11 Concrete Jointing. . . 8-1-27 1.12 Proportioning. . . 8-1-31 1.13 Mixing . . . 8-1-37 1.14 Depositing Concrete . . . 8-1-39 1.15 Depositing Concrete Under Water. . . 8-1-43 1.16 Concrete in Sea Water . . . 8-1-46 1.17 Concrete in Alkali Soils or Alkali Water . . . 8-1-47 1.18 Curing . . . 8-1-48 1.19 Formed Surface Finish . . . 8-1-51 1.20 Unformed Surface Finish . . . 8-1-52 1.21 Decorative Finishes . . . 8-1-53 1.22 Penetrating Water Repellent Treatment of Concrete Surfaces . . . 8-1-53 1.23 Repairs and Anchorage Using Reactive Resins . . . 8-1-55 1.24 High Strength Concrete (1995) . . . 8-1-56 1.25 Specialty Concretes . . . 8-1-57 1.26 Self-Consolidating Concrete . . . 8-1-62 Commentary . . . 8-1-64
2 Reinforced Concrete Design . . . 8-2-1
2.1 General . . . 8-2-5 2.2 Notations, Definitions and Design Loads . . . 8-2-8 2.3 Materials . . . 8-2-20 2.4 Hooks and Bends. . . 8-2-21 2.5 Spacing of Reinforcement (2005) . . . 8-2-22 2.6 Concrete Protection for Reinforcement. . . 8-2-22 2.7 Minimum Reinforcement of Flexural Members (1992) . . . 8-2-23 2.8 Distribution of Reinforcement in Flexural Members (2005) . . . 8-2-23 2.9 Lateral Reinforcement of Flexural Members (2005) . . . 8-2-24 2.10 Shear Reinforcement – General Requirements . . . 8-2-24 2.11 Limits for Reinforcement of Compression Members . . . 8-2-25 2.12 Shrinkage and Temperature Reinforcement (2005) . . . 8-2-27 2.13 Development Requirements . . . 8-2-27 2.14 Development Length of Deformed Bars and Deformed Wire in Tension (2005). . . 8-2-29 2.15 Development Length of Deformed Bars in Compression (2005) . . . 8-2-30 2.16 Development Length of Bundled Bars (1990) . . . 8-2-30 2.17 Development of Standard Hooks in Tension (2005). . . 8-2-31 2.18 Combination Development Length . . . 8-2-32 2.19 Development of Welded Wire Fabric in Tension . . . 8-2-32
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Part/Section Description Page
2.20 Mechanical Anchorage (1992) . . . 8-2-33 2.21 Anchorage of Shear Reinforcement (2005) . . . 8-2-33 2.22 Splices of Reinforcement . . . 8-2-35 2.23 Analysis Methods . . . 8-2-37 2.24 Design Methods (1992). . . 8-2-42 2.25 General Requirements (1992) . . . 8-2-42 2.26 Allowable Service Load Stresses . . . 8-2-42 2.27 Flexure (2005). . . 8-2-44 2.28 Compression Members with or without Flexure (1992). . . 8-2-44 2.29 Shear . . . 8-2-45 2.30 Strength Requirements . . . 8-2-52 2.31 Design Assumptions . . . 8-2-53 2.32 Flexure . . . 8-2-53 2.33 Compression Members with or without Flexure . . . 8-2-56 2.34 Slenderness Effects in Compression Members. . . 8-2-58 2.35 Shear . . . 8-2-60 2.36 Permissible Bearing Stress (2005) . . . 8-2-68 2.37 Serviceability Requirements . . . 8-2-68 2.38 Fatigue Stress Limit for Reinforcement (2005) . . . 8-2-68 2.39 Distribution of Flexural Reinforcement (2005) . . . 8-2-69 2.40 Control of Deflections. . . 8-2-69 Commentary . . . 8-2-70
3 Spread Footing Foundations . . . . 8-3-1
3.1 General . . . 8-3-2 3.2 Information Required . . . 8-3-3 3.3 Depth of Base of Footings . . . 8-3-6 3.4 Sizing of Footings. . . 8-3-7 3.5 Footings with Eccentric Loads . . . 8-3-12 3.6 Footing Stresses . . . 8-3-14 3.7 Field Conditions . . . 8-3-14 3.8 Combined Footings. . . 8-3-15 4 Pile Foundations . . . . 8-4-1 4.1 General . . . 8-4-2 4.2 Design . . . 8-4-4 4.3 Pile Length Determination . . . 8-4-7 4.4 Pile Structural Design . . . 8-4-10 4.5 Installation of Piles . . . 8-4-15 4.6 Inspection of Pile Driving. . . 8-4-18 Commentary . . . 8-4-18
5 Retaining Walls, Abutments and Piers . . . . 8-5-1
5.1 Definitions. . . 8-5-2 5.2 Information Required . . . 8-5-4 5.3 Computation of Applied Forces . . . 8-5-5 5.4 Stability Computation . . . 8-5-7 5.5 Design of Backfill . . . 8-5-8 5.6 Designing Bridges to Resist Scour . . . 8-5-9
Part/Section Description Page 5.7 Details of Design and Construction for Abutments and Retaining Walls . . . 8-5-11 5.8 Details of Design and Construction for Bridge Piers . . . 8-5-12
6 Crib Walls . . . 8-6-1
6.1 General . . . 8-6-2 6.2 Design of Crib Walls . . . 8-6-2 6.3 Requirements for Reinforced Concrete Crib Walls. . . 8-6-3 6.4 Requirements for Metal Crib Walls. . . 8-6-5 6.5 Requirements for Timber Crib Walls . . . 8-6-6
7 Mechanically Stabilized Embankment . . . 8-7-1
7.1 General . . . 8-7-2 7.2 Design of Mechanically Stabilized Embankments . . . 8-7-2 7.3 Construction . . . 8-7-3
10 Reinforced Concrete Culvert Pipe . . . 8-10-1
10.1 General . . . 8-10-2 10.2 Materials . . . 8-10-3 10.3 Design . . . 8-10-4 10.4 Installation. . . 8-10-12
11 Lining Railway Tunnels . . . 8-11-1
11.1 General . . . 8-11-2 11.2 Design . . . 8-11-2 11.3 Forms. . . 8-11-7 11.4 Concrete . . . 8-11-8 12 Cantilever Poles . . . 8-12-1 12.1 General . . . 8-12-2 12.2 Materials . . . 8-12-2 12.3 Construction . . . 8-12-2 12.4 Design . . . 8-12-3
14 Repair and Rehabilitation of Concrete Structures. . . 8-14-1
14.1 Scope (2006) . . . 8-14-3 14.2 Determination of the Causes of Concrete Deterioration (2006) R(2015) . . . 8-14-3 14.3 Evaluation of the Effects of Deterioration and Damage . . . 8-14-4 14.4 Principal Materials Used in the Repair of Concrete Structures . . . 8-14-5 14.5 Repair Methods . . . 8-14-7 14.6 Repair Methods for Prestressed Members . . . 8-14-22 Commentary . . . 8-14-24
16 Design and Construction of Reinforced Concrete Box Culverts. . . 8-16-1
16.1 General . . . 8-16-2 16.2 Materials . . . 8-16-4 16.3 Design Methods. . . 8-16-6 16.4 Design Loads. . . 8-16-6 16.5 Details of Design. . . 8-16-13 16.6 Manufacture of Precast Units . . . 8-16-15
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16.7 Construction . . . 8-16-17
17 Prestressed Concrete. . . . 8-17-1
17.1 General Requirements and Materials . . . 8-17-4 17.2 Notations (2014) . . . 8-17-5 17.3 Terms (2014) . . . 8-17-7 17.4 Materials . . . 8-17-9 17.5 Details of Prestressing Tendons and Ducts . . . 8-17-11 17.6 General Analysis (2014) . . . 8-17-13 17.7 Expansion and Contraction (2014) . . . 8-17-13 17.8 Span Length (2014). . . 8-17-13 17.9 Frames and Continuous Construction. . . 8-17-14 17.10 Effective Flange Width . . . 8-17-15 17.11 Flange and Web Thickness-Box Girders (2014). . . 8-17-15 17.12 Diaphragms (2014) . . . 8-17-16 17.13 Deflections (2014) . . . 8-17-16 17.14 General Design . . . 8-17-17 17.15 Load Factors . . . 8-17-18 17.16 Allowable Stresses . . . 8-17-18 17.17 Loss of Prestress . . . 8-17-20 17.18 Flexural Strength. . . 8-17-26 17.19 Ductility Limits. . . 8-17-28 17.20 Non-Prestressed Reinforcement (2014) . . . 8-17-29 17.21 Shear . . . 8-17-30 17.22 Post-Tensioned Anchorage Zones. . . 8-17-34 17.23 Pretensioned Anchorage Zones (2014) . . . 8-17-44 17.24 Concrete Strength at Stress Transfer (2014) . . . 8-17-45 17.25 General Detailing . . . 8-17-45 17.26 General Fabrication. . . 8-17-48 17.27 Mortar and Grout . . . 8-17-52 17.28 Application of Loads (2014) . . . 8-17-52 17.29 Materials - Reinforcing Steel . . . 8-17-53 17.30 Prestressed Concrete Cap and/or Sill for Timber Pile Trestle (2014). . . 8-17-54 Commentary (2014) . . . 8-17-57
19 Rating of Existing Concrete Bridges . . . . 8-19-1
19.1 General . . . 8-19-2 19.2 Rating . . . 8-19-2 19.3 Loads and Forces . . . 8-19-4 19.4 Materials . . . 8-19-5 19.5 Load Combinations and Rating Formulas . . . 8-19-8 19.6 Excessive Loading . . . 8-19-10 Commentary . . . 8-19-11
20 Flexible Sheet Pile Bulkheads . . . . 8-20-1
20.1 General . . . 8-20-2 20.2 Information Required . . . 8-20-3 20.3 Computation of Lateral Forces Acting on Bulkheads. . . 8-20-5 20.4 Stability . . . 8-20-9
Part/Section Description Page 20.5 Design of Anchored Bulkheads. . . 8-20-10 20.6 Cantilever Bulkheads . . . 8-20-14 20.7 Notations (1993) . . . 8-20-15 Commentary . . . 8-20-16
21 Inspection of Concrete and Masonry Structures . . . 8-21-1
21.1 General (2006). . . 8-21-1 21.2 Reporting of Defects (2006) . . . 8-21-2 21.3 Inspection . . . 8-21-2 Commentary . . . 8-21-19
22 Geotechnical Subsurface Investigation . . . 8-22-1
22.1 General (1992). . . 8-22-2 22.2 Scope (1992) . . . 8-22-2 22.3 Classification of Investigations . . . 8-22-2 22.4 General . . . 8-22-3 22.5 Exploration Methods . . . 8-22-4 22.6 Determination of Groundwater Level (1992) . . . 8-22-6 22.7 Sampling . . . 8-22-6 22.8 Records . . . 8-22-7 22.9 Inspection (1992). . . 8-22-9 22.10 Geophysical Explorations (1992) . . . 8-22-9 22.11 In-Situ Testing of Soil (1992) . . . 8-22-9 22.12 Backfilling Bore Holes (1992) . . . 8-22-10 22.13 Cleaning Site (1992) . . . 8-22-10
23 Pier Protection Systems at Spans Over Navigable Streams . . . 8-23-1
23.1 General . . . 8-23-2 23.2 Special Considerations . . . 8-23-3 23.3 Design . . . 8-23-4 23.4 Construction . . . 8-23-20 Commentary (2010) . . . 8-23-24
24 Drilled Shaft Foundations . . . 8-24-1
24.1 General . . . 8-24-2 24.2 Information Required . . . 8-24-5 24.3 Design . . . 8-24-5 24.4 Material . . . 8-24-8 24.5 Construction . . . 8-24-9 24.6 Testing . . . 8-24-12 C - Commentary (2010) . . . 8-24-12
25 Slurry Wall Construction . . . 8-25-1
25.1 General . . . 8-25-2 25.2 Design . . . 8-25-3 25.3 Materials . . . 8-25-7 25.4 Construction . . . 8-25-9 Commentary (2012) . . . 8-25-13
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Part/Section Description Page
26 Recommendations for the Design of Segmental Bridges. . . . 8-26-1
26.1 General Requirements and Material . . . 8-26-4 26.2 Methods of Analysis . . . 8-26-8 26.3 Design Loads . . . 8-26-12 26.4 Load Factors . . . 8-26-16 26.5 Allowable Stresses . . . 8-26-21 26.6 Prestress Losses (1996). . . 8-26-22 26.7 Flexural Strength. . . 8-26-23 26.8 Shear and Torsion . . . 8-26-23 26.9 Fatigue Stress Limits . . . 8-26-32 26.10 Design of Local and General Anchorage Zones, Anchorage Blisters and Deviation Saddles . . . 8-26-32 26.11 Provisional Post-Tensioning Ducts and Anchorages . . . 8-26-35 26.12 Duct Details . . . 8-26-36 26.13 Couplers (1996) . . . 8-26-38 26.14 Connection of Secondary Beams (1996) . . . 8-26-38 26.15 Concrete Cover and Reinforcement Spacing . . . 8-26-40 26.16 Inspection Access (1996) . . . 8-26-40 26.17 Box Girder Cross Section Dimensions and Details . . . 8-26-40 Commentary . . . 8-26-41
27 Concrete Slab Track . . . . 8-27-1
27.1 Scope and Notations . . . 8-27-3 27.2 Application and Definitions . . . 8-27-3 27.3 General Considerations. . . 8-27-6 27.4 Materials . . . 8-27-7 27.5 Design . . . 8-27-8 27.6 Construction . . . 8-27-10 27.7 Direct Fixation Fastening System. . . 8-27-14 27.8 Special Considerations . . . 8-27-16 Commentary . . . 8-27-24
28 Temporary Structures for Construction. . . . 8-28-1
28.1 General . . . 8-28-2 28.2 Information Required . . . 8-28-4 28.3 Computation of Lateral Forces (2002) R(2015) . . . 8-28-5 28.4 Stability (2002) R(2015) . . . 8-28-5 28.5 Design of Shoring Systems. . . 8-28-5 28.6 Design of Falsework Systems. . . 8-28-13 Commentary . . . 8-28-18 29 Waterproofing . . . . 8-29-1 29.1 General Principles. . . 8-29-4 29.2 Waterproofing (2001) . . . 8-29-4 29.3 Dampproofing (1994) . . . 8-29-5 29.4 Specific Application . . . 8-29-5 29.5 Terms (2001) . . . 8-29-7 29.6 Applicable ASTM Designations . . . 8-29-8 29.7 General Practices . . . 8-29-12 29.8 Primers . . . 8-29-13
Part/Section Description Page 29.9 Membranes . . . 8-29-13 29.10 Membrane Protection . . . 8-29-17 29.11 Sealing Compounds for Joints and Edges of Membrane Protection (2001) . . . 8-29-20 29.12 Anti-Bonding Paper (2001) . . . 8-29-20 29.13 Inspection and Tests (1994). . . 8-29-20 29.14 Construction . . . 8-29-20 29.15 Introduction to Damproofing . . . 8-29-27 29.16 Materials for Damproofing . . . 8-29-27 29.17 Application of Damproofing . . . 8-29-29 C - Commentary . . . 8-29-29
Chapter 8 Glossary. . . 8-G-1 References . . . 8-R-1
INTRODUCTION
The Chapters of the AREMA Manual are divided into numbered Parts, each comprised of related documents (specifications, recommended practices, plans, etc.). Individual Parts are divided into Sections by centered headings set in capital letters and identified by a Section number. These Sections are subdivided into Articles designated by numbered side headings.
Page Numbers – In the page numbering of the Manual (8-2-1, for example) the first numeral designates the Chapter
number, the second denotes the Part number in the Chapter, and the third numeral designates the page number in the Part. Thus, 8-2-1 means Chapter 8, Part 2, page 1.
In the Glossary and References, the Part number is replaced by either a “G” for Glossary or “R” for References.
Document Dates – The bold type date (Document Date) at the beginning of each document (Part) applies to the document
as a whole and designates the year in which revisions were last made somewhere in the document, unless an attached footnote indicates that the document was adopted, reapproved, or rewritten in that year.
Article Dates – Each Article shows the date (in parenthesis) of the last time that Article was modified.
Revision Marks – All current year revisions (changes and additions) which have been incorporated into the document are
identified by a vertical line along the outside margin of the page, directly beside the modified information.
Proceedings Footnote – The Proceedings footnote on the first page of each document gives references to all Association
action with respect to the document.
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Materials, Tests and Construction Requirements
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TABLE OF CONTENTS
Section/Article Description Page
1.1 General . . . . 8-1-6 1.1.1 Purpose (2004) . . . 8-1-6 1.1.2 Scope (2004) . . . 8-1-6 1.1.3 Terms (2006) . . . 8-1-6 1.1.4 Acceptability (2004). . . 8-1-7 1.1.5 ASTM - International (2004) . . . 8-1-7 1.1.6 Selection of Materials (2004). . . 8-1-7 1.1.7 Test of Materials (2004). . . 8-1-7 1.1.8 Defective Materials (2004) . . . 8-1-8 1.1.9 Equipment (2004) . . . 8-1-8 1.2 Cement. . . . 8-1-8 1.2.1 General (2004) . . . 8-1-8 1.2.2 Specifications (2004) . . . 8-1-8 1.2.3 Quality, Sampling and Testing (2004) . . . 8-1-9
1.3 Other Cementitious Materials. . . . 8-1-10
1.3.1 General (2004) . . . 8-1-10 1.3.2 Acceptability (2004). . . 8-1-10 1.3.3 Specifications (2004) . . . 8-1-10 1.3.4 Materials Not Included in This Recommended Practice (2004) . . . 8-1-10 1.3.5 Documentation (2004) . . . 8-1-11
1.4 Aggregates . . . . 8-1-11
1.4.1 General (2004) . . . 8-1-11 1.4.2 Fine Aggregates (2004) . . . 8-1-12 1.4.3 Normal Weight Coarse Aggregate (2004) . . . 8-1-14 1 References, Vol. 3, 1902, p. 311; Vol. 4, 1903, pp. 336,397; Vol. 5, 1904, pp. 605,610; Vol. 6, 1905, pp. 704,726; Vol. 11, 1910, p. 956; Vol. 13, 1912, pp.
333, 1564; Vol. 24, 1923, pp. 478, 1324; Vol. 28, 1927, pp. 1056, 1436; Vol. 29, 1928, pp. 607, 1399; Vol. 30, 1929, pp. 783, 1461; Vol. 31, 1930, pp. 1148, 1737; Vol. 32, 1931, pp. 330, 796; Vol. 33, 1932, pp. 622, 732; Vol. 34, 1933, pp. 578, 868; Vol. 35, 1934, pp. 953, 1130; Vol. 36, 1935, pp. 843, 1018; Vol. 37, 1936, pp. 632, 1040; Vol. 39, 1938, pp. 136, 332; Vol. 45, pp. 227, 642; Vol. 54, 1953, pp. 793, 1341; Vol. 56, 1955, pp. 436, 1084; Vol. 58, 1957, pp. 650, 1182; Vol. 59, 1958, pp. 637, 1970, p. 230; Vol. 72, 1971, p. 136; Vol. 74, 1973, p. 138; Vol. 75, 1974, p. 465; Vol. 78, 1977, p. 108; Vol. 83, 1982, p.
TABLE OF CONTENTS (CONT)
Section/Article Description Page
1.4.4 Lightweight Coarse Aggregate for Structural Concrete (2004) . . . 8-1-15
1.5 Water . . . 8-1-16 1.5.1 General (2010) . . . 8-1-16 1.6 Reinforcement . . . 8-1-16 1.6.1 General (2013) . . . 8-1-16 1.6.2 Welding (2013) . . . 8-1-16 1.6.3 Specifications (2013) . . . 8-1-16 1.6.4 Bending and Straightening Reinforcing Bars (2013) . . . 8-1-19
1.7 Concrete Admixtures . . . 8-1-19
1.7.1 General (2013) . . . 8-1-19 1.7.2 Types of Admixtures and Standard Specifications (2013) . . . 8-1-19
1.8 Storage of Materials . . . 8-1-20
1.8.1 Cementitious Materials and Concrete Admixtures (2009) . . . 8-1-20 1.8.2 Aggregates (2009) . . . 8-1-20 1.8.3 Reinforcement (2013). . . 8-1-21 1.9 Forms . . . 8-1-21 1.9.1 General (2009) . . . 8-1-21 1.9.2 Safety (2009) . . . 8-1-21 1.9.3 Design (2009) . . . 8-1-21 1.9.4 Construction (2009) . . . 8-1-22 1.9.5 Moldings (2009) . . . 8-1-22 1.9.6 Form Coating and Release (2009) . . . 8-1-23 1.9.7 Temporary Openings (2009). . . 8-1-23 1.9.8 Removal (2009) . . . 8-1-23
1.10 Details of Reinforcement . . . 8-1-24
1.10.1 Surface Conditions of Reinforcement (2013). . . 8-1-24 1.10.2 Fabrication (2003) . . . 8-1-24 1.10.3 Provisions for Seismic Loading (2013) . . . 8-1-24 1.10.4 Placing of Reinforcement (2013) . . . 8-1-24 1.10.5 Spacing of Reinforcement (2003) . . . 8-1-26 1.10.6 Concrete Protection for Reinforcement (2003) . . . 8-1-26 1.10.7 Future Bonding (2003) . . . 8-1-26
1.11 Concrete Jointing . . . 8-1-27
1.11.1 Scope (2009). . . 8-1-27 1.11.2 Types of Jointing (2009). . . 8-1-27 1.11.3 Expansion Joints (2009) . . . 8-1-27 1.11.4 Expansion Joints in Walls (2009) . . . 8-1-28 1.11.5 Contraction Joints (2009) . . . 8-1-28 1.11.6 Construction Joints (2009) . . . 8-1-29 1.11.7 Watertight Construction Joints (2009) . . . 8-1-29
1.12 Proportioning . . . 8-1-31
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TABLE OF CONTENTS (CONT)
Section/Article Description Page
1.12.2 Measurement of Materials (2009) . . . 8-1-31 1.12.3 Water-Cementitious Materials Ratio (2009) . . . 8-1-31 1.12.4 Air Content of Air-Entrained Concrete (2009). . . 8-1-32 1.12.5 Strength of Concrete Mixtures (2011) . . . 8-1-33 1.12.6 Workability (2009) . . . 8-1-34 1.12.7 Slump (2009) . . . 8-1-35 1.12.8 Compression Tests (2009) . . . 8-1-35 1.12.9 Field Tests (2009). . . 8-1-35 1.12.10 Special Provisions When Using Cementitious Materials Other Than Portland Cement (2009) . . . 8-1-35
1.13 Mixing . . . . 8-1-37
1.13.1 General (2009) . . . 8-1-37 1.13.2 Site-Mixed Concrete (2009). . . 8-1-38 1.13.3 Ready-Mixed Concrete (2009). . . 8-1-38 1.13.4 Delivery (2009) . . . 8-1-38 1.13.5 Requirements When Using Silica Fume in Concrete (2009) . . . 8-1-39
1.14 Depositing Concrete . . . . 8-1-39
1.14.1 General (2000) . . . 8-1-39 1.14.2 Handling and Placing (1993) . . . 8-1-39 1.14.3 Chuting (1993) . . . 8-1-40 1.14.4 Pneumatic Placing (Shotcreting) (1993) . . . 8-1-40 1.14.5 Pumping Concrete (1993) . . . 8-1-40 1.14.6 Compacting (1993) . . . 8-1-41 1.14.7 Temperature (1993) . . . 8-1-41 1.14.8 Continuous Depositing (1993) . . . 8-1-42 1.14.9 Bonding (1993) . . . 8-1-42 1.14.10 Placing Cyclopean Concrete (1993) . . . 8-1-42 1.14.11 Placing Rubble Concrete (1993) . . . 8-1-42 1.14.12 Placing Concrete Containing Silica Fume (2004) . . . 8-1-42 1.14.13 Placing Concrete Containing Fly Ash (2004) . . . 8-1-43 1.14.14 Water Gain (1993) . . . 8-1-43
1.15 Depositing Concrete Under Water . . . . 8-1-43
1.15.1 General (2014) . . . 8-1-43 1.15.2 Capacity of Plant (2014) . . . 8-1-43 1.15.3 Standard Specifications (1993) . . . 8-1-43 1.15.4 Cement (2014) . . . 8-1-43 1.15.5 Coarse Aggregates (2014) . . . 8-1-43 1.15.6 Mixing (2014) . . . 8-1-44 1.15.7 Caissons, Cofferdams or Forms (1993) R(2014) . . . 8-1-44 1.15.8 Leveling and Cleaning the Bottom to Receive Concrete (2014) . . . 8-1-44 1.15.9 Continuous Work (2014) . . . 8-1-44 1.15.10 Methods of Depositing (2014) . . . 8-1-44 1.15.11 Soundings (2014) . . . 8-1-46 1.15.12 Removing Laitance (2014). . . 8-1-46 1.15.13 Concrete Seals (2014) . . . 8-1-46
TABLE OF CONTENTS (CONT)
Section/Article Description Page
1.16.1 Concrete (2004) . . . 8-1-46 1.16.2 Depositing in Sea Water (1993) . . . 8-1-46 1.16.3 Construction Joints (1993) . . . 8-1-46 1.16.4 Minimum Cover (1993) . . . 8-1-47 1.16.5 Protecting Concrete in Sea Water (1993) . . . 8-1-47
1.17 Concrete in Alkali Soils or Alkali Water. . . 8-1-47
1.17.1 Condition of Exposure (1993) . . . 8-1-47 1.17.2 Concrete for Moderate Exposure (1993) . . . 8-1-47 1.17.3 Concrete for Severe Exposure (1993) . . . 8-1-48 1.17.4 Concrete for Very Severe Exposure (1993) . . . 8-1-48 1.17.5 Concrete for Alkali Soils or Alkali Water (2004) . . . 8-1-48 1.17.6 Construction Joints (1993) . . . 8-1-48 1.17.7 Minimum Cover (1993) . . . 8-1-48 1.17.8 Placement of Concrete (1993) . . . 8-1-48
1.18 Curing . . . 8-1-48
1.18.1 General (2000) . . . 8-1-48 1.18.2 Hot Weather Curing (1993) . . . 8-1-49 1.18.3 Wet Curing (1993) . . . 8-1-49 1.18.4 Membrane Curing (1993) . . . 8-1-50 1.18.5 Steam Curing (1993) . . . 8-1-50 1.18.6 Curing Concrete Containing Silica Fume (2003). . . 8-1-50 1.18.7 Curing Concrete Containing Ground Granulated Blast-Furnace Slag (2004) . . . 8-1-51 1.18.8 Curing Concrete Containing Fly Ash (2004) . . . 8-1-51
1.19 Formed Surface Finish . . . 8-1-51
1.19.1 General (2005) . . . 8-1-51 1.19.2 Rubbed Finish (2005) . . . 8-1-52
1.20 Unformed Surface Finish . . . 8-1-52
1.20.1 General (2005) . . . 8-1-52 1.20.2 Sidewalk Finish (2005). . . 8-1-52 1.20.3 Finishing Concrete Containing Silica Fume (2004). . . 8-1-52 1.20.4 Finishing Concrete Containing Ground Granulated Blast-Furnace Slag (2004) . . . 8-1-52 1.20.5 Finishing Concrete Containing Fly Ash (2004) . . . 8-1-52
1.21 Decorative Finishes . . . 8-1-53 1.22 Penetrating Water Repellent Treatment of Concrete Surfaces . . . 8-1-53
1.22.1 General (1993) . . . 8-1-53 1.22.2 Surface Preparation (2003). . . 8-1-53 1.22.3 Environmental Requirements (2003) . . . 8-1-53 1.22.4 Application (2003) . . . 8-1-53 1.22.5 Materials (2003) . . . 8-1-54 1.22.6 Quality Assurance (1993) . . . 8-1-55 1.22.7 Delivery, Storage and Handling (1995) . . . 8-1-55
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TABLE OF CONTENTS (CONT)
Section/Article Description Page
1.23.1 General (2003) . . . 8-1-55 1.23.2 Surface Preparation (2003) . . . 8-1-56 1.23.3 Application (2003) . . . 8-1-56
1.24 High Strength Concrete . . . . 8-1-56
1.24.1 General (1995) . . . 8-1-56 1.24.2 Materials (1995). . . 8-1-56 1.24.3 Concrete Mixture Proportions (1995) . . . 8-1-57
1.25 Specialty Concretes. . . . 8-1-57 1.25.1 General . . . 8-1-57 1.25.2 Sulfur Concrete . . . 8-1-57 1.25.3 Heavyweight Concrete. . . 8-1-58 1.25.4 Polymer Concrete (2013) . . . 8-1-59 1.25.5 Fiber-Reinforced Concrete (2014) . . . 8-1-61 1.25.6 High-Performance Concrete (2014). . . 8-1-61 1.26 Self-Consolidating Concrete . . . . 8-1-62 1.26.1 General (2013) . . . 8-1-62 1.26.2 Mix Design and Testing (2013) . . . 8-1-63 1.26.3 Forms and Reinforcement (2013) . . . 8-1-63 1.26.4 Mixing Concrete (2013). . . 8-1-64 1.26.5 Placement (2013) . . . 8-1-64 1.26.6 Curing (2013). . . 8-1-64 Commentary. . . 8-1-64
LIST OF FIGURES
Figure Description Page
8-1-1 Full-Depth Expansion Joint . . . 8-1-28 8-1-2 Two Methods for Making Contraction Joints for Slabs-on-Grade . . . 8-1-30 8-1-3 Keyed Construction Joint with Waterstop Inserted Perpendicular to the Plane of the Joint. . . 8-1-30
LIST OF TABLES
Table Description Page
8-1-1 Portland Cement ASTM C150. . . 8-1-9 8-1-2 Blended Hydraulic Cements ASTM C595 . . . 8-1-9 8-1-3 Sampling and Testing Methods in Addition to those of ASTM C33 . . . 8-1-12 8-1-4 Aggregate Soundness. . . 8-1-12 8-1-5 Fine Aggregate Grading. . . 8-1-13 8-1-6 Deleterious Substances in Fine Aggregate . . . 8-1-14 8-1-7 ASTM Specifications for Reinforcement . . . 8-1-17 8-1-8 ASTM Specifications for Coated Reinforcement . . . 8-1-18
LIST OF TABLES (CONT)
Table Description Page
8-1-9 Maximum Permissible Water-Cementitious Materials Ratio (by Weight) for Different Types of Structures and Degrees of Exposure . . . 8-1-32 8-1-10 Air-Entrained Concrete Volume . . . 8-1-33 8-1-11 Water-Cementitious Materials Ratio for Air Entrained Concrete . . . 8-1-33 8-1-12 Concrete Exposed to Deicing Chemicals. . . 8-1-36 8-1-13 Concrete Temperature Limits. . . 8-1-42 8-1-14 Recommendations For Concrete In Sulfate Exposures . . . 8-1-47
SECTION 1.1 GENERAL
1.1.1 PURPOSE (2004)
This recommended practice is for work carried out by the Company or by Contractors for the Company when so requested by the Engineer.
1.1.2 SCOPE (2004)
This recommended practice describes the selection, sampling and testing of materials to be used, the composition of concrete, and the mixing, transporting, placing, finishing and curing of concrete. This recommended practice shall govern whenever it is in conflict with other cited references.
1.1.3 TERMS (2006)
Following is a list of terms associated with this Part. These terms are defined in the Glossary located at the end of this Chapter. AASHTO Absorption ACI International Admixture Admixture, Accelerating Admixture, Air-Entraining Admixture, Retarding Admixture, Water Reducing
Admixture, Water Reducing (High Range) Admixture, Water Reducing and Accelerating Admixture, Water Reducing and Retarding Agent, Bonding Aggregate Air, Entrained Approved or Approval ASTM - International Blast-Furnace Slag
Blast-Furnace Slag, Ground Granulated Bleeding Cement, Blended Cement, Hydraulic Cement, Slag Cementitious Centering Company Compound, Curing Concrete Concrete, Cyclopean Concrete, Polymer Concrete, Polymer Cement
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Concrete, Structural Lightweight Contractor Engineer Falsework FHWA Fly Ash Form / Formwork Honeycomb Joint, Expansion Laitance Modulus, Fineness PCI Plans Plasticizer Pozzolan Reinforcement Reinforcement, Deformed Reinforcement, Plain Resistance, Chemical Shore / Shoring Sieve Sieve Analysis Sieve Number Silica Fume Slump Soundness Strength, Compressive Superplasticizer USDOT Water Absorption
Water-Cementitious Material Ratio
1.1.4 ACCEPTABILITY (2004)
a. Concrete shall be proportioned, mixed, transported, placed and cured by the methods herein recommended. b. All materials used in the work shall be subject to the approval of the Engineer who shall be the sole judge of their
quality, suitability, and acceptability as to type. The Engineer shall be notified in advance whenever any phase of the work is to begin.
1.1.5 ASTM - INTERNATIONAL (2004)
Whenever reference is made to the ASTM - International (ASTM), the letter ‘M’ indicating a metric edition and the number indicating the year of issue are omitted from the designation. The latest issue of the referenced designation is to be used in each case.
1.1.6 SELECTION OF MATERIALS (2004)
The concrete materials shall be selected for strength, durability and chemical resistance, and ability to attain specified properties as required, in accordance with this recommended practice and as approved by the Engineer. They shall be combined in such a manner as to produce uniformity of color and texture in the surface of any structure or group of structures in which they are to be used. No change shall be made in the brand, type, source or characteristics of cementitious materials, the character and source of aggregate or water, or the class of concrete and method of transporting, placing, finishing or curing without approval of the Engineer.
1.1.7 TEST OF MATERIALS (2004)
a. The Engineer shall have the right to order testing of any materials used in concrete construction to determine if they are of the quality specified.
b. Tests of materials and concrete shall be made in accordance with appropriate standards of the ASTM - International as specified.
c. Pre-construction tests shall be carried out on cementitious materials, other than portland cement, as indicated in this recommended practice.
1.1.8 DEFECTIVE MATERIALS (2004)
All materials of any kind rejected by the Engineer shall be immediately removed from the site and any work affected by the defective material shall be remedied by the Contractor at his own expense and to the satisfaction of the Engineer.
1.1.9 EQUIPMENT (2004)
The Contractor shall provide all equipment required for the work, including all staging, scaffolding, apparatus, tools, etc., as necessary. All equipment must be approved by the Engineer who may require the removal of any piece of equipment. The Contractor shall substitute satisfactory equipment to replace rejected equipment without delay. Upon request, the Contractor shall furnish for approval a statement of methods and equipment proposed for use in all aspects of the work. Exercise of this approval by the Engineer shall not relieve the Contractor of his sole responsibility for the safe, adequate and lawful
construction, maintenance and use of such methods and equipment.
SECTION 1.2 CEMENT
1.2.1 GENERAL (2004)
Cement shall be furnished by the Contractor or the Company as provided for in the contract. Cement used in the work shall be the same as that required by the mix design.
1.2.2 SPECIFICATIONS (2004)
1a. Cement shall conform to one of the following Standard Specifications except as modified in this Chapter. (1) ASTM C150 Standard Specification for Portland Cement as shown in Table 8-1-1
(2) ASTM C595 Standard Specification for Blended Hydraulic Cements as shown in Table 8-1-2
b. The use of slag cement Types ‘S’ and ‘S(A)’ as defined in ASTM C595 are not included in this recommended practice. c. Refer also to Section 1.3 Other Cementitious Materials.
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1.2.3 QUALITY, SAMPLING AND TESTING (2004)
The quality of the cement and the methods of sampling and testing shall meet the requirements of the appropriate ASTM Standard Specification or Method of Test.
Table 8-1-1. Portland Cement ASTM C150
Type Description
Type I For use when the special properties specified for any other type are not required.
Type IA Air-entraining cement for the same uses as Type I, where air-entrainment is desired.
Type II For general use, especially when moderate sulfate resistance, or moderate heat of hydration is
desired.
Type IIA Air-entraining cement for the same uses as Type II, where air-entrainment is desired.
Type III For use when high early strength is desired.
Type IIIA Air-entraining cement for the same use as Type III, where air-entrainment is desired.
Type IV For use when a low heat of hydration is desired.
Type V For use when high sulfate resistance is desired.
Table 8-1-2. Blended Hydraulic Cements ASTM C595
Type Description
Portland Blast-Furnace Slag Cement
Type IS Portland blast-furnace slag cement for use in general concrete construction.
Type IS( ) Modified sulfate resistant (MS), air-entrainment (A), or moderate heat of hydration (MH), or any combination may be specified by adding the appropriate suffixes.
Portland-Pozzolan Cement
Type IP Portland-pozzolan cement for use in general concrete construction.
Type IP( ) Moderate sulfate resistance (MS), air-entrainment (A), or moderate heat of hydration (MH), or any combination may be specified by adding the appropriate suffixes.
Type P Portland-pozzolan cement for use in concrete construction where high early strengths are not required. Type P( ) Modified sulfate resistance (MS), air-entrainment (A), or low heat of hydration (LH), or any
combination may be specified by adding the appropriate suffixes.
Pozzolan-Modified Portland Cement
Type I(PM) Pozzolan-modified portland cement for use in general concrete construction.
Type I(PM)( ) Modified sulfate resistance (MS), air-entrainment (A), or moderate heat of hydration (MH), or any combination may be specified by adding the appropriate suffixes.
Slag-Modified Portland Cement
Type I(SM) Cement for use in general concrete construction.
Type I(SM)( ) Modified sulfate resistance (MS), air-entrainment (A), or moderate heat of hydration (MH), or any combination may be specified by adding the appropriate suffixes.
SECTION 1.3 OTHER CEMENTITIOUS MATERIALS
1.3.1 GENERAL (2004)
When using cementitious materials other than portland cement, reference should also be made to the provisions of Section 1.12 Proportioning;Section 1.13 Mixing;Section 1.14 Depositing Concrete;Section 1.16 Concrete in Sea Water;Section 1.17 Concrete in Alkali Soils or Alkali Water;Section 1.18 Curing; and Section 1.20 Unformed Surface Finish.
1.3.2 ACCEPTABILITY (2004)
Cementitious materials other than portland cement will be permitted only if approved in writing by the Engineer of the Railroad Company.
1.3.3 SPECIFICATIONS (2004)
1The specifications listed in Articles 1.3.3.1 and 1.3.3.2 apply to the use of other cementitious materials, either supplied in blended form with portland cement or added separately at the time of mixing.
1.3.3.1 ASTM C595 Standard Specification for Blended Hydraulic Cements; and ASTM C618 Standard Specification for Fly Ash and Raw or Calcined Natural Pozzolan for Use as a Mineral Admixture in Portland Cement Concrete, and the following:
a. Silica Fume - ASTM C1240 Standard Specification for Silica Fume for Use in Hydraulic-Cement Concrete, Mortar, and Grout, of the following types:
(1) As-produced silica fume -- in its original form of an extremely fine powder (2) Slurried silica fume -- in a water base, containing 40 to 60% silica fume by mass (3) Densified silica fume -- a compacted form of as-produced silica fume
b. Fly Ash - ASTM C618 Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use as a Mineral Admixture in Concrete, of the following Classes:
(1) Class F -- Normally produced from high energy coals such as bituminous and anthracite coals, but sometimes produced with sub-bituminous and lignite coals
(2) Class C -- Normally produced from sub-bituminous and lignite coals
(3) Class N – Natural materials such as highly reactive volcanic ash, metakaolin (and other calcined clays), diatomaceous earths, calcined shales, and other reactive materials
1.3.3.2 Ground Granulated Blast-Furnace Slag - ASTM C989 Standard Specification for Ground Granulated Iron Blast-Furnace Slag for Use in Concrete and Mortars.
1.3.4 MATERIALS NOT INCLUDED IN THIS RECOMMENDED PRACTICE (2004)
The following materials are not included in this recommended practice:
a. Pelletized silica fume -- consisting of hard pellets, not presently being used as an additive for concrete.
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b. Types of slag not produced in the iron making process.
c. Types ‘S’ and ‘S(A)’ blended hydraulic cements containing ground granulated blast-furnace slag, as defined in ASTM C595.
d. Blended cements containing ground granulated blast-furnace slag blended with hydrated lime.
1.3.5 DOCUMENTATION (2004)
a. Each shipment of fly ash or silica fume or ground granulated blast-furnace slag used on a project shall have a certificate of compliance which includes the following:
(1) Name of supplier
(2) Consignee and destination of the shipment (3) Vehicle identification number
(4) A unique unrepeated order number or other identification number for each shipment (5) Source
b. Each shipment of fly ash shall also include a certificate of compliance indicating the Class (either Class C or Class F), with certified test numbers demonstrating that the material meets ASTM C618.
c. Each shipment of silica fume shall also include a certificate of compliance demonstrating that it meets the requirements of ASTM C1240.
d. Each shipment of ground granulated blast-furnace slag shall also include a certificate of compliance indicating its grade (either Grade 80, 100 or 120), with certified test numbers demonstrating that it meets the requirements of ASTM C989.
SECTION 1.4 AGGREGATES
1.4.1 GENERAL (2004)
1.4.1.1 Specifications
Except as specified otherwise herein, all aggregates shall conform to the requirements of ASTM C33, Standard Specification for Concrete Aggregates.
1.4.1.2 Sampling and Testing
a. Representative samples shall be selected and sent to the testing laboratory at frequent intervals as directed by the Engineer. Aggregates may not be used until the samples have been tested by the laboratory and approved by the Engineer.
b. Sampling and testing shall be in accordance with ASTM C33 and the Standard Specifications and Methods of Test of ASTM - International found in Table 8-1-3.
c. The required tests shall be made on test samples that comply with requirements of the designated test methods and are representative of the grading that will be used in the concrete. The same test sample may be used for sieve analysis and for determination of material finer than the No. 200 (75 Pm) sieve. Separated sizes from the sieve analysis may be used in preparation of samples for soundness or abrasion tests. For determination of all other tests and for evaluation of potential alkali reactivity where required, independent test samples shall be used.
d. The fineness modulus of an aggregate is the sum of the percentages of a sample retained on each of a specified series of sieves divided by 100, using the following standard sieve sizes: No. 100, No. 50, No. 30, No. 16, No. 8, No. 4, 3/8 inch, 3/4 inch, 1-1/2 inches (150 Pm, 300 Pm, 600 Pm, 1.18 mm, 2.36 mm, 4.75 mm, 9.5 mm, 19.0 mm, 37.5 mm) and larger, increasing in the ratio of 2 to 1. Sieving shall be done in accordance with ASTM Method C136.
1.4.1.3 Soundness
a. Except as provided in Paragraph 1.4.1.3(b), aggregate subjected to five cycles of ASTM C88 Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate shall show a loss weighed in accordance with the grading procedures, not greater than the percentages found in Table 8-1-4.
b. Aggregate failing to meet the requirements of Paragraph 1.4.1.3(a) may be accepted provided that concrete of comparable properties, made with similar aggregate from the same source, has given satisfactory service when exposed to weathering similar to that to be encountered.
1.4.2 FINE AGGREGATES (2004)
1.4.2.1 General1
Fine aggregate shall consist of natural sand or, subject to the approval of the Engineer, manufactured sand with similar characteristics. Lightweight fine aggregate shall not be used.
1.4.2.2 Grading
a. Sieve Analysis–Fine aggregate, except as provided in ASTM C33, shall be graded within the limits found in Table 8-1-5.
Table 8-1-3. Sampling and Testing Methods in Addition to those of ASTM C33
Type DesignationASTM
Surface Moisture in Fine Aggregate C70
Specific Gravity and Absorption of Coarse Aggregate C127
Specific Gravity and Absorption of Fine Aggregate C128
Standard Sand C778
Table 8-1-4. Aggregate Soundness
Aggregate Sodium Sulfate Magnesium Sulfate
Fine 10 15
Coarse 12 18
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b. The minimum percentages shown above for material passing the No. 50 (300 Pm) and No. 100 (150 Pm) sieves may be reduced to 5 and 0, respectively, if the aggregate is to be used in air-entrained concrete containing more than 420 lb of cement per cubic yard (250 kg per cubic meter), or in non-air-entrained concrete containing more than 520 lb of cement per cubic yard (310 kg per cubic meter). Air-entrained concrete is here considered to be concrete containing air-entraining cement or an air-entraining admixture and having an air content of more than 3%.
c. The fine aggregate shall have not more than 45% retained between any two consecutive sieves of those shown in
Table 8-1-5 and its fineness modulus shall be not less than 2.3 nor more than 3.1.
d. For walls and other locations where smooth surfaces are desired, the fine aggregate shall be graded within the limits shown in Table 8-1-5, except that not less than 15% shall pass the No. 50 (300 Pm) sieve and not less than 3% shall pass the No. 100 (150 Pm) sieve.
e. To provide the uniform grading of fine aggregate, a preliminary sample representative of the material to be furnished shall be submitted at least 10 days prior to actual deliveries. Any shipment made during progress of the work which varies by more than 0.2 from the fineness modulus of the preliminary sample shall be rejected or, at the option of the Engineer, may be accepted provided that suitable adjustments are made in concrete proportions to compensate for the difference in grading.
f. The percentages listed above do not apply when using pozzolans or ground granulated blast-furnace slag. Such percentages shall be determined by tests as outlined in this recommended practice.
1.4.2.3 Mortar Strength
Fine aggregate shall be of such quality that when made into a mortar and subjected to the mortar strength test prescribed in ASTM C87, the mortar shall develop a compressive strength not less than that developed by a mortar prepared in the same manner with the same cementitious materials and graded standard sand having a fineness modulus of 2.40±0.10. The graded sand shall conform to the requirements of ASTM C778.
1.4.2.4 Deleterious Substances
a. The amount of deleterious substances in fine aggregate shall not exceed the limits found in Table 8-1-6. Table 8-1-5. Fine Aggregate Grading
Sieve Size Total Passing Percentage by Weight 3/8 inch (9.5 mm) 100 No. 4 (4.75 mm) 95-100 No. 8 (2.36 mm) 80-100 No. 16 (1.18 mm) 50-85 No. 30 (600 Pm) 25-60 No. 50 (300 Pm) 10-30 No. 100 (150 Pm) 2-10 No. 200 (75 Pm) zero
b. A fine aggregate failing the test for organic impurities may be used provided that, when tested for mortar-making properties, the mortar develops a compressive strength at 7 and 28 days of not less than 95% of that developed in a similar mortar made from another portion of the same sample which has been washed in a 3% solution of sodium hydroxide followed by thorough rinsing in water. The treatment shall be sufficient so that the test of the washed material made in accordance with ASTM C40 will have a color lighter than the standard color solution.
c. Fine aggregate for use in concrete that will be subject to wetting, extended exposure to humid atmosphere, or contact with moist ground shall not contain any materials that are deleteriously reactive with the alkalies in the cement in an amount sufficient to cause excessive expansion of mortar or concrete, except that if such materials are present in injurious amounts, the fine aggregate may be used with a cement containing less than 0.6% alkalies as measured by percentage of sodium oxide plus 0.658 times percentage of potassium oxide, or with the addition of a material that has been shown to prevent harmful expansion due to the alkali-aggregate reaction.
1.4.3 NORMAL WEIGHT COARSE AGGREGATE (2004)
1.4.3.1 General
a. Coarse aggregate shall consist of crushed stone, gravel, crushed slag, or a combination thereof or, subject to the approval of the Engineer, other inert materials with similar characteristics, having hard, strong durable pieces, free from adherent coatings, and shall conform to the requirements of ASTM C33 except as required by this Part.
b. Crushed slag shall be rough cubical fragments of air-cooled blast-furnace slag, which when graded as it is to be used in the concrete, shall have a compact weight of not less than 70 lb per cubic foot (1100 kg per cubic meter). It shall be obtained only from sources approved by the Engineer.
1.4.3.2 Grading
a. Coarse aggregate shall be graded between the limits specified by ASTM C33.
b. The maximum size of aggregate shall be not larger than one-fifth of the narrowest dimension between forms of the member for which concrete is used, nor larger than one-half of the minimum clear space between reinforcing bars, except as provided for precast concrete in Section 2.5.
Table 8-1-6. Deleterious Substances in Fine Aggregate
Item Percentage by WeightMaximum Limit
Clay Lumps 1.0
Coal and Lignite 0.5 (Note 1)
Material finer than No. 200 sieve (75 Pm): Concrete subject to abrasion
All other classes of concrete
3.0 (Note 2) 5.0 (Note 2) Note 1: Does not apply to manufactured sand produced from blast-furnace slag.
Note 2: For manufactured sand, if the material finer than the No. 200 (75 Pm) sieve consists of the dust of fracture, essentially free from clay or shale, these limits do not apply.
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1.4.3.3 Deleterious Substancesa. The amount of deleterious substances in coarse aggregate shall not exceed the limits found in ASTM C33.
1.4.3.4 Abrasion Loss
Coarse aggregate to be used in concrete when subjected to test for resistance to abrasion (ASTM C535 or ASTM C131) shall show a loss of weight not more than the following:
a. For concrete subject to severe abrasion such as concrete in water, precast concrete piles, paving for sidewalks, platforms or roadways, floor wearing surfaces, and concrete cross or bridge ties, the loss of weight shall not exceed 40%.
b. For concrete subject to medium abrasion such as concrete exposed to the weather, the loss of weight shall not exceed 50%.
c. For concrete not subject to abrasion, the loss in weight shall not exceed 60%.
1.4.3.5 Rubble Aggregate
Rubble aggregate shall consist of clean, hard, durable stone retained on a 6-inch (150 mm) square opening and with individual pieces weighing not more than 100 lb (45 kg).
1.4.3.6 Cyclopean Aggregate
Cyclopean aggregate shall consist of clean, hard, durable stone with individual pieces weighing more than 100 lb (45 kg).
1.4.4 LIGHTWEIGHT COARSE AGGREGATE FOR STRUCTURAL CONCRETE (2004)
1.4.4.1 Scope
a. This recommended practice covers lightweight coarse aggregates intended for use in lightweight concrete in which prime considerations are durability, compressive strength, and light weight. Structural lightweight concrete shall only be used where shown on the plans or specified.
b. Aggregates for use in non-structural concrete such as fireproofing and fill, and for concrete construction where capacity is based on load tests rather than conventional design procedures, are not included in this recommended practice.
1.4.4.2 General Characteristics
The aggregates shall conform to the requirements of ASTM C330 Standard Specifications for Lightweight Aggregates for Structural Concrete, except as otherwise specified herein.
1.4.4.3 Unit Weight (Mass Density)
a. The dry weight (mass density) of lightweight aggregates shall not exceed 55 lb per cubic foot (880 kg per cubic meter), measured loose by accepted ASTM practice.
b. Uniformity of weight (density). The unit weight (mass density) of successive shipments of lightweight aggregate shall not differ by more than 6% from that of the sample submitted for acceptance tests.
1.4.4.4 Concrete Making Properties
Concrete specimens containing lightweight coarse aggregate under test shall conform to ASTM C330 and shall meet the following requirements. A magnesium sulfate soundness test shall be conducted for 10 cycles in accordance with ASTM C88. Loss thus determined shall not exceed 15%. Loss of individual gradation size shall not exceed 20% of that size.
SECTION 1.5 WATER
11.5.1 GENERAL (2010)
1.5.1.1 Specifications
Mixing water shall conform to the requirements of ASTM C 1602, Standard Specification for Mixing Water Used in the Production of Hydraulic Cement Concrete.
SECTION 1.6 REINFORCEMENT
1.6.1 GENERAL
2(2013)
Reinforcement shall be deformed reinforcement, except that plain bars and plain wire shall be permitted for spirals or tendons, or for dowels at expansion or contraction joints. Reinforcement consisting of structural steel, steel pipe, or steel tubing shall be permitted for composite compression members.
1.6.2 WELDING (2013)
a. Welding of reinforcing bars shall conform to “Structural Welding Code–Reinforcing Steel” (AWS D1.4/D1.4M) of the American Welding Society. Type and location of welded splices and other required welding of reinforcing bars shall be indicated on the plans or in the project specifications. The ASTM specifications for reinforcing bars, except for ASTM A706/A706M, shall be supplemented to require a report of the chemical composition necessary to conform to welding procedures specified in AWS D1.4/D1.4M.
b. If welding of wire to wire, and of wire or welded wire reinforcement to reinforcing bars or structural steel is to be required on a project, the Engineer shall specify procedures or performance criteria for the welding.
c. Welders of reinforcing bars shall maintain certification by the American Welding Society.
1.6.3 SPECIFICATIONS (2013)
1.6.3.1 Reinforcement
Bars, wire, welded wire reinforcement, prestressing tendons, structural steel, steel pipe and tubing shall conform to one of the ASTM specifications listed in Table 8-1-7.
1 See C - Commentary 2 See C - Commentary
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1.6.3.2 Coated Reinforcement
a. Coated reinforcement, when specified or shown on the plans as a corrosion-protection system, shall conform to one of the ASTM specifications listed in Table 8-1-8.
Table 8-1-7. ASTM Specifications for Reinforcement
Type Specifications
Bars, Wire and Welded Wire
Deformed and Plain Carbon-Steel Bars A615/A615M
Deformed and Plain Low-Alloy Steel Bars A706/A706M
Deformed Rail-Steel and Axle-Steel Bars A996/A996M
Deformed and Plain Stainless Steel Bars A955/A955M
Headed Steel Bars A970/A970M
Deformed and Plain Low-Carbon, Chromium Steel Bars A1035/A1035M
Steel Wire, Plain (wire shall not be smaller than size W4 (0.226 inch (5.74 mm) dia.))
A1064/A1064M
Steel Welded Wire Reinforcement, Plain A1064/A1064M
Steel Wire, Deformed (wire shall not be smaller than size D4 (0.225 inch (5.72 mm) dia.))
A1064/A1064M Steel Welded Wire Reinforcement, Deformed (welded intersections shall not be
spaced farther apart than 16 inches (400 mm) in direction of primary flexural reinforcement)
A1064/A1064M
Stainless Steel Wire and Welded Wire Reinforcement, Deformed and Plain A1022/A1022M
Prestressing Tendons
Uncoated Seven-Wire Steel Strand A416/A416M
Uncoated Stress-Relieved Steel Wire A421/A421M
Uncoated High-Strength Steel Bar A722/A722M
Structural Steel, Steel Pipe and Tubing
Structural-Steel A36/A36M, A242/A242M,
A529/A529M, A572/A572M,
A588/A588M or A709/A709M (Grade 36, 50 or 50W)
Steel Pipe A53/A53M (Grade B)
Steel Tubing A500/A500M, A501/A501M or
b. Repair all damaged epoxy coating on reinforcing bars with patching material conforming to ASTM A775/A775M, A934/A934M or A1055/A1055M. Repair shall be done in accordance with the material manufacturer’s
recommendations.
c. Repair all damaged epoxy coating on wire or welded wire reinforcement with patching material conforming to ASTM A884/A844M. Repair shall be done in accordance with the material manufacturer’s recommendations.
d. Repair all damaged zinc coating on reinforcing bars in accordance with ASTM A780/A780M. The maximum amount of damaged areas shall not exceed 2% of the total surface area in each linear foot (300 mm) of the bar. If the damaged areas exceed 2% of the total surface area in each linear foot (300 mm) of the bar, the bar shall be replaced.
e. Equipment for handling epoxy-coated reinforcing bars shall have protected contact areas. Bundles of coated bars shall be lifted at multiple pickup points to prevent bar-to-bar abrasion from sags in the bundles. Coated bars or bundles of coated bars shall not be dropped or dragged. Coated bars shall be stored on protective cribbing. All damaged coating shall be repaired. The maximum amount of damaged areas shall not exceed 2% of the surface area of each linear foot (300 mm) of the bar. If the damaged areas exceed 2% of the total surface area in each linear foot (300 mm) of the bar, the bar shall be replaced.
f. After installation of mechanical splices on epoxy-coated, zinc-coated (galvanized), or zinc and epoxy dual-coated reinforcing bars, all damaged coating shall be repaired. All parts of mechanical splices used on coated bars, including steel splice sleeves, bolts, and nuts shall be coated with the same material used for repair of damaged coating on the spliced material. Remove coating for 2 inches (50 mm) back from the mechanical splice to bright metal before repair. g. After completion of welding for welded splices on epoxy-coated, zinc-coated (galvanized), zinc and epoxy dual-coated reinforcing bars, all damaged coating shall be repaired. All welds, and steel splice members when used to splice bars, shall be coated with the same material used for repair of damaged coating. Remove coating for 6 inches (150 mm) back from the welded splice to bright metal before repair.
h. Repair all damaged zinc coating on welded wire reinforcement in accordance with ASTM A780/A780M. i. Plants applying fusion-bonded epoxy coatings to reinforcing bars shall maintain certification by the Concrete
Reinforcing Steel Institute.
Table 8-1-8. ASTM Specifications for Coated Reinforcement
Type Specification
Epoxy-Coated Steel Reinforcing Bars A775/A775M
Epoxy-Coated Prefabricated Steel Reinforcing Bars A934/A934M
Epoxy-Coated Steel Wire and Welded Wire Reinforcement A884/A884M
Epoxy-Coated Seven-Wire Prestressing Steel Strand A882/A882M
Zinc-Coated (Galvanized) Steel Reinforcing Bars A767/A767M
Zinc and Epoxy Dual-Coated Steel Reinforcing Bars A1055/A1055M
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1.6.4 BENDING AND STRAIGHTENING REINFORCING BARS
1(2013)
a. Reinforceing bars shall be fabricated in accordance with Article 1.10.2andPart 2, Reinforced Concrete Design,
Article 2.4.2. Field bending and/or straightening of bars that are partially embedded in concrete shall be done in accordance with the Plans or as permitted by the Engineer.
b. When epoxy-coated reinforcing bars, zinc and epoxy dual-coated reinforcing bars, or zinc-coated (galvanized) reinforcing bars are field bent and/or straightened, damaged coating shall be repaired in accordance with Articles
1.6.3.2b or 1.6.3.2d. Field bending and/or straightening of epoxy-coated reinforcing bars conforming to ASTM A934/A934M shall be prohibited.
SECTION 1.7 CONCRETE ADMIXTURES
1.7.1 GENERAL (2013)
a. The selection of admixtures to be used in concrete, if any, shall be subject to the prior approval of the Engineer. b. An admixture shall be shown capable of maintaining essentially the same composition and performance throughout the
work as the product used in establishing concrete proportions in accordance with Section 1.12 Proportioning. c. Admixtures containing chloride ions shall not be used unless approved by the Engineer.
d. Special purpose admixtures may be used if approved in writing by the Engineer. However, before an admixture can be approved for use, it must be shown that its use will not adversely affect the placement, strength and/or durability of the concrete. Admixtures used in combination may be incompatible and their performance should be verified by prior testing from a certified third party agency.
1.7.2 TYPES OF ADMIXTURES AND STANDARD SPECIFICATIONS (2013)
The specifications listed in Paragraphs 1.7.2(a) and 1.7.2(b) apply in the use of admixtures. a. ASTM C260 Standard Specification for Air-Entraining Admixtures for Concrete. b. ASTM C494 Standard Specification for Chemical Admixtures for Concrete:
(1) Type A--Water-reducing admixtures (2) Type B--Retarding admixtures (3) Type C--Accelerating admixtures
(4) Type D--Water-reducing and retarding admixtures (5) Type E--Water-reducing and accelerating admixtures (6) Type F--Water-reducing, high range admixtures
(8) Type S--Specific performance admixtures
SECTION 1.8 STORAGE OF MATERIALS
1.8.1 CEMENTITIOUS MATERIALS AND CONCRETE ADMIXTURES (2009)
a. Immediately upon delivery, all cement shall be stored in watertight ventilated structures to prevent absorption of water. b. Sacked cement shall be stacked on pallets or similar platforms to permit circulation of air and access for inspection.
The cement sacks shall not be stacked against outside walls.
c. Cement sacks shall not be stacked more than 14 layers high for periods of up to 60 days, nor more than 7 layers high for periods over 60 days. Older cement shall be used first.
d. Storage facilities for bulk cement shall include separate compartments for each type of cement used. The bins shall be so constructed as to prevent dead storage in corners.
e. All cement shall be subject at any time to retest. If under retest it fails to meet any of the requirements of the specifications, it will be rejected and shall be promptly removed from the site of the work by the Contractor. f. Where the Company furnishes the cement and the failure of the cement to pass the retest is due to negligence on the
part of the Contractor to store it properly, the cost of such cement shall be charged to the Contractor.
g. The above provisions also apply to other cementitious materials and blended cementitious materials, except that fly ash shall be stored in a separate structure or bin without common walls to avoid leakage of the fly ash into the other cementitious materials.
h. Liquid admixtures shall be protected from freezing. If freezing occurs then the material shall not be used in concrete unless the manufacturer approves a method of ensuring the effectiveness of the thawed material, such as agitation.
1.8.2 AGGREGATES (2009)
a. The storage of coarse aggregates shall be minimized, as to avoid the natural tendency of such stockpiles to segregate. b. Fine and coarse aggregates shall be stored separately and in such a manner as to avoid the inclusion of foreign
materials in the concrete. Aggregates shall be unloaded and piled in such a manner as to maintain the uniform grading of the sizes. Stockpiles of coarse aggregates shall be built in horizontal layers, not by end dumping, to avoid
segregation. Equipment such as dozers and loaders shall not be operated on the stockpile, so as to avoid contamination, segregation and breakage.
c. A hard base shall be provided to prevent contamination from underlying material. Overlap of the different sizes shall be prevented by suitable walls or ample spacing between stockpiles. Stockpiles shall not be contaminated by swinging aggregate-filled buckets or clams over the various stockpiled aggregate sizes. Crushed slag shall be wetted down when necessary to ensure a minimum 3% moisture content.
d. Special measures shall be taken to maintain a uniform moisture content in the aggregates as batched. Control and testing procedures shall be subject to the approval of the Engineer.
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1.8.3 REINFORCEMENT (2013)
a. Reinforcement shall be stored in such a manner as to avoid contact with the ground. If reinforcement remains in storage at the site for more than a month, it shall be covered to protect it from the weather. If reinforcement
accumulates rust, dirt, mud, loose scale, paint, oil, or any foreign substance during storage, it shall be cleaned before being used. Deterioration may be a basis for rejection. Coated reinforcement shall be handled in accordance with
Section 1.6.
b. Epoxy-coated reinforcing bars, epoxy-coated wire and welded wire reinforcement, and zinc and/or epoxy dual-coated reinforcing bars shall be covered by opaque polyethylene sheeting or other suitable opaque protective material as approved by the Engineer. For stacked bundles, the protective covering shall be draped around the perimeter of the stack. The covering shall be secured in a manner that allows for air circulation around the coated reinforcement to minimize condensation under the covering. Epoxy-coated reinforcing bars, epoxy-coated wire and welded wire reinforcement, and zinc and epoxy dual-coated reinforcing bars shall be handled and repaired in accordance with
Section 1.6.
SECTION 1.9 FORMS
1.9.1 GENERAL (2009)
Forms shall be constructed of wood, steel, or other suitable material, and be of a type, size, shape, quality and strength, which will produce true, smooth lines and surfaces conforming to the lines and dimensions shown on the plans. Forms shall be substantial and designed to resist the pressures to which they are subjected. Lumber in forms for exposed surfaces should be dressed to a uniform thickness. Undressed lumber may be used in forms for unexposed surfaces. Forms shall be kept free of rust, grease and other foreign matter which will discolor the concrete.
Forms may be omitted for foundation concrete if, in the opinion of the Engineer, the sides of the excavation are sufficiently firm so that the concrete may be thoroughly vibrated without causing the adjacent earth to slough. The actual dimensions of the excavation shall then be slightly greater than the plan dimensions of the foundation so as to ensure design requirements.
1.9.2 SAFETY (2009)
The Contractor shall follow all local, state and federal codes, ordinances and regulations pertaining to forming of concrete at all stages of construction, in addition to the requirements of this Section and the railroad Company.
1.9.3 DESIGN (2009)
a. The Contractor shall be responsible for the design of all forms required to complete the work.
b. Structural design of forms shall be performed in conformance with ACI 347R, Guide to Formwork for Concrete, or other generally accepted standards, subject to the approval of the Engineer.
c. Forms shall be designed by a licensed engineer.
d. Drawings and structural design calculations shall be provided to the Engineer for review and acceptance prior to undertaking the work, unless excluded by the project Plans.
e. Documentation demonstrating the adequacy of forms supports to safely resist the design loads shall be provided for review and acceptance prior to undertaking the work, unless excluded by the project Plans.
g. Special provision for load transfer and movements shall be taken into account in the design of forms for prestressed concrete.
h. Special provision for forms supporting concrete that is required to act compositely with other materials in the finished work shall be made.
i. The review and acceptance of Contractor’s submittals shall not relieve the Contractor of responsibility for the safe and functional design of the forms and their supports.
1.9.4 CONSTRUCTION (2009)
a. The supervisor responsible for construction of forms should be certified by the American Concrete Institute Inspector Certification Program as a Concrete Transportation Construction Inspector. The Contractor may appoint a similarly qualified and experienced individual with the approval of the Engineer.
b. Forms shall be constructed mortar-tight, and shall be made sufficiently rigid by the use of ties and bracing to prevent displacement or sagging and to withstand the pressure and vibration without deflection and/or objectionable distortion from the prescribed lines during and after placement of the concrete.
c. Joints in forms shall be horizontal or vertical, and suitable devices shall be used to hold adjacent edges together in accurate alignment.
d. All forms shall be constructed and maintained so as to prevent warping and the opening of joints. e. All forms shall be constructed so that they may be readily removed without damaging the concrete.
f. Bolts and/or rods shall be used for internal form ties. They shall be so arranged that, when the forms are removed, no corrodible metal shall be within 1-1/2 inches (38 mm) of any surface.
g. When wire form ties are used, where permitted, spacer blocks shall be removed as the concrete is placed. Wire form ties shall be cut back 1-1/2 inches (38 mm) from the face of the concrete upon removal of the forms.
h. All fittings for ties shall be of such a design that upon their removal the remaining cavities will be the smallest practicable size. The cavities shall be filled with cement mortar and the surfaces left in a sound condition, even and uniform in color with respect to the original surface.
i. All temporary fasteners in contact with concrete shall be countersunk.
j. Any material once used in forms shall be thoroughly cleaned and form release agent shall be applied before erection in a new location. All rough surfaces shall be smoothed and repairs made to the satisfaction of the Engineer. Forms which have been used repeatedly and are not acceptable to the Engineer for further use shall be removed from the site. k. In the case of long spans where no intermediate supports are possible, deflection in the forms due to the weight of the
fresh concrete shall be compensated for by using camber strips, wedges or other devices so that the finished members conform accurately to the desired line and grade.
l. Foundations for falsework shall be provided in accordance with Part 28.
1.9.5 MOLDINGS (2009)
Unless otherwise specified or directed by the Engineer, suitable moldings or bevels shall be placed in the angles of forms to round or bevel the edges of the concrete, including abutting edges of expansion joints.