SECTION 03450 - ARCHITECTURAL PRECAST CONCRETE TRIM

Part 1 - GENERAL

1.1 REFERENCES:

A. Prestressed Concrete Institute MNL 117 "Manual for Quality Control for Plants and Production of Architectural Precast Concrete Products" - 3rd Edition, primarily Appendix J.

B. Prestressed Concrete Institute's "Architectural Precast Concrete Design Manual, 2nd Edition".

C. ASTM standards as stated herein.

1.2 SUMMARY

A. This specification covers all labor, materials and services for the furnishing and setting of the integrally colored architectural precast concrete units as indicated on the drawings and specifications herein.

B. The Fabricator shall have a minimum of 5 years successful experience in fabrication of architectural precast concrete units, similar to units required for this project. Fabricator must be an APA (Architectural Precast Association) Certified Plant or a PCI (Prestressed/Precast Concrete Institute) certified Plant for category AT or A1 (Architectural Precast). Fabricator must adhere to procedures that are applicable to the manufacturing of Architectural Precast Concrete trim pieces as outlined in Appendix J of PCI MNL-117 (3rd Edition) and the PCI Design Manual (2nd Edition).

1. Qualified Fabricators:

a. Steps Plus, Inc., 6375 Thompson Rd., Syracuse, NY 13206, web: steps-plus.com, ph.: 315-432-0806, fax: 315-432-0612.

b. Any fabricator that can submit all of the following:

i. Proof of APA Plant Certification or proof of PCI Certification for category AT or A1.

ii. Brochures or photos showing integrally colored precast from at least three previous projects that are of acceptable appearance in the opinion of the Architect. Names and locations of projects must be provided.

iii. At least three test reports less than 12 months old showing that the 5000 psi compressive cylinder strength and absorption requirements (less than 5%) called for in this specification can be met. Tests must have been performed by a professional testing laboratory.

iv. List of five successfully completed precast jobs at least five years old that include project name, location, General Contractor, and Architect.

2. Under no circumstances shall items labeled as precast concrete be cast in the field.

C. The setting contractor shall unload, store, protect, and install as covered by this Specification and shall provide and install all anchors and accessories for same. The setting contractor shall have a minimum of 3 years successful experience in erection of architectural precast concrete units similar to units required for this project.

1.3 SUBMITTALS: Submit the following in accordance with Conditions of Contract and Division 1 Specification Sections.

A. Fabricator information as listed above under section 1.2-B-1-b if the proposed fabricator is not listed as a qualified manufacturer.

B. Shop Drawings:

1. Prepared by an experienced professional detailer showing complete information for fabrication and installation of precast concrete units.

a. Show layout, dimensions, and identification of each precast unit corresponding to sequence and procedure of installation.

b. Make design modifications only as necessary to meet field conditions and to ensure proper fitting of the work and only as acceptable to the Architect.

2. The Fabricator shall submit the shop drawings to the General Contractor who shall verify all drawing dimensions and coordinate the shop drawings with field conditions and other trades. The General Contractor shall submit the shop drawings to the Architect for approval. The Fabricator shall not start production until the shop drawings are approved by the Architect and General Contractor in writing.

C. Samples

1. Minimum size - 6" x 6" x 2" to illustrate the quality, color, and surface finish texture.

2. Color: Fabricator must develop a custom colored mix to match a colored sample provided by the Architect. The color sample to match would either be an earthtone color shade (such as: Indiana limestone color, off-white, buff, brown, brick orange, brick red, light gray, dark gray, dull yellow) or pure white. Painted, stained, or coated precast is not acceptable. Unless otherwise noted, all the precast units on the project will be the same color and of the same mix design.

3. Texture: Smooth, dense, fine-grained texture achieved by acid etching to thoroughly remove all surface cement paste.

D. Sealer Product Data: If any of the precast includes exterior stair treads or other units that may come in contact with salt or other deicing compounds, those units, and only those units, must be sealed with a penetrating sealer after they are installed and cleaned. The installer shall submit product data on the proposed penetrating sealer.

1.4 DELIVERY, STORAGE, AND HANDLING.

A. Deliver precast concrete units to project site in such quantities and at such times to assure continuity of installation. Store units at project site to prevent cracking, distortion, warping, staining, or other physical damage and so that markings are visible. Lift and support units only at designated lifting or supporting points as shown on final shop drawings.

Part 2 - PRODUCTS

2.1 FORMWORK

A. Provide forms and, where required, form-facing materials of metal, plastic, wood, or other acceptable material that is nonreactive with concrete and will produce required finish surfaces per the approved sample. Maintain form work to provide completed precast concrete trim units within specified fabrication tolerances.

2.2 REINFORCEMENT

A. All precast concrete units shall be reinforced with new billet steel reinforcing bars, as necessary for safe handling, setting and structural stress, and the size of the reinforcing shall be specified with a minimum area of steel equal to one quarter of one percent of the cross section area. If the surfaces are to be exposed to the weather, the reinforcement shall be galvanized or epoxy coated when covered with less than 2 inches of material for bars larger than 5/8 inch and 1-1/2 inches for bars 5/8 inch or smaller. The material covering in all cases shall be at least twice the diameter of the bars.

1. Reinforcing Bars: ASTM A 615, Grade 60, deformed.

2. Epoxy-Coated Reinforcing Bars: ASTM A 775.

3. Galvanized Reinforcing Bars: ASTM A 767, Class II (2.0 oz. zinc psf), hot-dip galvanized after fabrication and bending.

4. Welded Wire Fabric: ASTM A 185.

B. For exposed-to-view concrete surfaces, where legs of supports are in contact with forms, provide supports with legs that are plastic protected (CRSI, Class I) or stainless steel protected (CRSI, Class 2).

2.3 CONCRETE MATERIALS

A. Portland Cement: ASTM C 150, Type I or Type III, Color to be white or gray as required to achieve proper color as determined by the Architect.

B. Coarse Aggregate: ASTM C 33, except for gradation. Color to be white. Darker aggregates may be used as long as the proper color mix is achieved as determined by the Architect.

C. Fine Aggregate: ASTM C 33, except for gradation. Color to be white. Darker aggregates may be used as long as the proper color mix is achieved as determined by the Architect.

D. Pigments: ASTM C 979; Inorganic, nonfading, resistant to lime and other alkalis. Pigments not to exceed 10% of the cement weight.

E. Water: Drinkable, free from foreign materials in amounts harmful to concrete or cast in steel.

F. Air-Entraining Admixture: ASTM C 260.

G. Water-Reducing, Retarding, or Accelerating Admixtures: ASTM C 494, type as selected by Fabricator and containing not more than 0.1 percent chloride ions.

2.4 CONNECTION MATERIALS

A. Anchors - Non-corrosive; galvanized, brass or stainless steel type 304.

B. Finish of Other Steel Units (Plates, braces, etc.): Units exposed to weather to be hot-dip galvanized after fabrication, ASTM A 153; Units not exposed to weather to be painted with one coat of rust-inhibitive primer; threaded inserts cast into precast units, hot-dip galvanized, electrogalvanized, or cadmium plated.

2.5 PROPORTIONING AND DESIGN OF MIXES

A. Unless otherwise noted, all the precast units on the project will be the same color and of the same mix design. Design mixes may be prepared by independent testing facility or by qualified precast manufacturing plant personnel, at precast fabricator's option.

B. Mix Properties: Standard-weight concrete consisting of specified portland cement, aggregates, pigments, admixtures, and water to produce the following properties;

1. Compressive Strength: Minimum 5000 psi at 28 days using 6" x 12" cylinders per ASTM C39-86.

2. Total Air Content: Not less than 4% nor more than 8%.

3. Water Absorption: Not to exceed 6% by weight when tested per ASTM C 642.

4. Color: As selected by Architect per the approved precast concrete sample.

2.6 FABRICATION

A. Tolerances of Finished Units: In accordance with Appendix J (Architectural Trim Requirements) in PCI MNL - 117 "Manual for Quality Control for Plants and Production of Architectural Precast Concrete Products" (3rd Edition) and PCI's "Architectural Precast Concrete Design Manual, 2nd Edition".

B. Fabricate units straight, smooth, and true to size and shape, with exposed edges and corners formed or stoned to a minimum radius unless otherwise indicated.

C. Testing: Tests to be performed by a certified testing laboratory. Testing to be paid for by the Fabricator. Results to be kept on file for at least two years and submitted upon Architect's request. No testing is required on projects where the total volume of concrete is under 25 CF.

1. Perform one set of 6" x 12" cylinder tests for every 500 cubic feet of concrete placed.

2. Perform one absorption test for every 500 cubic feet of concrete placed.

D. Curing: Cure units in a warm, moist, totally enclosed curing room for a minimum of 20 hours.

E. Cast-In Items: Fabricator to provide reglets, slots, holes, inserts, and other accessories in units to receive dowels, reglets, waterstops, flashings, anchors and other similar work as indicated.

F. Surface Finish: Remove all surface cement paste by means of acid etching to provide a smooth, dense, fine-grained texture with no streaks or blotches. Texture and quality of finish to be generally equal to the approved sample when viewed in direct daylight at a 10 foot distance.

G. Color: The color shall be generally equal to the approved sample when viewed in direct daylight at a 10 foot distance. Color variation between pieces shall be minimal.

Part 3 - EXECUTION

3.1 INSTALLATION

A. Anchorages: The Setting Contractor is to provide loose steel plates, clip angles, seat angles, anchors, dowels, cramps, hangers, and other miscellaneous loose steel shapes not provided by other trades, necessary for securing precast units to supporting and/or adjacent members.

B. Do not install any precast units that have any defects that exceed the acceptable PCI MNL-117 tolerances for dimensions and color if installation would result in unsatisfactory performance or appearance in the opinion of the Architect.

C. Install precast concrete members plumb, level, and in alignment in accordance with PCI MNL-117 erection tolerances and the contract documents. Provide temporary supports and bracing as required to maintain position, stability, and alignment as members are being permanently connected.

D. Protect the precast units from discoloration and staining when washing down the surrounding masonry by covering the precast units with plastic sheeting and/or by thoroughly soaking them with clear water to prevent dirty washdown water from being absorbed into them. If dirty washdown water gets on the precast, hose it off immediately with clear water.

E. Patching: The repair of chipped or damaged precast shall be done with materials and instructions furnished by the Fabricator. The precast shall show no obvious repairs or imperfections other than minimal color variations when viewed with the unaided eye under good typical day lighting at a 20 foot distance.

F. Cleaning: Before pointing and/or caulking, the face of all precast shall be scrubbed with a fiber brush, using mild detergent and water and shall then be thoroughly rinsed with clean running water. Any mortar on the face of the precast shall be removed. No acids or prepared cleaners shall be used without the approval of the precast Fabricator.

G. Sealing: Only exterior stair treads and other units that may come in contact with salt or other deicing compounds must be sealed with a penetrating sealer approved by the Architect. The sealer is to be applied in accordance with the sealer manufacturer's instructions after the units have been installed, cured, patched, and cleaned. Do not apply sealer before installation since it may prevent mortar, joint sealant and patches from adhering.

3.2 PERFORMANCE REQUIREMENTS

A. Applicable standards for inspection and quality control shall be Appendix J (Architectural Trim Requirements) in PCI MNL - 117 "Manual for Quality Control for Plants and Production of Architectural Precast Concrete Products" (3rd Edition) and PCI's "Architectural Precast Concrete Design Manual, 2nd Edition".

B. The Architectural Precast Concrete units shall show no obvious repairs or imperfections other than minimal color variations when viewed with the unaided eye at a 20 foot distance in good typical daylight illumination.

C. Any unacceptable precast units that can not be repaired to the Architect's satisfaction in accordance with the aforementioned criteria are deemed unacceptable and are to be replaced by the Contractor.

-END OF SECTION 03450-
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