Project Number: AW-2225

Contract Number: TW-0839

December 1996

SPECIAL SPECIFICATION

SECTION 03301

[CAST-IN-PLACE CONCRETE SUPPLEMENT]{.underline}

[PART 1 - GENERAL]{.underline} [Page]{.underline}

1.01 Description of Work

1.02 References

1.03 Definitions 3

1.04 Quality Assurance

1.05 Submittals

PART 2 - PRODUCTS

2.01 Form Materials

2.02 Shielding Concrete

2.03 Pool Liner Bedding Grout

2.04 Grout Under Movable Wall Sill Plate

PART 3 - EXECUTION

3.01 Placing Embeds

3.02 Joints in Shielding Concrete

3.03 Working Within Wall Forms

3.04 Placing Shielding Concrete

3.05 Finishes

3.06 Curing Shielding Concrete

3.07 Shielding Concrete Surface Repairs

3.08 Test Cell Ceiling Plugs

3.09 Movable Shield Wall

3.10 Bedding Of Stainless Steel Pool Liner

SPECIAL SPECIFICATION

SECTION 03301

[CAST-IN-PLACE CONCRETE SUPPLEMENT]{.underline}

# PART 1 - GENERAL

## 1.01 [DESCRIPTION OF WORK]{.underline}

A.  [Section Includes]{.underline}: Additional requirements for
    cast-in-place concrete materials to be used for the construction of
    radiation shielding, for grouting beneath the stainless steel pool
    liner and beneath the movable shield wall sill plate and for
    concrete slabs to support trucks.

B.  [Products Installed but not Specified Under this
    Section:]{.underline}

C.  Serpentine access tubes, ceiling plug frames, elevator ceiling
    embeds, and embedded steel shielding are specified in Division 5,
    Section "Metal Fabrications."

D.  Pool liner is specified in Division 5 Section "Stainless Steel Pool
    Liner."

E.  Hollow metal frames in openings are specified in Division 8, Section
    "Steel Doors and Frames."

F.  Movable shield wall shell, its jamb and head liners and its sill
    plate are specified in Division 13, "Movable Shield Wall."

G.  Manipulator arm wall tubes, and shielded window frames will be
    Sandia Furnished Equipment (SFE).

H.  [Refer to the following sections for related work]{.underline}:

1\. Division 1, Section "Environment, Safety, and Health Requirements."

2\. Division 3, Section "Cast-in-Place Concrete."

## 1.02 [REFERENCES]{.underline}

A. [American Concrete Institute (ACI)]{.underline}

301 Specifications for Structural Concrete for Buildings

308 Standard Practice for Curing Concrete

309 Standard Practice for Consolidation of Concrete (Attached hereto).

B. [American Society for Testing and Materials (ASTM)]{.underline}

A36 Standard Specification for Structural Steel

A525 Specification for General Requirements for Steel Sheet, Zinc-coated
(Galvanized) by the Hot-Dip Process

C78 Flexural Strength of Concrete (Using Simple Beam with Third-Point
Loading)

C138 Standard Test Method for Unit Weight, Yield, and Air Content
(Gravimetric) of Concrete

C150 Specification for Portland Cement

C494 Specification for Chemical Admixtures for Concrete

C618 Specification for Fly Ash and Raw or Calcined Natural Pozzolan for
use as a Mineral Admixture in Portland Cement Concrete

C847 Specification for Metal Lath

C1017 Specification for Chemical Admixtures for Use in Producing Flowing
Concrete

C1107 Specification for Packaged Dry, Hydraulic-Cement Grout
(non-shrink)

## 1.03 [DEFINITIONS]{.underline}

A.  [Shielding]{.underline}: Any material or assembly that encloses a
    nuclear source in order to reduce the amount of radiation that
    escapes into the surrounding area.

B.  [Shielding Concrete]{.underline}: Shielding concrete is defined as
    all Portland cement concrete around the Test Cells and above
    elevation 95'-10" where adjacent to the pool or above elevation
    99'-0" where not adjacent to the pool.

## 1.04 [QUALITY ASSURANCE]{.underline}

A.  [General]{.underline}: In addition to the following provisions,
    comply with the requirements of Division 3, Section "Cast-in-Place
    Concrete."

B.  [Quality Control]{.underline}:

C.  Complete and thorough quality control, including documentation is
    mandatory for every placement of shielding concrete, pool concrete,
    embedded steel shielding and other items embedded in shielding
    concrete. Towards that end, the contractor shall coordinated with
    the SDR to provide for complete inspection of all reinforcement,
    embeds and forms for shielding concrete before its placement; to
    provide for complete inspection of the assembled pool liner and pool
    reinforcement before pool concrete placement; to provide for
    complete inspection of the movable wall shell, reinforcement, jamb
    and head liners, sill plate and bearings before their grouting and
    concrete placement; and to provide for thorough inspection during
    grout and concrete placement for all these items. The Contractor
    shall provide a minimum of 48 hours notice prior to any concrete
    placement. He shall provide complete access to the work during
    concrete placement. The satisfactory construction of these items and
    complete documentation that it has occurred is critical to the
    success of this project.

D.  Contractor shall arrange for a concrete pre-placement conference to
    take place at least two weeks prior to the first placement of
    shielding concrete or of pool liner bedding grout (whichever comes
    first). Representatives of the general contractor, the concrete
    subcontractor(s), the concrete producer and the form designer will
    attend. The foremen of the crews responsible for placement of
    shielding concrete, its reinforcement and forming; placement of
    shield window frames, serpentine access tubes, manipulator wall
    tubes; placement of pool liner bedding grout and pool wall concrete;
    placement of concrete within and adjacent to the movable shield wall
    and of grout below the movable shield wall sill plate; and placement
    and removal of forms shall also attend. Sandia's project manager,
    structural engineer, inspectors, testing laboratory representatives
    and shielding specialists will also attend. The subjects of
    discussion will include approved designs, coordination with
    inspectors, concrete sampling and testing requirements, authority to
    accept or reject fresh concrete, authority to add water to concrete
    at the site, distribution of test reports, basic radiation shielding
    construction requirements, concrete consolidation, thick concrete
    wall placement and curing practices, shield wall bulkhead and cold
    joint requirements, concrete finishing, and concrete placement rates
    and delivery schedules. The contractor shall take minutes of the
    meeting and distribute copies to all participants.

E.  The density of shielding concrete test specimens shall be measured
    in accordance with ASTM C138 at the time of placement and at 28
    days. The concrete supplier's documented correlation between newly
    placed plastic concrete ("wet" concrete) density will form the basis
    for accepting the "wet" concrete for inclusion in shielding based on
    its measured wet density. Concrete not acceptable for shielding
    shall be used in other applications or shall be removed from the
    site for disposal off base. For further information about shielding
    concrete density, refer to Section 2.02 B.

F.  The elapsed time from batching until the concrete mix is no longer
    of sufficient plasticity for vibratory consolidation shall be
    determined by the concrete supplier for all shielding concrete mix
    designs. This will establish the time limit for placing additional
    concrete lifts on previously placed concrete with consolidation of
    the concrete layers without resorting to use of a cold joint.

G.  Concrete shall be tested for modulus of rupture for concrete slabs
    to support trucks as noted on drawings in accordance with ASTM C78;
    one set of four (4) standard beams will be taken for each day of
    concrete placement; two (2) specimens shall be tested at 14 days and
    two (2) specimens shall be tested at 28 days.

    If the average strength of two (2) consecutive beams tested at 28
    days falls below the required tensile strength by more than 50 psi
    (350 kPa) below the specified strength, the in-place concrete
    represented by the low-strength beams shall be tested at the
    contractor's expense in accordance with ASTM C42. If the concrete
    still does not meet these requirements, it shall be replaced at the
    contractor's expense.

## 1.05 [SUBMITTALS]{.underline} 

A. [General]{.underline}: In addition to submittals required in Division
3, Section "Cast-in-Place Concrete," provide the following submittals.

B. [Concrete Placement Plan]{.underline}: The contractor shall submit a
plan for placement of concrete on this project. This plan shall consider
required placement rates, timing of consolidation of upper and lower
lifts of concrete, crane and pump placement at the site, the number of
workers and equipment required, staging of delivery trucks, possible
equipment and truck breakdowns, bulkhead locations and resultant
placement volumes, coordination with convoys that can close roadways
providing access to the site and the characteristics of the concrete
mixes.

C.  [Shielding Concrete Forming Plan]{.underline}: Submit shop drawings
    and calculations showing details of forming and tie locations for
    review and acceptance of the concept and joint and tie locations.
    Design forms and shoring to resist hydrostatic and gravitational
    forces due to the concrete placement. The shop drawings shall be
    stamped and signed by a Professional Engineer registered in the
    State of jurisdiction.

D.  [Concrete Batch Tickets]{.underline} shall be submitted to the SDR
    at the end of each day's placement. The tickets shall include the
    date and time of batching, the mix design code, time of departure
    from plant, admixtures, temperature of concrete at departure from
    plant, and time of discharge.

E.  [Safety Plan]{.underline}: Submit a safety plan for working within
    wall forms with the general site safety plan.

# PART 2 - PRODUCTS

## 2.01 [FORM MATERIALS]{.underline}

A.  [General]{.underline}: In addition to the following provisions,
    comply with the requirements of Division 3, "Cast-in-Place
    Concrete."

B.  [Forms for Exposed Finish Shielding Concrete]{.underline}:

C.  Construct all form work for exposed concrete surfaces with plywood,
    metal, metal framed plywood facing or other acceptable panel type
    materials to provide continuous, straight, smooth, exposed surfaces.
    Furnish in largest practicable sizes to minimize number of joints.
    Provide form material with sufficient thickness to withstand
    pressure of newly place concrete without bow or deflection.

D.  Use A-B permanently sealed plyform, sanded, Class 1, EXT grade
    trademark of the American Plywood Association, PSI-83. Only new
    material will be accepted for concrete formwork and may be used only
    twice for this project. Any material with deformed or marred finish
    will be rejected.

E.  [Forms for Movable Shield Wall]{.underline}: The forms for the
    movable shield wall, its jambs and head liner will be steel sheet as
    specified in Division 13, "Movable Shield Wall."

F.  [Forms for Test Cell Ceiling Plugs]{.underline}: The forms for the
    test cell ceiling plugs and their socket liners will consist of ASTM
    A36 plate continuously welded to frames of ASTM A36 shapes and will
    be cast integrally with the concrete.

G.  [Shielding Concrete Bulkhead Forms]{.underline}:

H.  Construct all formwork for bulkheads in shielding concrete of
    stay-in-place expanded metal mesh with cut lumber and/or reinforcing
    steel supports. Provide supports of adequate strength and spacing to
    withstand pressure of newly placed concrete without bow or
    deflection of the metal mesh or its supports.

I.  Stay-in-place form shall be of a ribbed expanded metal fabricated in
    accordance with ASTM C847 from galvanized sheet steel complying with
    ASTM A525. It shall be formed by lancing and expanding 26 gage or 25
    gage sheet in such a manner as to form solid V-ribs of ¾" depth and
    spaced 3 7/8" apart with 15/64" x 3/8" parallelogram shaped mesh
    openings between ribs.

F. [Form Ties for Shielding Concrete]{.underline}: Only solid metal form
ties that remain in the concrete and snap off just below or are cut at
the surface are allowed.

## 2.02 [SHIELDING CONCRETE]{.underline}

A.  [General]{.underline}: Shielding concrete shall comply with the
    requirements of Division 3, Section "Cast-in-Place Concrete" in
    addition to the following provisions.

B.  [Density]{.underline}: The minimum cured density of shielding
    concrete shall be 144 pcf. The concrete supplier shall provide
    documentation for each shielding concrete mix design showing the
    relationship for the density of the plastic concrete and the density
    of the 28-day old concrete. The concrete supplier shall analyze his
    data to determine the standard deviation of the relationship between
    plastic concrete density and 28-day old concrete density. If based
    on less than 30 tests, use the modified formula or modification
    factor, as appropriate, from ACI 318 section 5.3.1. Based on this
    data and 1.5 times the standard deviation, the acceptable minimum
    plastic concrete density to satisfy the requirements for the minimum
    28-day concrete density for each shielding concrete mix design will
    be established.

C.  [Concrete Materials]{.underline}:

D.  Use only ASTM C150 Type V Portland cement.

E.  Coarse aggregate shall have an absorption of less than 3%, a
    specific gravity greater than 2.5 and a sulfates and sulfites
    content less than 0.5% by weight and a maximum aggregate dimension
    as shown on the plans.

F.  Mixed concrete shall have a temperature of at least 50° F (10° C)
    and not more than 75° F (24° C) at the time of placing.

## 2.03 [POOL LINER BEDDING GROUT]{.underline}

A.  [Genera]{.underline}l: Special bedding grout shall comply with the
    requirements of Division 3, Section "Cast-in-Place Concrete" in
    addition to the following provisions.

B.  [Materials]{.underline}:

C.  Coarse aggregate shall be 100% passing the 3/8 inch (0.95 cm) sieve.

D.  Admixtures to improve flowability shall comply with ASTM C1017.

E.  The non-shrink admixture shall impart the properties of low water
    content, good flowability, minimum of bleed and expansion
    properties. The admixture shall not contain chloride ions in excess
    of 0.25 percent by weight.

F.  [Mix Design]{.underline}: Design and document a mix design with good
    flowability and expansion properties such that the expansion of the
    grout does not exceed 0.4 percent and shrinkage is 0.0 percent.

G.  [Minimum Compressive Strength]{.underline} at 28 days shall be 4000
    psi (27.6 MPa).

## 2.04 [GROUT UNDER MOVABLE WALL SILL PLATE]{.underline}

A. [General]{.underline}: The grout to be used under the sill plate
shall be non-metallic, non-shrink high-strength grout complying with
ASTM C1107 with a minimum compressive strength of 28 days of 4000 psi
(27.6 MPa).

# PART 3 - EXECUTION

## 3.01 [PLACING EMBEDS]{.underline}

A.  [General]{.underline}: Coordinate carefully with SDR to provide
    accurate, correct and documented placement of all embeds within the
    tolerances shown on the drawings.

B.  [Shielding Window Frames]{.underline}: Employ the manufacturer of
    the shield window frames to coordinate installation of the frames
    within the forms. Frame, shim, and weld frames in place to hold them
    in correct positions during concrete placement.

## 3.02 [JOINTS IN SHIELDING CONCRETE]{.underline}

A. [Bulkhead Joints]{.underline}: Bulkhead joints must occur only at
accepted locations and in the correct geometry. Bulkhead locations will
effect the requirements for the rate of concrete placement and thus have
a direct effect on the contractor's plan for placing concrete.

B.  [Cold Joints]{.underline}: Cold joint locations are not shown on the
    drawings. The contractor shall be prepared, however, to place cold
    joints at all times during the placement of shielding concrete in
    the case of emergency shutdown. All cold joints, whether planned or
    emergency, shall meet the requirements shown on the drawings. In no
    case will joints with straight, unbroken planes be allowed.

C.  [Alternate Joint Locations]{.underline}: If the contractor desires
    to use alternate bulkhead or cold joint locations from those shown
    on the drawings, he must submit a drawn plan of the new proposed
    joint locations at least ten working days prior to placement and
    have it accepted prior to implementation.

## 3.03 [WORKING WITHIN WALL FORMS]{.underline}

A. [Safety]{.underline}: Work within wall forms qualifies as a confined
space and require special measures to conform to Division 1, Section
"Environment, Safety, and Health Requirements"

B. [Cleanliness]{.underline}: Do not transport soil and trash into forms
when entering. Clean out all soil and trash before placing concrete
within forms.

## 3.04 [PLACING SHIELDING CONCRETE]{.underline}

A. [General]{.underline}: In addition to the requirements of Division 3,
Section "Cast-in-Place Concrete", comply with the following provisions.

B. [Consolidation]{.underline}: Proper consolidation is absolutely
essential. Compliance with the requirements of ACI 309 will be strictly
enforced. Provide access to inspectors for visual observation of
concrete placement and consolidation at all times including, if
necessary, construction of elevated and safety-railed observation
platforms. Demonstrate that the vibration techniques and equipment to be
used are more than adequate for the purpose with the mix, reinforcement
and volumes of concrete to be used. Provide at least two additional
vibrators on site for emergency use or replacement.

C. [Forms]{.underline}: Forms and their joints must be mortar and paste
tight and capably of resisting pressures from high lift placements.

## 3.05 [FINISHES]{.underline} 

A.  [General]{.underline}: Comply with the provisions of Division 3,
    Section "Cast-in-Place Concrete."

B.  Provide Trowel Finish for all interior slabs-on-grade and for the
    tops of test cell ceilings.

C.  Provide Nonslip Broom Finish to exterior concrete aprons.

D.  Provide Grout-Cleaned Finish to exposed walls and bottoms of
    ceilings of test cells within 24 hours of stripping forms and
    completion of the wet curing process.

## 3.06 [CURING SHIELDING CONCRETE]{.underline}

A.  [General]{.underline}: Unless noted otherwise in the following
    provisions, comply with the requirements of Division 3, Section
    "Cast-in-Place Concrete."

B.  [Water Curing]{.underline}: The internal and external temperatures
    of the concrete will be monitored on a daily basis by the
    laboratory. Should the interior temperature of the concrete exceed
    the exterior temperature by more than 25 degrees F (13.9 degrees C),
    watercuring will be required to the concrete. Cure concrete surfaces
    by the use of water misting in combination with burlap matting. In
    addition to keeping the newly placed concrete damp, the curing will
    keep the concrete surface cool. Towards that end, water will not be
    allowed to pond on the concrete, forming pools that could collect
    heat; the concrete will be kept moist by misting at a rate that
    provides cooling by evaporation without collecting in pools. Apply
    mist to forms to keep them cool during curing. When forms are
    stripped, apply mist and burlap matting to the sides of concrete
    after stripping forms. Cure all shielding concrete for at least
    fourteen (14) days after placement.

## 3.07 [SHIELDING CONCRETE SURFACE REPAIRS]{.underline}

A.  [General]{.underline}: Unless noted otherwise, comply with the
    provisions of Division 3, "Cast-in-Place Concrete."

B.  [Patching Defective Areas]{.underline}: Cut out honeycomb rock
    pockets and voids only after the SDR has reviewed each location. If
    necessary, use a bush hammer at the edges of cut outs to insure that
    the edges are rough in texture. Do not begin patching the cut out
    holes until the SDR has reviewed the areas and approved the holes
    for patching. Proprietary bonding agents are acceptable only if they
    do not contain organic chemicals (hydrocarbons).

## 3.08 [TEST CELL CEILING PLUGS]{.underline}

A.  [Frames]{.underline}: Shop assemble the inner and outer form frames
    for each plug and its socket to the tolerance as shown on the
    drawings. Fit the two frames for each set of plug and socket forms
    together and check that the gap between the two frames does not
    exceed 1/4 inch (6.4 mm) at any location along the top and bottom
    and that the two frames fit easily together. Correct any
    deficiencies and matchmark each set of fitted frames showing which
    frames go together and which is the north side of each frame. Set
    the socket frames in the proper locations, true and square. Insert
    the plug frames into the sockets and shim all around to center.
    Tightly fill the gap all around with cord or other removable plug to
    exclude entry of concrete paste between the frames.

B.  [Reinforcement and Concrete Placement]{.underline}: Install and
    secure reinforcement for the ceiling around and within each plug.
    Accurately locate and secure lifting inserts in each plug. Place
    shielding concrete in the ceiling around and within each plug in
    accordance with specifications.

C.  [Markings]{.underline}: Mark the top of each completed plug in 1 ½"
    high letters with two coats of red exterior acrylic with the
    following captions:

D.  An arrow pointing toward the north next to the inscription, "NORTH,"

E.  An inscription, "TEST CELL #X" where "X" is the number, "1," "2," or
    "3" as applicable, and

F.  The inscription, Centered between the lifting coils, "MINIMUM
    LIFTING BOLT PENETRATION: 2 ½ INCHES."

G.  [Operability]{.underline}: After concrete in the ceilings and in the
    plugs has cured for at least 28 days, verify the operability of each
    plug by lifting each plug out of its socket and replacing it in the
    presence of the SDR.

H.  [Deliverables]{.underline}: At the project close out, deliver to SNL
    four (4) Dayton 1" T-26 double swivel lifting plates and four (4)
    Dayton 1" B-14 coil bolts, or approved equal, to match coil inserts
    used in plugs, new or used only to lift these plugs, and in good
    condition.

## 3.09 [MOVABLE SHIELD WALL]{.underline}

A.  [General]{.underline}: Coordinate placement of shielding concrete
    with the movable shield wall liner and from bulkheads to jamb and
    head liners with the movable shield wall manufacturer and the SDR.
    Coordinate sill plate placement and grouting with the movable shield
    wall manufacturer and the SDR. Coordinate placement of movable
    shield wall electrical and compressed air utilities and trolley beam
    and equipment anchorages with movable shield wall manufacturer and
    the SDR.

## 3.10 [BEDDING OF STAINLESS STEEL POOL LINER]{.underline}

A. [General]{.underline}: Grout below the pool liner using a flowable,
non-shrink, non-ferrous mix expressly designed for this purpose and in
careful coordination with the pool liner fabricator and the SDR. Refer
to the suggested methods and procedures for Field Assembly and
Installation in Division 5, Section "Stainless Steel Pool Liner."

END OF SECTION