HomeMy WebLinkAbout03 49 00 Glass-Fiber Reinforced Concrete.DOCSECTION 03 49 00 - GLASS-FIBER-REINFORCED CONCRETE (GFRC)
GENERAL
RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary Conditions and
Division 01 Specification Sections, apply to this Section.
SUMMARY
Section includes glass-fiber-reinforced concrete (GFRC) panels consisting of GFRC, panel frames, anchors, and connection
hardware.
GFRC panels and column covers, including capitals and bases.
Related Requirements:
Section 03 30 00 "Cast-in-Place Concrete" for embedding weld plates and angles in concrete
for attaching connection devices.
Section 05 12 00 "Structural Steel Framing" for attaching connection devices to steel framing.
Section 07 92 00 "Joint Sealants" for elastomeric joint
sealants and sealant backings.
PRE-INSTALLATION MEETINGS
Pre-installation Conference: Conduct conference at Project site.
ACTION SUBMITTALS
Product Data: For each type of product. Include
GFRC design mixes.
Shop Drawings: Show fabrication and installation details for GFRC panels including the following:
Panel elevations, sections, and dimensions.
Thickness of facing mix,
GFRC backing, and bonding pads for typical panels.
Finishes.
Joint and connection details.
Erection details.
Panel frame details for typical panels including sizes, spacings, thicknesses,
and yield strengths of various members.
Locations and details of connection hardware attached to structure.
Sizes, locations, and details of flex, gravity, and seismic anchors for typical
panels.
Other items sprayed into panels.
Erection sequence for special conditions.
Relationship to adjacent materials.
Description of loose, cast-in, and field hardware.
Samples for Verification: For each type of finish indicated on exposed GFRC surfaces, representative of finish, color, and texture variations expected, approximately 12 by 12 inches
by actual thickness.
Delegated-Design Submittal: For GFRC panels, including analysis data signed and sealed by the qualified professional engineer responsible for their preparation.
INFORMATIONAL
SUBMITTALS
Qualification Data: For manufacturer.
Welding certificates.
Steel Sheet Certificates: For steel sheet used in cold-formed steel panel framing, mill certificates signed by
manufacturers of steel sheet, or test reports from a qualified testing agency, indicating that steel sheet used in cold-formed metal panel framing complies with requirements including
uncoated steel thickness, yield strength, tensile strength, total elongation, chemical requirements, and galvanized-coating thickness.
Mill Certificates: For structural-steel shapes
and hollow structural sections used in panel framing.
Source Quality-Control Program: For GFRC manufacturer.
Source Quality-Control Test Reports: For GFRC, inserts, and anchors.
QUALITY
ASSURANCE
Manufacturer Qualifications: Designated a PCI-certified plant for Group G - Glass Fiber Reinforced Concrete.
Installer Qualifications: Manufacturer of GFRC panels.
Welding
Qualifications: Qualify procedures and personnel according to AWS D1.1, "Structural Welding Code - Steel," and AWS D1.3, "Structural Welding Code - Sheet Steel."
Mockups: Build mockups,
if requested in writing by Architect, to demonstrate aesthetic effects and to set quality standards for fabrication and installation.
Build mockup of typical wall area as shown on Drawings.
Include
typical components, attachments to building structure, and methods of installation.
Include window opening with GFRC returns.
Include sealant-filled joint complying with requirements
in Section 079200 "Joint Sealants."
Subject to compliance with requirements, approved mockups may become part of the completed Work if undisturbed at time of Substantial Completion.
DELIVERY, STORAGE, AND HANDLING
Handle and transport GFRC panels supported on non-staining material and with non-staining resilient spacers between panels.
Store GFRC panels off of ground
on firm, level, and smooth surfaces supported on non-staining material and with non-staining resilient spacers between panels. Place stored panels so identification marks are clearly
visible.
PRODUCTS
MANUFACTURERS
Manufacturers: Refer to Section 1.6.A. above.
Source Limitations: Obtain GFRC panels from single source from single manufacturer.
PERFORMANCE REQUIREMENTS
Delegated
Design: Engage a qualified professional engineer, as defined in Section 01 40 00 "Quality Requirements," to design GFRC panels, including panel frames, anchors, and connections.
Structural
Performance: GFRC panels, including panel frames, anchors, and connections, shall withstand the following design loads as well as the effects of thermal- and moisture-induced dimensional
changes within limits and under conditions indicated:
Loads: As indicated.
Dead Loads: As indicated.
Live Loads: As indicated.
Wind Loads: As indicated.
Seismic Loads: As indicated.
Deflection
Limits: Design panel frames to withstand design loads without lateral deflections greater than 1/240 of wall span.
Thermal Movements: Provide for thermal movements resulting from annual
ambient temperature changes of 80 deg F.
Design panel frames and connections to accommodate deflections and other building movements.
Design panel frames to transfer window loads to
building structure.
PCI Manuals: Comply with requirements and recommendations in the following PCI manuals unless more stringent requirements are indicated:
PCI MNL 128, "Recommended
Practice for Glass Fiber Reinforced Concrete Panels."
PCI MNL 130, "Manual for Quality Control for Plants and Production of Glass Fiber Reinforced Concrete Products."
AISI Specifications:
Comply with AISI's "North American Specification for the Design of Cold-Formed Steel Structural Members."
AISC Specifications: Comply with AISC 360, "Specification for Structural Steel
Buildings."
MOLD MATERIALS
Molds: Rigid, dimensionally stable, non-absorptive material, warp and buckle free, that provides continuous GFRC surfaces within tolerances; nonreactive with GFRC and
capable of producing required finish surfaces.
Mold-Release Agent: Commercially produced liquid-release agent that does not bond with, stain, or adversely affect GFRC surfaces and does
not impair subsequent surface or joint treatments of GFRC.
Form Liners: Units of face design, texture, arrangement, and configuration indicated. Provide solid backing and form supports
to ensure that form liners remain in place during GFRC application. Use with manufacturer's recommended liquid-release agent that does not bond with, stain, or adversely affect GFRC
surfaces and does not impair subsequent surface or joint treatments of GFRC.
Surface Retarder: Chemical liquid-set retarder capable of temporarily delaying hardening of newly placed
GFRC face mix to depth of reveal specified.
GFRC MATERIALS
Portland Cement: ASTM C 150; Type I, II, or III.
For surfaces exposed to view in finished structure, use gray of same type,
brand, and source throughout GFRC production.
Metakaolin: ASTM C 618, Class N.
Glass Fibers: Alkali resistant, with a minimum zirconia content of 16 percent, 1 to 2 inches long, specifically
produced for use in GFRC, and complying with ASTM C 1666.
Sand: Washed and dried silica, complying with composition requirements in ASTM C 144; passing a No. 20 sieve with a maximum
of 2 percent passing a No. 100 sieve.
Facing Aggregate: ASTM C 33, except for gradation, and PCI MNL 130, 1/4-inch maximum size.
Aggregates: Selected, hard, and durable; free of material
that reacts with cement or causes staining; to match sample.
Fine Aggregate: Natural or manufactured sand with a maximum of 5 percent passing a No. 100 sieve and a maximum of 3 percent
passing a No. 200 sieve.
Coloring Admixture: ASTM C 979, synthetic mineral-oxide pigments or colored water-reducing admixtures, temperature stable, nonfading, and alkali resistant.
Water:
Potable; free from deleterious material that may affect color stability, setting, or strength of GFRC and complying with chemical limits in PCI MNL 130.
Polymer-Curing Admixture: Acrylic
thermoplastic copolymer dispersion complying with PCI MNL 130.
Air-Entraining Admixture: ASTM C 260, containing not more than 0.1 percent chloride ions.
Chemical Admixtures: ASTM C 494,
containing not more than 0.1 percent chloride ions.
ANCHORS, CONNECTORS, AND MISCELLANEOUS MATERIALS
Stainless-Steel Plates: ASTM A 240Retain one of two "Finish" subparagraphs below. Finishes are listed in descending order of corrosion
resistance.
Finish: Shop primed with paint complying with MPI#79 on surfaces prepared to comply with SSPC-SP 2, "Hand Tool Cleaning," or better.
Steel Channels and Angles: ASTM A 36,
finished as follows:
Finish: Shop primed with paint complying with MPI#79 on surfaces prepared to comply with SSPC-SP 2, "Hand Tool Cleaning," or better.
GFRC MIXES
Mist Coat: Portland
cement, sand slurry, and admixtures; of same proportions as backing mix without glass fibers.
Face Mix: Proportion face mix of portland cement, sand, facing aggregates, and admixtures
to comply with design requirements.
Backing Mix: Proportion backing mix of portland cement, glass fibers, sand, and admixtures to comply with design requirements. Provide nominal glass-fiber
content of not less than 5 percent by weight of total mix.
Polymer-Curing Admixture: 6 to 7 percent by weight of polymer-curing admixture solids to dry portland cement.
Air Content:
8 to 10 percent; ASTM C 185.
Coloring Admixture: Not to exceed 10 percent of cement weight.
PANEL FRAME FABRICATION
Fabricate panel frames and accessories plumb, square, true to line,
and with components securely fastened.
Fabricate panel frames using jigs or templates.
Cut cold-formed metal framing members by sawing or shearing; do not torch cut.
Fasten cold-formed
metal framing members by welding. Comply with AWS D1.3.
Fasten framing members of hollow structural sections, steel channels, or steel angles by welding. Comply with AWS D1.1.
Weld anchors
to panel frames.
Reinforce framing assemblies, as necessary, to withstand erection stresses.
Galvanizing Repair: Touch up damaged galvanized surfaces according to ASTM A 78.
Painting
Repair: Touch up damaged painted surfaces using same primer.
MOLD FABRICATION
Construct molds that result in finished GFRC complying with profiles, dimensions, and tolerances indicated, without damaging GFRC during stripping. Construct molds to
prevent water leakage and loss of cement paste. Retain one of two subparagraphs below, usually first. Retain second if exposed-aggregate surfaces require surface retarder to achieve
desired finish.
Place form liners accurately to provide finished surface texture indicated. Provide solid backing and supports to maintain stability of liners during GFRC application.
Coat form liner with form-release agent.
Locate, place, and secure flashing reglets accurately.
GFRC FABRICATION
Proportioning and Mixing: For backing mix, meter sand/cement slurry and
glass fibers to spray head at rates to achieve design mix proportions and glass-fiber content according to PCI MNL 130 procedures.
Spray Application: Comply with general procedures as
follows:
Spray mist coat over molds to a nominal thickness of 1/8 inch on planar surfaces.
Spray or place face mix in thickness indicated on Shop Drawings.
Proceed with spraying backing
mix before face mix has set, using procedures that produce a uniform thickness and even distribution of glass fibers and matrix.
Consolidate backing mix by rolling or other technique
to achieve complete encapsulation of glass fibers and compaction.
Measure thickness with a pin gage or other acceptable method at least once for every 5 sq. ft. of panel surface. Take
no fewer than six measurements per panel.
Hand form and consolidate intricate details, incorporate formers or infill materials, and overspray before material reaches initial set to ensure
complete bonding.
Attach panel frame to GFRC before initial set of GFRC backing, maintaining a minimum clearance of 1/2 inch from GFRC backing, and without anchors protruding into GFRC
backing.
Build up homogeneous GFRC bonding pads over anchor feet, maintaining a minimum thickness of 1/2 inch over tops of anchor feet, before initial set of GFRC backing. Measure bonding
pad thickness at 25 percent of anchor locations.
Inserts and Embedments: Build up homogeneous GFRC bosses or bonding pads over inserts and embedments to provide enough anchorage and
embedment to comply with design requirements.
Curing: Employ initial curing method that ensures sufficient strength for removing units from mold. Comply with PCI MNL 130 procedures.
Keep
moisture off of the surfaces of mixes with polymer curing admixtures during the first three hours of curing. Maintain temperature between 60 and 120 deg F during the first 16 hours.
Prevent
drying of moist curing mixes during the first 24 hours. Maintain units in surface-damp condition at a temperature above 60 deg F and 95 percent relative humidity for seven days.
Panel Identification: Mark each GFRC panel to correspond with identification mark on Shop Drawings. Mark each panel with its casting date.
FABRICATION TOLERANCES
Manufacturing Tolerances:
Manufacture GFRC panels so each finished unit complies with PCI MNL 130 for dimension, position, and tolerances.
Manufacturing Tolerances: Manufacture GFRC panels so each finished unit
complies with the following dimensional tolerances. For dimensional tolerances not listed below, comply with PCI MNL 130.
Overall Height and Width of Units, Measured at the Face Adjacent
to Mold: As follows:
10 fee or less, plus or minus 1/8 inch.
More than 10, plus or minus 1/8 inch per 10 feet; 1/4 inch maximum.
Edge Return Thickness: Plus 1/2 inch, minus zero inch.
Architectural
Facing Thickness: Plus 1/8 inch, minus zero inch.
Backing Thickness: Plus 1/4 inch, minus zero inch.
Panel Depth from Face of Skin to Back of Panel Frame or Integral Rib: Plus 3/8 inch,
minus 1/4 inch.
Angular Variation of Plane of Side Mold: Plus or minus 1/32 inch per 3 inches of depth, or plus or minus 1/16 inch total, whichever is greater.
Variation from Square
or Designated Skew (Difference in Length of Two Diagonal Measurements): Plus or minus 1/8 inch per 72 inches or plus or minus 1/4 inch total, whichever is greater.
Local Smoothness:
1/4 inch per 10 feet.
Bowing: Not to exceed L/240 unless unit complies with erection tolerances using connection adjustments.
Length and Width of Block Outs and Openings within One Unit:
Plus or minus 1/4 inch.
Location of Window Opening within Panel: Plus or minus 1/4 inch.
Maximum Permissible Warpage of One Corner out of the Plane of the Other Three: 1/16 inch per
12 inches of distance from nearest adjacent corner.
Position Tolerances: Measured from datum line locations, as indicated on Shop Drawings.
Panel Frame and Track: Plus or minus 1/4 inch.
Flashing
Reglets at Edge of Panel: Plus or minus 1/4 inch.
Inserts: Plus or minus 1/2 inch.
Special Handling Devices: Plus or minus 3 inches.
Location of Bearing Devices: Plus or minus 1/4 inch.
Blockouts:
Plus or minus 3/8 inch.
Panel Frame Tolerances: As follows:
Vertical and Horizontal Alignment: 1/4 inch per 10 feet.
Spacing of Framing Member: Plus or minus 3/8 inch.
Squareness of
Frame: Difference in length of diagonals of 3/8 inch.
Overall Size of Frame: Plus or minus 3/8 inch (10 mm).
FINISHES
Exposed faces shall be free of joint marks, grain, and other obvious defects. Corners, including false joints, shall be uniform, straight, and sharp. Finish exposed-face surfaces
of GFRC to match approved as follows:
As-Cast-Surface Finish: Provide surfaces to match approved sample for acceptable surface, air voids, sand streaks, and honeycomb, with uniform color
and texture.
Textured-Surface Finish: Impart by form liners.
Retarded Finish: Use chemical-retarding agents applied to concrete forms and washing and brushing procedures to expose aggregate
and surrounding matrix surfaces after form removal.
Sand- or Abrasive-Blast Finish: Use abrasive grit, equipment, application techniques, and cleaning procedures to expose aggregate
and surrounding matrix surfaces.
Acid-Etched Finish: Use acid and hot-water solution equipment, application techniques, and cleaning procedures to expose aggregate and surrounding matrix
surfaces.
SOURCE QUALITY CONTROL
Quality-Control Testing: Establish and maintain a quality-control program for manufacturing GFRC panels according to PCI MNL 130.
Test materials and
inspect production techniques.
Quality-control program shall monitor glass-fiber content, spray rate, unit weight, product physical properties, anchor pull-off and shear strength, and
curing period and conditions.
Prepare test specimens and test according to ASTM C 1228, PCI MNL 130, and PCI MNL 128 procedures.
Test GFRC inserts and anchors according to ASTM C 1230
to validate design values.
For each test board, determine glass-fiber content according to ASTM C 1229 and flexural yield and ultimate strength according to ASTM C 947.
EXECUTION
EXAMINATION
Examine
structure and conditions for compliance with requirements for installation tolerances, bearing surfaces, and other conditions affecting performance of the Work.
Proceed with installation
only after unsatisfactory conditions have been corrected.
ERECTION
Install clips, hangers, and other accessories required for connecting GFRC panels to supporting members and backup
materials.
Install GFRC panels level, plumb, square, and in alignment. Provide temporary supports and bracing as required to maintain position, stability, and alignment of panels until
permanent connections are completed.
Maintain horizontal and vertical joint alignment and uniform joint width.
Remove projecting hoisting devices.
Connect GFRC panels in position by bolting or welding, or both, as indicated on Shop Drawings. Remove temporary shims, wedges, and spacers as soon as possible after connecting is completed.
Welding:
Comply with applicable AWS D1.1 and AWS D1.3 requirements for welding, appearance, quality of welds, and methods used in correcting welding work.
Protect GFRC panels from damage by field
welding or cutting operations, and provide noncombustible shields as required.
At bolted connections, use lock washers or other acceptable means to prevent loosening of nuts.
ERECTION
TOLERANCES
Erect GFRC panels to comply with the following noncumulative tolerances:
Plan Location from Building Grid Datum: Plus or minus 1/2 inch.
Top Elevation from Nominal Top Elevation:
As follows:
Exposed Individual Panel: Plus or minus 1/4 inch.
Non-exposed Individual Panel: Plus or minus 1/2 inch.
Exposed Panel Relative to Adjacent Panel: 1/4 inch.
Non-exposed Panel
Relative to Adjacent Panel: 1/2 inch.
Support Elevation from Nominal Elevation: As follows:
Maximum Low: 1/2 inch.
Maximum High: 1/4 inch.
Maximum Plumb Variation over the Lesser of
Height of Structure or 100 Feet: 1 inch.
Plumb in Any 10 Feet of Element Height: 1/4 inch.
Maximum Offset in Alignment of Matching Edges: 1/4 inch.
Face Width of Joint: As follows (governs
over joint taper):
Panel Dimension 20 Feet or Less: Plus or minus 1/4 inch.
Panel Dimension More Than 20 Feet: Plus or minus 3/8 inch.
Maximum Joint Taper: 3/8 inch.
Maximum Joint Taper
in 10 Feet: 1/4 inch.
Differential Bowing, as Erected, between Adjacent Members of Same Design: 1/4 inch.
REPAIRS
Repairs are permitted provided structural adequacy of GFRC panel and
appearance are not impaired, as approved by Architect.
Mix patching materials and repair GFRC so cured patches blend with color, texture, and uniformity of adjacent exposed surfaces.
Prepare
and repair accessible damaged galvanized coatings with galvanizing repair paint according to ASTM A 780.
Wire brush and clean accessible weld areas on prime-painted components and paint
with same type of shop primer.
Remove and replace damaged GFRC panels when repairs do not comply with requirements.
CLEANING AND PROTECTION
Perform cleaning procedures, if necessary, according to GFRC manufacturer's written instructions. Clean soiled GFRC surfaces with detergent and water, using soft
fiber brushes and sponges, and rinse with clean water. Prevent damage to GFRC surfaces and staining of adjacent materials.
END OF SECTION 03 49 00