1. CIB LUNCHEON SEMINAR THURSDAY, MARCH 13, 2014 NEW YORK CITY 2014 DOB BUILDING CODE
BY: CASIMIR J. BOGNACKI, PE
CHIEF OF MATERIALS ENGINEERING
THE PORT AUTHORITY OF NY & NJ

2. NYC DOB BUILDING CODE PROPOSED CHANGES TO CHAPTER 19 - CONCRETE

3. NYC DOB BUILDING CODE
CONSTRUCTION DOCUMENTS. THE CONSTRUCTION DOCUMENTS FOR STRUCTURAL CONCRETE CONSTRUCTION SHALL INCLUDE.
Areas of mass concrete where a thermal control plan is required.
MASS CONCRETE. ANY VOLUME OF CONCRETE WITH DIMENSIONS LARGE ENOUGH TO REQUIRE THAT MEASURES BE TAKEN TO COPE WITH GENERATION OF HEAT FROM HYDRATION OF THE CEMENT AND ATTENDANT VOLUME CHANGE TO MINIMIZE CRACKING, REDUCTION OF COMPRESSIVE STRENGTH, AND/OR DELAYED ETTRENGITE FORMATION.

4. TEMPERATURE RESTRICTIONS ACI 301
MASS CONCRETE FOR AREAS OF HIGH-STRENGTH MASS CONCRETE, INCLUDING BUT NOT LIMITED TO 8000 PSI OR GREATER AND THE LEAST DIMENSION EQUAL TO OR GREATER THAN 36 INCHES, AS INDICATED ON THE CONSTRUCTION DOCUMENTS, A THERMAL CONTROL PLAN COMPLYING WITH ACI 301, SECTION 8.1 AND ACCEPTABLE TO THE ENGINEER OF RECORD SHALL BE SUBMITTED BY THE CONTRACTOR.
TEMPERATURE RESTRICTIONS ACI 301
THE MAXIMUM IN-PLACE TEMPERATURE IN INITIAL 24 HOURS IS 158 DEGREES F.
THE MAXIMUM TEMPERATURE DIFFERENTIAL BETWEEN THE SURFACE AND CONCRETE CORE IS 35 DEGREES F.

5. MASS CONCRETE
FOR MASS CONCRETE SECTIONS IDENTIFIED AS REQUIRING MONITORING, INSTALL TEMPERATURE DEVICES THAT ARE CAPABLE OF MEASURING THE TEMPERATURE OF THE CONCRETE CONTINUOUSLY AND RECORD TEMPERATURE DATA IN INCREMENTS THAT DO NOT EXCEED 30 MINUTES FOR A MINIMUM PERIOD OF SEVEN DAYS PER ACI 301, SECTION 8.3 OR AS OTHERWISE DIRECTED BY THE REGISTERED DESIGN PROFESSIONAL OF RECORD.

12. CORE COMPARISON POUR DATE 2 -9-13
AVERAGE CORE STRENGTH AT 70 DAYS = 13,830 PSI
AVERAGE 56-DAY CYLINDER COMPRESSIVE STRENGTH = 14,210 PSI

13. ASTM C-31 STANDARD PRACTICE FOR MAKING AND CURING CONCRETE TEST SPECIMENS IN THE FIELD
INITIAL CURING
“SPECIMENS SHALL BE STORED FOR A PERIOD UP TO 48 HOURS IN A TEMPERATURE RANGE FROM 60OF AND 80OF AND IN AN ENVIRONMENT PREVENTING MOISTURE LOSS FROM THE SPECIMENS. FOR CONCRETE MIXTURES WITH A SPECIFIED STRENGTH OF 6000 PSI OR GREATER, THE INITIAL CURING TEMPERATURE SHALL BE BETWEEN 68OF – 78OF”.
LABORATORY CURE
“CURE SPECIMENS WITH FREE WATER MAINTAINED ON THEIR SURFACES AT ALL TIMES AT A TEMPERATURE OF OF USING WATER STORAGE TANKS OR MOIST ROOMS.

14. ACI-305 – HOT WEATHER CONCRETE
SECTION 1.1 GENERAL “IF THE INITIAL 24 HOUR CURING IS AT 100oF, THE 28- DAY COMPRESSIVE STRENGTH OF THE TEST SPECIMENS MAY BE 10% TO 15% LOWER THAN IF CURED AT THE REQUIRED ASTM C-31 CURING TEMPERATURE (Gaynor et al 1985). IF THE CYLINDERS ARE ALLOWED TO DRY AT EARLY AGES, STRENGTHS WILL BE REDUCED EVEN FURTHER (ccbedi 1987).”

15. # 1 # 2 # 3 MOCK-UPS – MIX DESIGNS Cementitious Factor (lbs.) 1029 941
820
Cement Factor (lbs.)
695
682
300
Slag (lbs.)
367
Fly Ash, Class C (lbs.)
301
234
129
Silica Fume (lbs.) 33 25 24
Sand (lbs.)
1375
1457
1338
Stone- 57/67 (lbs.)
1080
1040
1143
Stone – 8 (lbs.)
450
500
490
W/C
0.25
0.29
0.27
Air Content (%)
1.9
2.6
1.7
Slump / Flow (in.)
10.75
9.75
(20)
Unit Weight C-39 (pcf)
154.5
151.7
155.6

16. 14,000 PSI MOCK-UPS – CORE TEMPERATURE
182OF
162°F

17. MOCK-UP CORE LOCATIONS

18. MOCK-UP BLOCK #1 – TOTAL CEMENTITIOUS 1,029 LBS.
VERTICAL
HORIZONTAL
EDGE
CENTER
INTERIOR
NUMBER OF CORES
10 * 10 7 6
AVG. COMPRESSIVE STRENGTH (psi)
12,320
12,880
12,560
12,870
COEFFICIENT OF VARIATION (%)
6.70
6.00
5.60
2.80
AVG. CORE STRENGTH 12, DAYS
AVG. CYLINDER STRENGTH 18, DAYS
MAXIMUM CURING TEMPERTURE 30 HOURS
PERCENT REDUCTION IN COMPRESSIVE STRENGTH 30%
*TESTED AT 173 DAYS

19. MOCK-UP – TOTAL CEMENTITIOUS = 820 LBS.
VERTICAL
HORIZONTAL
EDGE
CENTER
INTERIOR
# OF CORES 8 9 7
AVG. COMPRESSIVE STRENGTH (psi)
15,780
15,570
16,380
15,470
COEFFICIENT OF VARIATION (%)
5.7
3.8
4.2
5.4
AVERAGE CORE STRENGTH , DAYS
AVERAGE CYCLE STRENGTH 17, DAYS
MAXIMUM CURING TEMPERATURE 30 HOURS
PERCENT REDUCTION IN COMPRESSIVE STRENGTH 9%

21. Cylinders Cast In-Slab
Block#
Standard Cylinders
Cylinders Cast In-Slab
Cores
PSI
Avg PSI
Within test Std. Dev.
Within-test CV %
Avg. PSI
Within-test Std. Dev.
Normal
15011
14450 **see note
577
3.75
13755
13260
950
6.80
15979
16020
393
2.56
13645
15779
14685
12365
16300
Dry
16202
15540
11617
13390
14472
14600
15398
14753
14464
15033
13790
14868
160
15738
15780
14722
14610
15420
15810
16306
14458
15975
15295
14650
16041
190
15557
15740
475
3.09
13806
14640
15573
14980
15922
15451
14460
14652
14898
Avg
15790***
15380
13970
15350
Std. Dev
629
754
673 CV
4.09%
5.40%
4.39%
** CYLINDER RESULTS ARE MISLEADING
***AVERAGE DOES NOT INCLUDE THE 14,450 PSI

22. REQUIREMENT FOR CONCRETE EXPOSED TO DEICING CHEMICALS
CONCRETE BC INSPECTION REQUIREMENTS. PANEL AGREES AND WILL CONSIDER WITH CHAPTER 17)
TABLE
REQUIREMENT FOR CONCRETE EXPOSED TO DEICING CHEMICALS
CEMENTITIOUS MATERIALS
MAXIMUM PERCENT OF TOTAL CEMENTITIOUS MATERAILS BY WEIGHT a,b
Fly ash of other pozzolans conforming to ASTM C 618
25 d
Slag conforming to ASTM C 989 50
Silica Fume conforming to ASTM C 1240 10
Total of fly ash or other pozzolans, slag and silica fume
50 c, d
Total of fly ash or other pozzolans and silica fume
35 c, d
The total cementitious material also includes ASTM C 150; ASTM C 595, ASTM C 845, and ASTM C 1157 cement.
The maximum percentages shall include:
Fly ash or other pozzolans present in Type IP or I (PM) blended cement, ASTM C 595, or ASTM C 1157.
Slag used in the manufacture of an IS or I (SM) blended cement, ASTM C 595, or ASTM C 1157.
Silica fume, ASTM C 1240, present in a blended cement.
c. Fly ash or other pozzolans and silica fume shall constitute no more than and 10 percent, respectively, of the total weight of the cementitious materials.
Amount of fly ash or other pozzolans conforming to ASTM C 618 in a given concrete mixture can be increased to 35% provided that the concrete is not placed during cold weather as defined by ACI 306 or the concrete is membrane cured and protected from freezing until the concrete has attained 3,500 psi {{{Concrete panel: proposed increase in line with recommendations of Mayor’s green Codes Task Force allowing for an increase in the amount of fly ash when concrete is not placed during cold weather. Concrete panel identified past research papers where 35% or more fly ash content was used successfully.}}}

23. TABLE 1904. 3 MINIMUM SPECIFIED COMPRESSIVE STRENGTH (f’c)
TYPE OR LOCATION OF CONCRETE CONSTRUCTION
MINIMUM SPECIFIED COMPRESSIVE STRENGTH (f’c at 28 days, psi
Basement walls, foundation walls, exterior walls and other vertical concrete surfaces, basement slabs, interior slabs on grade except for garage floor slabs, and foundations not exposed to the weather.
3000 a
Driveways, curbs, walks, patios, porches, carport slabs, steps and other flatwork exposed to the weather, and garage floor slabs.
3500 b, c
Structural concrete exposed to weather.
4500
w/c = .45
Concrete is these locations that can be subjected to freezing and thawing during construction shall be of air-entrained concrete in accordance with Section
Concrete shall be air-entrained in accordance with Section
Structural plain concrete basement walls are exempt from the requirements for special exposure conditions of Section (see Section )
TABLE IS APPLICABLE FOR OCCUPANCIES AND OCCUPANCIES AND APPURTENANGES THERE TO IN GROUP R OCCUPANCIES THAT ARE BUILDING LESS THAN FOUR STORIES ABOVE GRADE.

24. MINIMUM FREQUENCY
SAMPLES FOR STRENGTH TESTS FOR THE FIRST 250 CU.YDS. OF EACH CLASS OF CONCRETE PLACED SHALL BE TAKEN NOT LESS THAN ONCE A DAY, NOR LESS THAN ONCE FOR EACH 50 CU.YDS.OF CONCRETE, NOR LESS THAN ONCE FOR EACH 5000 SQ.FT. OF SURFACE AREA FOR SLABS OR WALLS UP TO 250 CU.YDS. IN A SINGLE DAY, AND ONCE PER 150 CU.YDS THEREAFTER.
FOR STRUCTURAL CONCRETE EXPOSED TO EXPOSURE CLASS C2*, ADDITIONAL FIELD TESTING OF THE CONCRETE FOR WATER CONTENT PER AASHTO T-318 SHALL BE REQUIRED. AT THE DISCRETION OF THE REGISTERED DESIGN PROFESSIONAL OF RECORD, THE FREQUENCY OF TESTING CAN BE REDUCED, BUT NOT LESS THAN ONCE FOR EACH 150 CU.YDS.
*CLASS C2 AS DEFINED IN ACI 318, SECTION 4.3, REINFORCED CONCRETE EXPOSED TO CLORIDES.

25. STRENGTH TEST A STRENGTH TEST SHALL BE THE AVERAGE OF THE STRENGTH OF TWO 6” X 12” OR 4” X 8” CYLINDERS MADE FROM THE SAME SAMPLE OF CONCRETE AND TESTED AT 28 DAYS OR AT THE TEST AGE, DESIGNATED FURTHER DETERMINATION OF f’c

26. METHOD OF CONVEYANCE CONCRETE SHALL BE CONVEYED FROM THE MIXER TO THE PLACE OF FINAL DEPOSIT BY METHODS THAT WILL PREVENT SEPARATION OR LOSS OF MATERIALS THAT MAY ALTER THE PROPERTIES OF THE CONCRETE DELIVERED. CYLINDERS SHALL BE MADE AT THE TRUCK OR AT THE POINT OF PLACEMENT TO DETERMINE THE QUALITY OF CONCRETE, AT THE DISCRETION OF THE SPECIAL INSPECTION AGENCY OR THE REGISTERED DESIGN PROFESSIONAL OF RECORD.

27. SHOTCRETE
PRECONSTRUCTION TESTS A TEST PANEL SHALL BE SHOT BY EACH NOZZLEMAN AND THEN CURED, CORED OR SAWED, EXAMINED AND TESTED PRIOR TO COMMENCEMENT OF THE PROJECT. THE SAMPLE PANEL SHALL BE REPRESENTATIVE OF THE PROJECT AND SIMULATE JOB CONDITIONS AS CLOSELY AS POSSIBLE. THE PANEL THICKNESS AND REINFORCING SHALL REPRODUCE THE THICKEST AND MOST CONGESTED AREA SPECIFIED IN THE STRUCTURAL DESIGN. CORES TAKEN FROM THE TEST PANEL SHALL BE USED TO DEMONSTRATE THAT THE PROPOSED MIX DESIGN MEETS THE REQUIREMENTS OF THE CONSTRUCTION DOCUMENTS AND THIS CODE. ALL SAMPLINE AND TESTING OF SHOTCRETE SHALL BE PERFORMED BY A LICENSED CONCRETE TESTING LABORATORY, CONSTRUCTION OF THE TEST PANELS SHALL BE WITNESSED BY THE SPECIAL INSPECTION AGENCY RESPONSIBLE FOR THE SHOTCRETE CONSTRUCTION.

28. NOZZELMAN SHALL BE ACI CERTIFIED 1913.5.1: SAMPLING AND TESTING.
: QUALIFICATIONS.
NOZZELMAN SHALL BE ACI CERTIFIED
: SAMPLING AND TESTING.
SIX CORE SAMPLES SHALL BE OBTAINED FROM EACH PRECONSTRUCTION TEST PANEL.
THREE SPECIMENS WITH NO REINFORCING STEEL SHALL BE SAMPLED AND PREPARED IN ACCORDANCE WITH ASTM C-42.
THREE SAMPLES WITH REINFORCING STEEL.

29. 1913.5.3 EVALUATION OF STRENGTH TESTS
THE SHOTCRETE TEST PANEL STRENGTH SHALL BE DEEMED ACCEPTIBLE IF THE MEAN COMPRESSIVE STRENGTH OF THE SET OF THREE CORES SHALL EQUAL OR EXCEED f’c WITH NO INDIVIDUAL CORES LESS THAN .75 f’c.

30. 1913.5.4: VISUAL GRADING OF CORES
CORE SAMPLES AND/OR TEST PANELS SHALL BE CUT WITH REINFORCING STEEL AND SHALL BE VISUALLY EVALUATED BY THE REGISTERED DESIGN PROFESSIONAL OF RECORD OR A REGISTERED DESIGN PROFESSIONAL ACCEPTABLE TO THE REGISTERED DESIGN PROFESSIONAL OF RECORD FOR THE STRUCTURAL DESIGN. THE NOZZLEMAN SHALL NOT PROCEED WITH WORK IF CORES AND/OR SECTIONS CUT SHOW THE REBAR NOT TO BE ENCAPSULATED WITH CONRETE TO THE SATISFACTION OF THE REGISTERED DESIGN PROFESSIONAL OF RECORD.

31. SAMPLING
SPECIMENS SHALL BE TAKEN FROM THE IN-PLACE WORK AND SHALL BE TAKEN AT LEAST ONCE EACH SHIFT, BUT NOT LESS THAN THREE CORES FOR EACH 50 CU.YDS. OF SHOTCRETE WITH THE APPROVAL OF THE REGISTERED DESIGN PROFESSIONAL OF RECORD. WHEN IN-PLACE CORES ARE NOT FEASIBLE DUE TO REBAR SPACING, PANELS WILL BE SHOT IN THE SAME POSITION AS THE WORK REPRESENTED. ONE PANEL SHALL BE CAST FOR EACH 50 CU.YDS. OF CONCRETE AND THREE CORES TAKEN PER ASTM C42.

32. SHOTCRETE – 8000 PSI MIX PROPORTION
CEMENT (LBS.)
225
GGBFS (LBS.)
525
SILICA FUME (LBS.)
100
FINE AGG. (LBS.)
1810
COARSE AGG. (LBS.)
985
WATER (LBS.)
298
WATER REDUCER (OZ.) 20
HRWR (OZ.) 80
AIR (%) 3
SLUMP (IN.)
W/C
.35
UNIT WEIGHT PCF
144.9

33. SHOTCRETE 8000 PSI FIELD TEST RESULTS
*COMPRESSIVE STRENGTH
12160 PSI
AIR
5.3%
SLUMP
4 INCHES
W/C
.34
UNIT WT.
141.0 PCF
*56-DAY CYLINDER RESULTS

34. 56-DAY COMPRESSIVE STRENGTH (psi)
The difference between cylinders and box cores is 1720 or 14%; The difference between box cores and in-situ cores is 1560 or 15%; The difference between in-site cores and cylinders is 3280 or 27%.
CYLINDERS
BOX CORES
IN-SITU CORES
AVERAGE
12160
10440
8880

35. ACI APPENDIX D
D INSTALLATION OF ADHESIVE ANCHORS HORIZONTALLY OR UPWARDLY INCLINED TO SUPPORT SUSTAINED TENSION LOADS SHALL BE PERFORMED BY PERSONNEL CERTIFIED BY AN APPLICABLE CERTIFICATION PROGRAM. CERTICATION SHALL INCLUDE WRITTEN AND PERFORMANCE TESTS IN ACCORDANCE WITH THE ACI/CRSI ADHESIVE ANCHOR INSTALLED CERTIFICATION PROGRAM OR EQUIVALENT.

36. THANK YOU!!!
Ken