"Manual of Concrete Practice for Details and Detailing of Concrete Reinforcement"




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Specifications & Requirements: 07 42 00

9/8/06


SLENDERWALL PREFABRICATED EXTERIOR WALL PANEL


PART 1 – GENERAL



    1. Reference Number: CONSTRUCTION SPECIFICATIONS INSTITUTE (CSI)




  1. MasterFormat™ 2004: 07 42 00 (Section 07, Thermal & Moisture

Protection, Wall Panels)

B. 16 Division System: 07415 (Section 7, Thermal & Moisture

Protection, Wall Panels)
1.02 SUMMARY
A. Section Includes:
1. Prefabricated exterior wall panels, factory fabricated with light-gauge metal framing backup.
2. Reinforcement of fabricated units, including anchorages, reinforcing bars, supports, etc.
3. Structural steel inserts, lifting hooks, anchor units, plates, dowels, etc., required for handling and for connections of light-gauge metal framing to structural steel framework of the building.
4. Preparation of engineering design calculations for architectural prefab units and connections; preparation of shop and erection drawings.
5. Testing and inspection of prefab units and erection work; provided and paid for by the Owner.
B. Related CSI Sections:
1. Cast-in-place Concrete Division 03 30 00
2. Structural Steel Framing: Division 05 12 00
3. Joint Sealants: Division 07 92 00

1.03 SUBMITTALS
A. Product Data. Submit fabricator's specifications, data, and instructions for manufactured materials and products, including the following:
1. Shop Drawings: Submit complete information essential to proper fabrication and installation of prefab units. Show dimensions, fabrication tolerances, and reinforcement sizes and locations, including locations and types of lifting devices required.
a. Show location of prefab units and identification of each, corresponding to planned sequence of installation.
b. Designate welded connections by means of standard AWS symbols.
c. Provide locations and details of anchorages for installations in other work; finish templates if required for accuracy.
d. Provide design calculations prepared by a professional structural engineer registered in the state of project construction.
1) Indicate all design loads (wind, live, dead loads), including stresses during shipment and erection and due to loads from construction procedures.
2) Submit calculations no later than four (4) weeks prior to start of fabrication.
e. Prepare shop drawings in accordance with ACI 315-99, "Manual of Concrete Practice for Details and Detailing of Concrete Reinforcement" except where in conflict with local building codes and regulations. Use scale of details as adequate to fully and clearly illustrate the work.
2. Samples: Architect's approval of samples will be for color, texture, appearance, and general condition only. Compliance with all other requirements of the contract documents is the exclusive responsibility of the contractor.
a. Submit two samples, 12-inches" square x 1½-inches thick, for each type of surface required (formed or unformed) showing finishes proposed for all exposed work, using proposed concrete mix and cast against the same form material to be actually used in the construction.

1.03 SUBMITTALS (con’t.)
b. Prior to production fabrication of wall panel units, prepare full size sample of required prefab unit; arrange for architect's review at manufacturer's plant.
1) Notify architect when full size samples are ready for review.
2) Do not start production fabrication of wall panel units until sample units have received architect's written approval.
3) Form materials are subject to rejection if forms used do not provide specified finish.


  1. Submit samples of patching methods to be used:

12-inches x 12-inches.
3. Product Information: Submit name of manufacturer and/or supplier of the following:
a. Cement, each type g. Stud framing

b. Aggregate, each type h. Inserts and anchors

c. Reinforcing bars & prestressing tendons i. i. Non-shrink grout

d. Welded steel wire fabric j. Neoprene pads

e. Concrete k. Form release agent

f. Welding electrodes l. Thermal coating material of mechanical fasteners

4. Certificates: Submit the following:
a. Mill certificates for each shipment of cement, identified by lot material.
b. Mill certificates for all reinforcing bars and welded steel wire fabric.
c. Mill certificates for all structural steel plates, shapes and members.
d. Certificates of compliance for anchors, bolts, shear studs, welding electrodes, concrete inserts, neoprene pads, shop paint, field paint, and non-shrink grout.
e. Certification of welders for welding reinforcement, shop and field connections.


1.03 SUBMITTALS (con’t.)


  1. Test Reports: Submit test results showing that the Panel System has
    met the required standards for the following tests:




    1. Air Infiltration: ASTM E 283-99

    2. Static Pressure Water Resistance: ASTM E 331-93

    3. Dynamic Pressure Water Resistance: AAMA 501.1-94

    4. Interstory Differential Movement: AAMA 501.4-2000

    5. Structural Performance: ASTM E 330-96

    6. Thermal Cycling/Condensation Evaluation: AAMA 501.5-98

    7. Uniform Load Deflection: ASTM E 330

    8. Seismic Test (Lateral Cycling): AAMA 501.4-98

    9. Sound Transmission: ASTM E 90-97, ASTM E 413-87,
      ASTM E 1332-90

    10. Steel-Stud Connection


1.04 QUALITY ASSURANCE
A. Codes and Standards: Comply with provisions of the following, except where exceeded by other requirements of the contract documents or of governing authorities:
1. ACI 211.1: Recommended Practice for Selecting Proportions for Normal and Heavyweight Concrete.
2. ACI 304: Recommended Practice for Measuring, Mixing, Transporting and Placing Concrete.
3. ACI 305: Hot Weather Concreting.
4. ACI 306: Cold Weather Concreting.


  1. ACI 315: Manual of Concrete Practice for Details and Detailing of

Concrete Reinforcement
6. ACI 318: Building Code Requirements for Reinforced Concrete.
7. ACI 347: Recommended Practice for Concrete Form Work.
8. ACI Manual of Steel Construction.


  1. AWS D1.1: Structural Welding Code.




  1. AWS D12.1: Reinforcing Steel Welding Code.


1.04 QUALITY ASSURANCE (con’t.)
11. Industrial Fasteners Institute, Handbook for Fastener Standards.
12. PCI MNL 117: Manual for Quality Control for Plants and Production of Architectural Precast Concrete Products.
13. PCI Design Handbook: Precast and Prestressed Concrete.
B. Design Requirements:
1. Design the panel system with a minimum ½-inch air space between the inside face of the panel and outside face of the metal stud. The connection between the metal stud and the precast concrete shall be coated to provide a thermal break that reduces thermal bridging from the concrete to the stud.


  1. Design the panel system so that the vertical shear of the precast concrete from the studs will exhibit a minimum vertical shear static factor of safety of 4.50.


3. Design the panel system to comply with all structural and seismic loading requirements.
4. Design units to support loads indicated and as required by applicable code requirements.
C. Fabrication Requirements: All prefabricated exterior wall panels are to be produced under controlled conditions at an NPCA- or PCI-certified prefabricated concrete plant. Producers shall also be a certified SLENDERWALL® manufacturer as licensed by EASI-SET® Industries, Midland, Virginia, or have a minimum of five years experience producing “thin wall” panel systems. Site produced units are not acceptable.
D. Erector Qualifications: Shall be a PCI-qualified erector firm or have a minimum of five (5) years experience in the successful erection of prefabricated units comparable to those specified; an entity licensed or otherwise approved by the fabricator.

1.05 DELIVERY, STORAGE AND HANDLING
Product Design/Fabricator: Deliver prefabricated units to ensure continuity of installation. Store to prevent damage such as cracking, distortion, or staining and to maintain visibility of markings. Handle and support units using only designated lift points and lifting devices.
PART 2 – PRODUCTS
2.01 GENERAL
Product Design/Fabricator: The design is based on SLENDERWALL®, a proprietary, prefabricated, architectural precast concrete, steel-stud, exterior- wall panel system developed and patented by SMITH-MIDLAND Corporation, Midland, Virginia.
2.02 FORM WORK
A. General: Construct forms accurately to size, mortar-tight, and of sufficient strength to withstand all fabrication operations without distortion of prefabricated units.
B. Wall Panel Tolerances: Maintain form work to provide finished wall units within fabrication tolerances specified in PCI MNL-117.
C. Facing Materials - General: Provide form facings of metal, plastic, or other non-reactive material that will produce required concrete finish.
1. Design form work to withstand vibration and lateral forces; provide accuracy in details, with sharp corners and arises.
2. Allow no visible joints or seam lines in the molds or in the finished surfaces unless joints or lines are required by the drawings.
2.03 REINFORCING MATERIALS
A. Reinforcing Bars: ASTM A 615, Grade 60, hot-dipped galvanized deformed, except where plain bars are indicated.
B. Welded Wire Fabric: ASTM A 185, triple-coated (3.6 Mils) galvanized wire.
C. Reinforcing Accessories:
1. Tie Wire: Epoxy coated annealed type, 16-½ gauge or heavier.
2. Supports: Bar supports conforming to specification of CRSI's Manual of Standard Practice.
2.04 CONCRETE MATERIALS
A. Portland Cement: ASTM C 150, Type I, II or III.
1. Use only one brand and type of cement throughout the project, unless otherwise approved by the architect.

2.04 CONCRETE MATERIALS (con’t.)
2. Use color of cement for facing concrete mix to match architect's control sample.
3. Standard gray cement may be used for non-exposed backup concrete.
B. Coarse Aggregate for Facing Mixes: ASTM C 33, hard durable, carefully selected and graded; free of material causing staining or reacting with cement.
Use aggregate from same source as used in architect's control sample.
C. Fine Aggregate for Facing Mixes: ASTM C 33, manufactured sand of same material as coarse aggregate, unless otherwise acceptable to the architect.
For material passing a No. 20 sieve, provide washed and dried silica sand.
D. Water: Potable.
E. Air-Entraining Admixture: ASTM C 260, with not more than 0.1% of soluble chloride ions by weight of cement.

2.05 METAL FRAMING MATERIALS
A. General: Provide all steel members with ASTM A 525 G-90 galvanized coating, unless otherwise indicated.
B. Light-gauge Metal Framing:
1. Stud Framing Members: Formed from steel that corresponds to requirements of ASTM A 570-50, with a minimum yield of 50,000 ksi.
2. Track, Bridging and Accessories: Gauge galvanized formed steel members.
3. Bent Plates: HR1020 (35,000 psi yield-strength) conforming to AISI requirements.
4. Provide welded stud connectors with thermal break non-corrosive coating.


    1. METAL FRAMING MATERIALS (con’t.)


C. Steel Hardware Units:


  1. Steel Plates and Shapes: Structural quality, hot rolled carbon steel complying with ASTM A 36 or ASTM A 283, Grade C.


2. Bar size steel shapes, flats and rounds: ASTM A 36 or ASTM A 306, Grade 65.
3. Anchor Bolts: ASTM A 307. low carbon steel bolts, regular hexagon nuts, carbon steel washers.
D. Weldments: Comply with requirements of AISC "Specification for the Design, Fabrication and Erection of Structural Steel for Buildings."


  1. Touch-up Galvanizing Compound: "ZRC cold galvanizing compound"; ZRC Chemical Company.



2.06 MISCELLANEOUS MATERIALS
A. Welding Electrodes and Fluxes: AWS D1.1, types as required by materials being welded.


  1. Accessories: Hangers, clips and other items required for installation of prefabricated units and support related construction.




  1. Joint Fillers: Factory-compressed, waterproof joint filler, installed to 25% compression.


2.07 CONCRETE MIX DESIGN
A. General: Prepare design mix of concrete on the basis of trial mixtures, as specified in ACI 301.
B. Review: Do not begin concrete production until proposed mix has been reviewed by the architect.
C. Mix: Design mix to achieve a minimum compressive strength of 5,000 psi at 28-days.


  1. Mix Adjustments: Provided that no additional expense to the owner is involved, contractor may submit for architect's approval requests for adjustment to approved concrete mixes when circumstances such as changed project conditions, weather, or unfavorable test results occur. Include laboratory test data substantiating performance characteristics with mix adjustment requests.


2.07 CONCRETE MIX DESIGN (con’t.)
E. Air-Entraining Admixture: Use in accordance with ACI 301 for maximum size of coarse aggregate.
F. Integral water repellant Darapel by Grace Chemical Company.


2.08 FABRICATION
A. General: Fabricate architectural prefabricated units in compliance with PCI MNL-117. Adequately reinforce units to resist stresses due to transporting and handling.
B. Form Work: Comply with ACI 347 and to requirements specified herein.
Molds: Prefab units in one-piece seamless rigid molds for exposed faces except where two pieces are permitted. Prevent deformation of molds and maintain mold surfaces free of irregularities, dents, sags, or damage of any kind.
C. Built-in Anchorages: Locate accurately and secure to form work. Position to avoid interference with main reinforcement or placement of concrete; do not relocate without architect's approval.
D. Openings: Cast openings with minimum dimension of 10-inches or larger. Smaller openings may be field cut as required, with the architect's prior approval.
E. Release Agent: Provide either form materials with permanent factory-applied non absorptive liner or form coating. If form coating is used, thoroughly clean and recondition form work and reapply coating before each use. Rust on form surfaces is acceptable.

F. Reinforcement: Clean reinforcement of loose rust and mill scale, soil, and other materials that adversely affect bond with concrete. Place reinforcement to achieve not less than minimum concrete coverages required for protection, and accurately position, secure, and support against displacement. Set wire ties to avoid contact with or penetration of exposed concrete surfaces.
G. Metal Stud Framing: Accurately position metal framing backup and anchorages and secure to form work. Locate anchorages where they will not affect the position of reinforcement or the placing of concrete.
H. Concrete: Place continuously for each unit, complying with requirements of ACI 304. Consolidate concrete by vibration while avoiding damage to dislocation of reinforcement, anchorages, and built-in accessories.

2.08 FABRICATION (con’t.)
I. Identification: Mark units to identify pickup points and final orientation, corresponding to final shop drawings. Imprint fabrication date on each unit in concealed location.
J. Architectural Finish: Fabricate exposed faces of prefabricated composite wall panel units to achieve a smooth, off-the-form finish, free of pockets, sand streaks, and other surface blemishes.


  1. Finish for Concealed Surfaces: Provide as-cast or float finish for surfaces which will be concealed.



2.09 SOURCE QUALITY CONTROL
A. General: Composite panel manufacturer shall assume responsibility for quality control procedures for the manufacture, inspection, and testing of prefabricated units in compliance with PCI MNL-117.
Furnish the architect with copies of test reports and certificates for materials and quality control testing of prefabricated units.
B. Non-conforming Work: Replace wall panel units which do not conform to specified requirements, as directed by the architect, and pay for corrections to other work necessitated by such replacement.
Dimensions: Prefabricated units smaller than allowed by specified tolerances will be rejected. Units larger than specified tolerance will be rejected if they interfere with other construction or if, in the opinion of the architect, the appearance of the work is adversely affected.

PART 3 – EXECUTION

3.01 INSTALLATION
A. General: Comply with erection recommendations of PCI MNL-127. Provide temporary shoring, bracing, and connections as required to maintain stability of structure and prefabricated units during construction, arranged to avoid interference with subsequent prefab unit installation.
B. Anchorage: Anchor units in final position by bolding, welding or as otherwise shown on approved shop drawings. Remove temporary shims, wedges and

spacers as soon as possible after anchoring is completed. Make adjustments as required to maintain accurate face joint dimensions.
1. At bolted connections, use lock washers, "Slotlok" system welding, or other approved method to prevent loosening of nuts.
2. At welded connections, apply two coats of rust-inhibitive zinc-rich coating on damaged areas.
C. Welding: Comply with requirements of AWS D1.1.
Protect adjacent concrete surfaces from damages due to weld splatter, smoke staining, or excessive heat.






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