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SECTION 03455 GLASS FIBER REINFORCED CONCRETE - GRC 00000000PART 1 - GENERAL 1.1 SECTION INCLUDES A. B. 1.

2 Design, fabrication, furnishing, and installation of architectural precast glass fiber reinforced concrete units as indicated on Drawings. Supports, anchors, and attachments related to the installation of GRC units.

REFERENCES A. ASTM - American Society for Testing and Materials: ASTM A 36 - Specification for Structural Steel ASTM A 27 - Specification for Steel Castings, Carbon, for General Applications ASTM A 47 - Specification for Ferritic Malleable Iron Castings ASTM A 153 - Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware ASTM A 307 - Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength ASTM A 325 - Specification for High-Strength Bolts for Structural Steel Joints ASTM A 666 - Specification for Austenitic Stainless Steel, Sheet, Strip, Plate, and Flat Bar for Structural Applications ASTM A 780 - Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized ASTM C 144 - Specification for Aggregate for Masonry Mortar ASTM C 150 - Specification for Portland Cement ASTM C 260 - Specification for Air-Entertaining Admixtures for Concrete ASTM C 494 - Specification Chemical Admixtures for Concrete ASTM C 618 - Specification for Fly Ash and Raw or Calcined Pozzolan for use as a Mineral Admixture in Portland cement Concrete B. AWS - American Welding Society: ANSI/AWS D1.1 - Structural Welding Code - Steel C. ANSI/AWS D1.4 - Structural Welding Code - Reinforcing Steel PCI - Prestressed Concrete Institute:
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PCI - Recommended Practice for Glass Fiber Reinforced Concrete Panels. PCI MNL-117 - Manual for Quality Control for Plants and Production of Architectural Precast Concrete Products. 1.3 SUBMITTALS A. Shop Drawings: Provide complete erection drawings showing the Units elevations and sections with complete details, dimensions and finishes showing the following: B. C. Joint and connection details Lifting and erection inserts Location and details of hardware attached to structure Other items sprayed in panels Description of loose, cast-in, and field-applied hardware

Test Reports: Submit two copies of test board reports. Design Calculations: Submit complete design calculations for GRC elements and connections, including loads used in design. Include creep shrinkage, deflections, temperature variations, stress and expansion requirements. Review of calculation by the Engineer does not relieve the Contractor of complete responsibility of design.

1.4

QUALITY CONTROL A. Design Responsibility: Design GRC frames by a registered professional Engineer employed or retained by panel Manufacturer, in accordance with procedures in Prestressed Concrete Institute - PCI, Recommended Practice for Glass Fiber Reinforced Concrete Panels. Manufacturer Qualifications: Manufacturer with a demonstrated capability to produce GRC products of quality and scope required for this Project, and actively involved in the production of GRC for at least 5 years.

B.

1.5

JOB MOCK-UP A. After samples are accepted by the Engineer for color and texture, produce full-scale unit meeting design requirements as follows: 1. 2. 3. Retain job mock-up on site as standard of quality for GRC panel work, when accepted by the Engineer. Incorporate mock-up into work in location acceptable to the Engineer. Prior to commencement of manufacture, submit 300 mm long samples representative of finished exposed face showing typical range of color and texture, and of appropriate thickness.

PART 2 - PRODUCTS 2.1 GLASS-FIBER REINFORCED CONCRETE ELEMENTS


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ITCC in Riyadh Residential Complex J10-13300

A.

Provide GRC elements consisting of the following materials: 1. Portland Cement: ASTM C 150, Type I. For surfaces exposed to view in finished structure, use same brand, type, and source of supply throughout GRC production. Sand: ASTM C 144, or other acceptable material with successful use in GRC production and shall all pass through No. 20 sieve also match sand aggregate samples on file with the Engineer. Water: Potable, free from deleterious matter that may interfere with color, setting, or strength of GRC. Admixtures: ASTM C 260, ASTM C 494, or ASTM C 618; at Manufacturer's option. Do not use admixtures which contain more than 0.1 percent chlorine ions. Glass Fiber: Special alkali resistant glass fiber designed for compatibility with aggressive alkaline environment of Portland cement base composites.

2.

3. 4.

5. B.

Anchors, Inserts and Sub-Systems: 1. 2. 3. 4. 5. 6. 7. 8. Carbon Steel Anchors: ASTM A 36. Stainless steel Anchors: ASTM A 66, Type 302/304. Malleable Steel Castings: ASTM A 47, grade as required. Carbon Steel Castings: ASTM A 27, grade 60 - 30. Anchor Bolts: ASTM A 307 or ASTM A 325. Galvanized Finish for Carbon Steel Anchors: ASTM A 153, hot-dipped after fabrication. Threaded Anchors Finish: Electro-deposited zinc or cadmium coated. Touch-up galvanized surfaces damaged by welding procedures in accordance with ASTM A 780.

C. 2.2

Mixes: Combine Portland cement, glass fibers, sand and selected admixtures, combined in proper proportions to meet design requirements.

FABRICATION A. Forms: Construct of rigid materials that will result in finished products conforming to profiles, dimensions, and tolerances indicated. Use form release agent compatible with architectural finish and joint sealants. Proportioning and Mixing: Carefully measure amounts of mix constituents to achieve desired mix proportions also meter glass fiber and cement slurry to spray head at rates to achieve desired mix proportion and glass content required. Check in accordance with standard procedures as recommended by PCI.
Glass Fiber Reinforced Concrete - GRC

B.

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C. D. E. F. G.

Hand Spray Application: Use only trained applicators. Spray mist coat consisting of matrix without fibers onto forms, if required. Do not exceed 0.8 mm thickness to prevent an un-reinforced surface. Proceed with spray-up of main body before mist coat has set, using procedures which produce a uniform thickness and distribution of glass fibers and matrix. Consolidate applied materials by rolling or other technique to achieve complete encapsulation of fibers and compaction. Control thickness by using pin-gauge or other acceptable method. Make a minimum of two thickness measurements per each 1/2 m2 (squared meter) of panel surface with not less than three measurements per panel. Perform hand-forming of intricate details, incorporation of formers or in-fill materials, and over-spraying before material has taken initial set to insure complete bonding. Inserts/Embedments: Properly embed inserts in built-up homogenous GRC bosses to develop their strength. Place rigid embedded items bonded to GRC so as not to create undesirable restraint to volume changes. Note: Inserts and anchor devices (where required) that shall be exposed to view at the front of the GRC shall be stainless steel.

H. I.

2.3

ALLOWABLE TOLERANCES A. Dimensional Tolerances: Manufacture units so that each frame complies with dimensional tolerances as follows: 1. Finished Units: Overall height and width of units measured at face adjacent to form. a. b. 2. 3. 4. 5. 6. 3 m or under: Plus or minus 3 mm Over 3 m: Plus or minus 3 mm per each 3 m

Skin Thickness: Plus 6 mm, minus 0. Side Return Thickness: Plus 9 mm, minus 0. Panel Depth: Plus 9 mm, minus 3 mm. Angular deviation of plane of side mould: 0.8 mm per 75 mm depth or 1.5 mm total, whichever is greater. Variation from Square or Designated Skew (difference in length of two diagonal measurements): 3 mm per 1.8 meters or 6 mm total, whichever is greater. Length and width of block-outs and openings within one unit: Plus or minus 6 mm.

7. B.

Position Tolerances: For sprayed-in items, measured from datum line locations as indicated:
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ITCC in Riyadh Residential Complex J10-13300

1. 2. 3. 4. C.

Insert bolts/Pipe Sleeves: Plus or minus 9 mm. Blockouts: Plus or minus 6 mm. Flashing Reglets (at the edge of panel): Plus or minus 6 mm. Reglets for glazing gaskets: Plus or minus 3 mm.

Finishes: Exposed face of frames to match the submitted samples previously approved by the Engineer. Joint marks, grain, or other obvious defects on face of frame will not be acceptable. Cover: Provide embedded anchors, inserts, and other sprayed-in items with sufficient anchorage and embedment to suit design requirements. Curing: Employ initial curing method which will ensure sufficient strength for removing units from form. After initial curing, remove panel from form and place in a controlled curing environments. Keep the frame units continuously moist for minimum 7 days in accordance with Manufacturer's standard curing practice. Maintain a temperature between 16 degree C and 42 degree C during this period. Frame Unit Identification: Mark each GRC frame unit to correspond to identification mark on shop drawings for panel identification. Mark each GRC frame unit.

D. E.

F.

PART 3 - EXECUTION 3.1. PRE-INSTALLATION RESPONSIBILITY A. Contractor Responsibility: Provide building lines, center and grades in sufficient detail to allow installation of GRC units. Provide true, level bearing surfaces. Provide for accurate placement and alignments of anchor bolts, plates, or dowels on structure.

B.

3.2.

Erector Responsibility: Prior to installation of units, check job site dimensions affecting erection of GRC units. Bring to Contractor's attention any discrepancy is between design dimensions and field dimensions which could adversely affect installation. If discrepancies do exist, do not proceed until correct or until installation requirements are modified as acceptable to the Engineer. ERECTION A. B. C. D. E. Protection: Provide adequate barricades, warning lights or signs to safeguard traffic in immediate area of hoisting and handling operations. Setting: Lift GRC units at lifting points established by Manufacturer. Set GRC units level, plumb and square within allowable tolerances. Supports and Bracing: Provide temporary supports and bracing as required to maintain position, stability and alignment as units are being permanently connected. Fastening: Fasten GRC units in place by bolting or welding, as indicated on erection drawings. Tolerances of Erected Units: Maintain erection tolerances for locating GRC units as
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ITCC in Riyadh Residential Complex J10-13300

follows: 1. Face width of joint shall be as follows: a. b. c. 2. 3. 3.3. PATCHING A. B. General: Patching will be permitted provided structural adequacy of unit and appearance are not impaired, as acceptable to the Engineer. Patching Mix: Match color and texture of GRC unit. Blend and mix materials so that cured patching blends with adjacent surfaces and are not evident when viewed from a distance of 2 m. Panel dimension 3 m or less: Plus or minus 4 mm Panel dimension 3 m to 6 m: Plus or minus 6 mm. Panel dimension over 6 meter: Plus 6 mm or minus 8 mm.

Warpage: Maximum permissible warpage of one corner out of plane; 3 mm total after installation. Bowing: Not over L/360, where (L) is panel length.

3.4.

CLEANING A. B. C. General: Perform cleaning procedures as recommended by the GRC Manufacturer. Clean solid GRC surfaces with detergent and water, using soft fiber brushes and sponges, and thoroughly rinsed with clean water. Use care to prevent damage to GRC surfaces and to adjacent materials. END OF SECTION

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Glass Fiber Reinforced Concrete - GRC