03105 WAFFLEMAT FOUNDATION FORMING SYSTEM.doc (MKM Job Number)

DIVISION 3 CONCRETE

SECTION 03105

WAFFLEMAT FOUNDATION FORMING SYSTEM

PART 1 - GENERAL

1.01 DESCRIPTION OF WORK

  1. Provide materials and labor to install the Wafflemat foundation forming system (hereinafter known as “Wafflemat”) for cast-in-place concrete foundation slabs.
  1. Coordinate work of this section with the work of all other sections, as required to properly execute the work of this section, and as necessary to maintain satisfactory progress of the work of all other sections.
  1. Design and construction of other formwork is the complete responsibility of the contractor.

1.02 RELATED WORK SPECIFIED ELSEWHERE

  1. EARTHWORK - SECTION 02200
  2. REINFORCEMENT - SECTION 03200
  3. CAST-IN-PLACE CONCRETE - SECTION 03300
  4. ROUGH CARPENTRY - SECTION 06100

1.03 RELATED DOCUMENTS

  1. Contract Drawings and all provisions of the Contract, including General and Supplementary Conditions, and Division 1 – General Requirements of these Specifications, apply to the work specified in this section.
  2. Published specifications, standards, tests or recommended methods of trade, industry or governmental organizations that apply to work of this section, including, but not limited to, the following:
  1. American Society for Testing and Materials (ASTM) “Standards in Building Codes”, latest edition.
  2. American Concrete Institute (ACI 347) "Guide to Formwork for Concrete", latest edition.
  3. Post-Tensioning Institute (PTI), “Design of Post-Tensioning Slabs-on-Ground”, latest edition.
  4. Post-Tensioning Institute (PTI), “Construction and Maintenance Manual For Post-Tensioned Slab-on-Ground Foundations”, latest edition.
  5. American Concrete Institute (ACI 360R), “Design of Slabs-on Ground”, latest edition.

1.04 QUALITY ASSURANCE

  1. All work under this section shall be fabricated and installed in strict accordance with the Contract Drawings, Specifications and other published documents specified in Section 1.03.
  1. All installation work shall be done by qualified experienced workers skilled in their trade, in conformance with established standards of good practice and the Wafflemat manufacturer's recommendations.
  1. Tolerances: Wafflemat locating dimensions shall not deviate more or less than 1/2" from the dimensions shown on approved drawings.
  1. Where provisions of codes, specifications,or drawings conflict, the more restrictive provisions shall govern.

1.05 SUBMITTALS

  1. Shop Drawings: When noted on the approved drawings. Provide shop drawings showing Wafflebox layouts, post-tension cables and/or rebar, and other pertinent details reflecting the design shown on the approved drawings.

PART 2 - PRODUCTS

2.01 MATERIALS

  1. Waffleboxes: Injection molded, polypropylene co-polymer plastic, with up to 100% recycled plastic content. Waffleboxes form the voids in the underside of the concrete foundation slab that provide accommodating space for the volume change of expanding soil and dissipate the soil’s energy of expansion. Waffleboxes are 8.5 inches high, 19” x 19” at the bottom (measured to the inside corner of the flange, not to the outside edge of the flange), 18” x 18” at the top, with 1” wide flanges on two adjacent sides, and with no flanges on the other two sides. Two adjacent sides of the Wafflebox are battered back 1” from bottom to top. The other two sides are straight vertically. Waffleboxes are used singly, in pairs, in threes, or in quads—as shown on the approved drawings.
  1. Upper Clip: Made of the same plastic as the Waffleboxes. Upper clips are used to connect the tops of Waffleboxes, and to support post-tension cables and supplemental rebar as shown on the approved drawings.
  1. Lower Clips: Made from the same plastic as the Waffleboxes. Lower clips are used to connect the bottoms of Waffleboxes, and to support post-tension cables and supplemental rebar as shown on the approved drawings.
  1. Plastic Sheet: 6 mil thickness or greater. Plastic sheet is placed on top of the soil and under the Waffleboxes. It is used (1) to ease the installation and positioning of Waffleboxes on soil pads, (2) to reduce concrete-to-soil friction during stressing of post-tension cables, (3) as an additional moisture barrier for the finished slab, and (4) to allow installation of Waffleboxes during rain without concern for wet soil. Plastic sheet is not required when only rebar reinforcement is used, but it is recommended. Plastic sheet is provided by others.

PART 3 - EXECUTION

3.01 SCHEDULING, SEQUENCING

  1. Ensure timely delivery of Wafflemat system components and related materials required for the installation.
  1. Coordinate with the design and installation of all underground utilities that will be permanently under the slab. Underground plumbing, electrical, etc. must be installed before the plastic sheet is laid down and Waffleboxes are installed. All such utility installations must have risers that extend a minimum of 6” above the top of the finished slab. Waffleboxes can be cut as required to allow the penetration of utility risers. Seal the gaps in the cuts in the Waffleboxes with duct tape to prevent ingress of concrete into the Wafflebox void during the pour. Waffleboxes shall only be removed for utility risers, if shown on the approved drawings or as approved by the Engineer.
  1. The method of placement of utilities in the ground under the Wafflemat slab must be designed to accommodate future soil movement and foundation loads. Also, if permitted by local codes, utility risers that pass through the concrete slab should have a bond breaker wrapped around them to allow slight vertical movements of either the slab or the riser in the slab penetration.
  1. Obtain necessary information for coordination of other formwork with installation of the Wafflemat components and related materials.
  1. Plan formwork erection to permit proper sequence of installingunderground utilities and placing the Waffleboxes.
  1. Notify the Engineer a minimum of 48 hours in advance, so that placement of the Wafflemat can be observed.

3.02 INSPECTION

  1. Examine all areas of the finish-graded building pad where Waffleboxes will be installed, and verify that the level of the pad in all locations is no more than ½” above or 1” below the pad elevation shown on the approved drawings.
  1. All trash and unnecessary loose items not required for the permanent foundation installation shall be completely removed before concrete is poured.

3.03 CONSTRUCTION

  1. Install Waffleboxes and clips true to lines, grades, dimensions, surfaces, and as shown on the approved drawings.
  1. Areas around all post-tension anchors and all areas of congested rebar installations shall be adequately vibrated during the concrete pour, to ensure that the concrete has been completely consolidated and that there are no entrapped air pockets in the concrete.
  1. Earth Forms:
  1. Earth forms (trenches) may be used for deeper footings, if required by the approved drawings, only where the soil is firm and stable. All such excavations shall be cut neat. All excavated soil shall be removed from within the area inside the perimeter formwork. No loose and improperly compacted soil shall be allowed under the Waffleboxes.
  2. Trenchesshall be lined with plastic sheet, or as otherwise required by the approved drawings.
  1. Slab Forms:
  2. Establish slab levels and set screeds as with any other slab design.
  3. Depress slab where required on the approved drawings.
  4. Slope slab to drain only where required on the approved drawings.
  1. Waffleboxes are designed to be stepped on during the construction process.
  1. Construction joints: Not allowed, unless shown on the approved drawings or as approved by the Engineer.
  1. Embedded Items: Properly locateand place all inserts and embedded items required by other trades prior to pouring concrete, as with any other slab design.
  1. Coordinate placement of Waffleboxes with other trades to allow for placement of piping, sleeves, conduit, and other items within and under the formed area. Pay particular attention to the location of utility and other penetrations when using post-tension cable reinforcement.

3.04 REMOVAL OF FORMWORK AND SHORING

  1. Formwork and shoring shall not be removed until the concrete has acquired sufficient strength. This is usually after a minimum of 24 hours, or as otherwise requiredby the approved drawings and specifications.
  1. Concrete shall not be subjected to superimposed loads (structure or construction) until it has attained its full design strength, or as otherwise allowed by the Engineer. The concrete slab shall not be subjected to construction loads in excess of design loads.
  1. Any request for early removal of formwork and shoring shall be made to the Engineer in writing, along with supporting evidence that the safety of the foundation will not be impaired. Such early removal must be approved by the Engineer.

3.05 FORM RE-USE

  1. Waffleboxes are sacrificial forms and remain in the slab for the life of the foundation.

3.06 RESPONSIBILITY

  1. Nothing herein shall be construed as relieving the contractor of any responsibility for the safety of the foundation.

END OF SECTION

WAFFLEMAT FOUNDATION FORMING SYSTEM03105.-1

(Job Name)2012-6/1