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Home My WebLink About20191016_03300-02-0 - Grout mix & Grout Bags Flowable Fill_YRC Review MAGGIORE CONSTRUCTION CORP. 13 Wheeling Avenue, Woburn, MA 01801 Phone 781.935.6100 FAX 781.933.8044 SUBMITTAL ACTION SHEET Oxoboxo Lofts 40 Pink Row Uncasville, CT General Contractor:Architect: Maggiore Construction Corp. Paul B Bailey Architects 13 Wheeling Ave. 110 Audobon Street Woburn, MA 01801 New Haven, CT 06510 Job No.: 1214 Job No.: 16-063 Prepared By:Maggiore Construction Corp. Form of Submittal: Samples Cut Sheets Schedule Shop Drawings Other Description:Grout mix & Grout bags Manufacturer:Euclid Chemical & Synthetex Other/Notes: To be used at Buildng J at Scour areas and helical piles Received By MCC:9/13/2019 Received By Owner: Reviewed:Comments: Approved Approved as Noted Rejected Revise and Re-submit Compliance Equal Submitted For Approval By: Gifford Perry - Senior Project Manager Approved By: Date:9/16/2019 Date: The use of Synthetex Concrete Grout Bags appears to be acceptable. A full engineered design submittal should be submitted by the manufacturer for review and approval. See enclosed notes and comments. Date: No. Attention: Project Name: From: Schumack@schumackconstruction.com We are sending you:For Approval For your Use As Requested Sent Via: MailƚŽ͗ Fax͗ Email͗ Signed: LLetter of 6XEmittal ŶĨĨŝƌŵĂƚŝǀĞĐƚŝŽŶͲƋƵĂůKƉƉŽƌƚƵŶŝƚǇŵƉůŽǇĞƌ WƌŽǀŝĚŝŶŐƋƵĂůKƉƉŽƌƚƵŶŝƚŝĞƐĨŽƌDŝŶŽƌŝƚŝĞƐͬ&ĞŵĂůĞƐͬsĞƚĞƌĂŶƐͬ/ŶĚŝǀŝĚƵĂůƐǁŝƚŚŝƐĂďŝůŝƚŝĞƐ 6XVDQ:HJOHLQ2SHUDWLRQV0DQDJHU To: ŐŝĨĨŽƌĚΛŵĂŐŐŝŽƌĞ͘ĐŽ DĂŐŐŝŽƌĞŽŶƐƚƌƵĐƚŝŽŶŽƌƉŽƌĂƚŝŽŶ ϭϯtŚĞĞůŝŶŐǀĞŶƵĞ tŽďƵƌŶ͕DϬϭϴϬϭ ŐŝĨĨŽƌĚΛŵĂŐŐŝŽƌĞ͘ĐŽ 'ŝĨĨŽƌĚWĞƌƌǇ KǆŽďŽǆŽ>ŽĨƚƐϰϮWŝŶŬZŽǁ͕DŽŶƚǀŝůůĞ WƌŽũĞĐƚη͗ ĞƐĐƌŝƉƚŝŽŶ^ƉĞĐŝĨŝĐĂƚŝŽŶƐ ^ƵƐĂŶtĞŐůĞŝŶ͕KƉĞƌĂƚŝŽŶƐDĂŶĂŐĞƌ Schumack ŶŐŝŶĞĞƌĞĚConstruction ŶhƉĚĂƚĞ ŽŵŵĞŶƚƐ͗ 09/3/2019 1 WƵŵƉĂďůĞ&ůŽǁĂďůĞ&ŝůůĨŽƌ'ƌŽƵƚĂŐƐEŽ^ƉĞĐŝĨŝĐĂƚŝŽŶηƉƌŽǀŝĚĞĚ ,ǇĚƌŽƚĞǆ'ƌŽƵƚĂŐƐ dŚŝƐƐƵďŵŝƚƚĂůĐŽŶƚĂŝŶƐϮϬƉĂŐĞƐŝŶĐůƵĚŝŶŐĐŽǀĞƌ y EŽƐƉĞĐŝĨŝĐĂƚŝŽŶηƉƌŽǀŝĚĞĚ ^ĐŚƵŵĂĐŬǁŝůůĚŝǀĞƌƚǁĂƚĞƌΘĞǆĐĂǀĂƚĞĂƐŶĞĐĞƐƐĂƌǇƉĞƌĚŝƌĞĐƚŝŽŶŽĨ^ŽŝůƚĞƐƚŝŶŐ͕/ŶĐ͘dŚĞĂŵŽƵŶƚŽĨďĂŐƐĂŶĚĚĞƐŝŐŶƉůĂĐĞŵĞŶƚƐŚĂůůďĞ ĚĞƚĞƌŵŝŶĞĚŝŶƚŚĞĨŝĞůĚŽŶĐĞĐŽŶƐƚƌƵĐƚŝŽŶŚĂƐďĞŐƵŶ͘ Builders Concrete Westbrook Plant Address: 129 Norris Avenue Westbrook, CT 06498 Dispatch: 860-399-9289 Schumack Engineered Construction Project: Grout Bags UOM Per Cubic Yard Quantity lbs. 265 lbs. 3225 gallon 36 ounce 12.00 ounce 15 percent N/A inches N/A 1.13 Source of Materials: N/A Optional Admixtures: 1)Non-Chloride Accelerator - Accelguard 80 Dosage Rate: 8 - 20 oz/cwt. 1)Retarder - Eucon Retarder 75 Dosage Rate: 2 - 6 oz/cwt. Sincerely, Builders Concrete Westbrook Benjamin M. Napierski Cold Weather Concrete Hot Weather Concrete Sand: Stone: May be used at the discretion of the Field Personnel Please add Builders Concrete Westbrook to the Lab Report Distribution list for this project. bnapier@bce-wm.com Admixtures: Fine Aggregate Lafarge Type I/II Mix ID: 065 WR 91 Description: Product Use: Pumpable Flowable Fill Water Materials Cement Cement: Water Cement Ratio The Euclid Chemical Co. Rawson Materials Air Mix 200 Air Content Slump Oxo Boxo 42 Pink Row Uncasville, CT 93 Glenwood Road Clinton, CT 06413 September 12, 2019 www.euclidchemical.com19215 Redwood Road t Cleveland, OH 44110 800-321-7628 t t 216-531-9596 f The Euclid Chemical Company EUCON WR 91EUCON WR 91 Water Reducing, Set Retarding Admixture Description EUCON WR 91 is a liquid, water-reducing and set retarding admixture for concrete. EUCON WR 91 shows LPSURYHGVHWWLQJDQGÀQLVKLQJFKDUDFWHULVWLFVZKHQFRPSDUHGWRRWKHUFRPPRQO\XVHG$670&7\SH$ ZDWHUUHGXFHUV(8&21:5PD\EHXVHGDWDZLGHUDQJHRIGRVDJHUDWHV(8&21:5GRHVQRWFRQWDLQ calcium chloride or other potential corrosion-enhancing ingredients. Primary Applications )ODWZRUNFRQFUHWH *HQHUDOUHDG\PL[FRQFUHWH $UFKLWHFWXUDOFRQFUHWH 0DVVFRQFUHWH %ULGJHGHFNV +RWZHDWKHUFRQFUHWH Features/Benefits Plastic Concrete ,PSURYHVÀQLVKDELOLW\ ,PSURYHVZRUNDELOLW\ 5HGXFHVZDWHUUHTXLUHPHQW 5HGXFHVVHJUHJDWLRQ ,PSURYHVVHWWLQJWLPHV Hardened Concrete ,QFUHDVHVVWUHQJWKDWDOODJHV 5HGXFHVSHUPHDELOLW\ ,PSURYHVÀQLVKHGDSSHDUDQFH 5HGXFHVFUDFNLQJ ,QFUHDVHVGXUDELOLW\ 1RQVWDLQLQJ Technical Information &RPSDWLEOHZLWKDLUHQWUDLQLQJDJHQWV Perfomance Data 7KHIROORZLQJWHVWUHVXOWVZHUHDFKLHYHGXVLQJW\SLFDO$670&PL[GHVLJQUHTXLUHPHQWVOE\G3 NJP3FHPHQWFRQWHQWDQGVLPLODUDLUFRQWHQW 7KHVHUHVXOWVZHUHREWDLQHGXQGHUODERUDWRU\FRQGLWLRQVZLWKPDWHULDOVDQGPL[GHVLJQVPHHWLQJWKHVSHFLÀFDWLRQV RI$670&&KDQJHVLQPDWHULDOVDQGPL[GHVLJQVFDQDIIHFWWKHGRVDJHUHVSRQVHRI(8&21:5 Eucon WR 91 Compressive Strength Data (psi) 2100 2640 4120 2570 3480 4920 3100 3940 5560 0 1000 2000 3000 4000 5000 6000 7000 3 Day 7 Day 28 Day Reference 3 oz/cwt 10 oz/cwt Eucon WR 91 Set Time Results (hr:min) 5:06 5:12 6:47 0:00 1:12 2:24 3:36 4:48 6:00 7:12 8:24 Reference 3 oz/cwt 10 oz/cwt Master Format #:Water Reducers WARRANTY:7KH(XFOLG&KHPLFDO&RPSDQ\´(XFOLGµVROHO\DQGH[SUHVVO\ZDUUDQWVWKDWLWVSURGXFWVVKDOOEHIUHHIURPGHIHFWVLQPDWHULDOVDQGZRUNPDQVKLSIRURQH\HDUIURPWKHGDWHRISXUFKDVH8QOHVVDXWKRUL]HGLQZULWLQJE\DQRIÀ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·VLQVWDOODWLRQLQIRUPDWLRQRULQVWUXFWLRQVLQLWVSURGXFWOLWHUDWXUHRURQLWVSDFNDJLQJODEHOV$Q\LQVWDOODWLRQRI(XFOLGSURGXFWVZKLFKIDLOVWRFRQIRUPZLWKVXFKLQVWDOODWLRQLQIRUPDWLRQRULQVWUXFWLRQVVKDOOYRLGWKLVZDUUDQW\3URGXFWGHPRQVWUDWLRQVLIDQ\DUHGRQHIRULOOXVWUDWLYH SXUSRVHVRQO\DQGGRQRWFRQVWLWXWHDZDUUDQW\RUZDUUDQW\DOWHUDWLRQRIDQ\NLQG%X\HUVKDOOEHVROHO\UHVSRQVLEOHIRUGHWHUPLQLQJWKHVXLWDELOLW\RI(XFOLG·VSURGXFWVIRUWKH%X\HU·VLQWHQGHGSXUSRVHV Rev. 11.14 Precautions/Limitations &DUHVKRXOGEHWDNHQWRPDLQWDLQ(8&21:5DERYHIUHH]LQJKRZHYHUIUHH]LQJDQGVXEVHTXHQWWKDZLQJ ZLOOQRWKDUPWKHPDWHULDOLIWKRURXJKO\DJLWDWHG 1HYHUDJLWDWHZLWKDLU $GGWRPL[LQGHSHQGHQWRIRWKHUDGPL[WXUHV ,QDOOFDVHVFRQVXOWWKH6DIHW\'DWD6KHHWEHIRUHXVH Directions for Use Specifications/Compliances EUCON WR 91 meets or exceeds the requirements of: $670&7\SH$ ' $$6+720 $16,16)67' Shelf Life \HDULQRULJLQDOXQRSHQHGFRQWDLQHU Packaging (8&21:5LVSDFNDJHGLQEXONJDO/WRWHVJDO/GUXPVDQGJDO/SDLOV (8&21:5LVW\SLFDOO\XVHGDWGRVDJHVRIWRR]SHUOEVWRP/SHUNJRIFHPHQWLWLRXV PDWHULDO+LJKHUGRVDJHVDUHDFFHSWDEOHZLWKSULRUWHVWLQJDQGFRQÀUPDWLRQRIWKHGHVLUHGSHUIRUPDQFHZLWK VSHFLÀFPDWHULDOVEHLQJXVHG (8&21:5VKRXOGEHDGGHGWRWKHLQLWLDOEDWFKZDWHURIWKHFRQFUHWHPL[WXUH'RQRWGLVSHQVHRQWRGU\ cement. The Euclid Chemical Company www.euclidchemical.com19215 Redwood Road t Cleveland, OH 44110 800-321-7628 t t 216-531-9596 f EUCON AIR MIX 200EUCON AIR MIX 200 Concentrated Air Entraining Agent For Concrete Description EUCON AIR MIX 200LVDFRQFHQWUDWHGDTXHRXVVROXWLRQRIPRGLÀHGUHVLQVXVHGIRUSURSHUDLUFRQWUROXQGHUD ZLGHUDQJHRIWHPSHUDWXUHV(8&21$,50,;LVVSHFLÀFDOO\IRUPXODWHGIRUXVHDVDQDLUHQWUDLQLQJDGPL[WXUH IRUFRQFUHWHRIDOOW\SHVDQGLVPDQXIDFWXUHGXQGHUULJLGFRQWUROZKLFKDVVXUHVXQLIRUPDQGSUHFLVHSHUIRUPDQFH ,WLVFRPSDWLEOHZLWKFRQFUHWHPL[HVFRQWDLQLQJFDOFLXPFKORULGHZDWHUUHGXFLQJDGPL[WXUHVRUKLJKUDQJHZDWHU UHGXFLQJDGPL[WXUHV,WVKRXOGEHDGGHGWRWKHPL[LQGHSHQGHQWO\DQGQRWZLWKRWKHUDGPL[WXUHV Primary Applications 5HDG\PL[HGFRQFUHWH 6WUXFWXUDOFRQFUHWH 0DVVFRQFUHWHFRQVWUXFWLRQ 3DYLQJFRQFUHWH ([WHULRUFRQFUHWHZRUNH[SRVHGWRIUHH]HWKDZFRQGLWLRQV Features/Benefits 3URYLGHVDVWDEOHDLUYRLGV\VWHPZLWKSURSHUEXEEOHVL]HDQGVSDFLQJ7KLVDLUYRLGV\VWHPSURWHFWVFRQFUHWH DJDLQVWGDPDJHFDXVHGE\UHSHDWHGIUHH]HWKDZF\FOHV &RQFUHWHLVPDGHPRUHUHVLVWDQWWRGHLFLQJVDOWVDQGVXOIDWHDWWDFN /HVVPL[LQJZDWHUFDQEHXVHGSHU\DUGPHWHURIFRQFUHWHDQGSODFHDELOLW\LVLPSURYHG 0LQLPL]HVEOHHGLQJDQGVHJUHJDWLRQ Shelf Life \HDUVLQRULJLQDOXQRSHQHGSDFNDJH Specifications/Compliances (8&21$,50,;PHHWVRUH[FHHGVWKHUHTXLUHPHQWVRIWKHIROORZLQJVSHFLÀFDWLRQV $670& $$6+720 $16,16)67'UHJLVWHUHG Directions for Use (8&21$,50,;LVW\SLFDOO\GRVHGDWDUDWHRIWRR]SHUOEVWRP/SHUNJRIWRWDO FHPHQWLWLRXVPDWHULDOWRHQWUDLQDLUFRQWHQW7KHDPRXQWRI(8&21$,50,;ZLOOYDU\GHSHQGLQJ RQW\SHRIFHPHQWÀQHQHVVRIVDQGWHPSHUDWXUHGHVLJQRIWKHPL[RWKHUDGPL[WXUHVHWF&RQFUHWHPL[HVPXVW EHWHVWHGUHJXODUO\WRFRQÀUPWKDWSURSHUDLUFRQWHQWLVDFKLHYHG Precautions/Limitations &RQVXOW\RXUORFDO(XFOLG&KHPLFDOUHSUHVHQWDWLYHIRUWKHSURSHUGRVDJHUDWHDGMXVWPHQWVZKHQXVLQJÁ\DVK VODJRUKLJKUDQJHZDWHUUHGXFHUV ,IPDWHULDOKDVIUR]HQZDUPPDWHULDOWR)&DQGDJLWDWHIRUWRKRXUV $GGWRPL[LQGHSHQGHQWRIRWKHUDGPL[WXUHV ,QDOOFDVHVFRQVXOWWKH6DIHW\'DWD6KHHWEHIRUHXVHAir EntrainersMaster Format #: WARRANTY:7KH(XFOLG&KHPLFDO&RPSDQ\´(XFOLGµVROHO\DQGH[SUHVVO\ZDUUDQWVWKDWLWVSURGXFWVVKDOOEHIUHHIURPGHIHFWVLQPDWHULDOVDQGZRUNPDQVKLSIRURQH\HDUIURPWKHGDWHRISXUFKDVH8QOHVVDXWKRUL]HGLQZULWLQJE\DQRIÀ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·VLQVWDOODWLRQLQIRUPDWLRQRULQVWUXFWLRQVLQLWVSURGXFWOLWHUDWXUHRURQLWVSDFNDJLQJODEHOV$Q\LQVWDOODWLRQRI(XFOLGSURGXFWVZKLFKIDLOVWRFRQIRUPZLWKVXFKLQVWDOODWLRQLQIRUPDWLRQRULQVWUXFWLRQVVKDOOYRLGWKLVZDUUDQW\3URGXFWGHPRQVWUDWLRQVLIDQ\DUHGRQHIRULOOXVWUDWLYH SXUSRVHVRQO\DQGGRQRWFRQVWLWXWHDZDUUDQW\RUZDUUDQW\DOWHUDWLRQRIDQ\NLQG%X\HUVKDOOEHVROHO\UHVSRQVLEOHIRUGHWHUPLQLQJWKHVXLWDELOLW\RI(XFOLG·VSURGXFWVIRUWKH%X\HU·VLQWHQGHGSXUSRVHV Rev. 11.14 Date:11/15/2018 Location: Material: CT DOT ASTM Sieve Wt. Ret. % Retained Total % Ret. % Passing Form 817 C33 3/8" 0 0.00% 0.00% 100.00% 100% 100% #4 5 0.41% 0.41% 99.59% 95-100% 95-100% #8 163.8 13.53% 13.95% 86.05% 80-100% 80-100% #16 293.1 24.22% 38.16% 61.84% 50-85% 50-85% #30 296.6 24.50% 62.67% 37.33% 25-60% 25-60% #50 255.4 21.10% 83.77% 16.23% 10-30% 10-30% #100 122.8 10.15% 93.91% 6.09% 2-10% 2-10% #200 48.1 3.97% 97.88% 2.12% 0-3% Pan 25.6 2.12% 100.00% 0.00% Total 1210.4 F.M. 2.93 - 2.3 - 3.1 Tested By: Concrete Sand Brian-Glen P-5 A Sand Chemical Item Limit ¹ Result 6L2ೣ $Oೣ2೤ PD[ )Hೣ2೤ PD[ &D2 0J2 PD[ 62೤t PD[ /RVVRQ,JQLWLRQೖ PD[ ,QVROXEOH5HVLGXH PD[ &2ೣ &D&2೤LQ/LPHVWRQH PLQ 3RWHQWLDO3KDVH&RPSRVLWLRQVu &೤6 &ೣ6 &೤$ PD[ &೥$) &೤6&೤$ Physical Item Limit ¹ Result $LU&RQWHQW PD[ %ODLQH)LQHQHVVPtNJ PLQ $XWRFODYH([SDQVLRQ& PD[ &RPSUHVVLYH6WUHQJWK03DSVL GD\ PLQ GD\ PLQ GD\SUHYLRXVPRQWK VGDWD ,QLWLDO9LFDWPLQXWHV 0RUWDU%DU([SDQVLRQ& PD[ Test Data on ASTM Standard Requirements This cement meets the specifications of ASTM C150 and AASHTO M85 for Type I-II cement. Certification General Information The following is based on average test data during the test period. The data is typical of product shipped from this source; individual shipments may vary. Supplier: Address: 8700 West Bryn Mawr AveChicago, IL 60631 Holcim (US) Inc. d/b/a LafargeHolcim US Contact: Source Location: Contact: Test Data on ASTM Optional Requirements Physical Item Limit ¹ Result Chemical Item Limit ¹ Result (TXLYDOHQW$ONDOLHV Notes (*1-9) Additional Data Base Cement Phase Composition Result &೤6 &ೣ6 &೤$ &೥$) Ravena Plant Silo: C1-C16, B1-B6 P.O. Box 3Ravena, NY 12143 'DVKHVLQWKH/LPLW5HVXOWFROXPQVPHDQ1RW$SSOLFDEOH ,WLVSHUPLVVLEOHWRH[FHHGWKHVSHFLILFDWLRQOLPLWSURYLGHGWKDW$670&0RUWDU%DU([SDQVLRQGRHVQRWH[FHHGDWGD\V $GMXVWHGSHU$QQH[$RI$670&DQG$$6+720 /LPLW ZKHQOLPHVWRQHLVQRWDQLQJUHGLHQWLQWKHILQDOFHPHQWSURGXFW Scott Derhammer / (518) 756-5000 Item Limestone Inorganic Processing Addition $PRXQW 6L2ೣ $Oೣ2೤ )Hೣ2೤ &D2 62೤ Scott Derhammer, Quality ManagerVersion: 180412 Printed: 5/17/2019 3:16:08 PM Material Certification Report Type: Portland Cement I-II Test Period:01-Apr-2019 to 30-Apr-2019Material: Date Issued:17-May-2019 Synthetex 5550 Triangle Parkway, Suite 220, Peachtree Corners, GA 30092 www.synthetex.com HYDROTEX®GROUT BAGS Hydrotex®Grout Bags are formed by positioning specially woven, double-layer synthetic forms on the surface to be protected and filling them with a pumpable fine aggregate concrete (structural grout) in such a manner as to form a grout bag of required thickness, weight and configuration. The fabric forms can be placed and filled either underwater or in-the-dry. The high-strength, fine aggregate concrete is used in place of conventional concrete because of its pumpability, high-strength, impermeability, and absorption resistance. The fabric forms are HYDROTEX ®Grout Bag fabric manufactured by Synthetex, LLC; 5550 Triangle Parkway, Suite 220 Peachtree Corners, Georgia 30092; Tel: 800.253.0561 or 770.399.5051; E-Mail: info@synthetex.com or engineer approved equal. Grout Bags are custom sized to the dimensions required. Self-sealing filling valves, suitable for use with an injection pipe at the end of a pump hose for fine aggregate concrete, shall be installed at predetermined locations. Additional items such as tie-down straps, cut-outs around obstructions, internal reinforcing cables are optional and can be incorporated into a grout bag. All sewn seams are made using a double line of U.S. Federal Standard Type 401 stitch. All seams sewn are not less than 100 lbf/inch when tested in accordance with ASTM D 4884. Both lines of stitches are sewn simultaneously and parallel to each other, spaced between 0.25 inches to 0.75 inches apart. Each row of stitching consists of 4 to 7 stitches per inch. The fabric forms are composed of 100% polyester yarns formed into a woven fabric. Forms are woven with a minimum of 50% textured yarns (by weight). Partially-oriented (POY), draw-textured, and/or staple yarns are not used in the manufacture of the fabric. Each layer of fabric conforms to the physical, mechanical and hydraulic requirements Mean Average Roll Values listed in the table below. The fabric forms are free of defects or flaws which significantly affect their physical, mechanical, or hydraulic properties. PROPERTY REQUIREMENTS Test Method Units Values Physical Properties Mass Per Unit Area ASTM D 5261 oz/yd2 8 Thickness ASTM D 5199 Mils 32 Mechanical Properties Wide-Width Strip Tensile Strength - MD | TD ASTM D 4595 lbs/in 325 |500 Elongation at Break - MD |TD %12 |11 Grab Tensile Strength –MD | TD ASTM D 4632 lbs 350 | 370 Grab Tensile Elongation –MD | TD %35 | 35 Trapezoidal Tear Strength - MD | TD ASTM D 4533 lbs 150 |200 CBR Puncture Strength ASTM D 6241 lbs 1500 Hydraulic Properties Apparent Opening Size (AOS)ASTM D 4751 U.S. Standard Sieve 40 Permittivity ASTM D 4491 sec-1 0.28 Flow Rate gal/min/ft2 20 HYDROCAST fabric forms provide an effective forming system for casting large concrete armor units in place, underwater or in-the-dry. Fabric formed concrete armor units meet the requirements for a reliable and economi- cal cast-in-place alternative to heavy quarry stone (rip rap) or large precast concrete blocks. They are used for the construction and repair of erosion control structures such as breakwaters, dikes, seawalls, groins, and jetties as well as for foundation structures (such as underwater pipelines), footing supports, and other hydraulic and ma- rine structures. They are also extensively used by de- partments of transportation to prevent or repair scour at bridge piers and abutments. Figures 56, 57, 58, and 59 illustrate typical applications of fabric-formed armor units. When filled with a fine aggregate or conventional con- crete they form individual, cylindrical units that assume a flattened cross section, as demonstrated in figures 56 and 57. The concrete is pumped under pressure, result- ing in rapid concrete stiffening, improved concrete prop- erties [e.g., “case hardening” of the outer 3 to 6 inches (75 to 150 mm) of concrete], strength and durability. They have the required mass and stability to withstand the severe forces of large storm waves and rapidly flowing water. The concrete armor units may be placed side-by- side or stacked to form an inherently interlocked struc- ture. Since they are concrete filled in place, they can adapt to variations in the subgrade or bottom contours. Fabric-formed concrete armor unit installations do not require dewatering, a crucial advantage in emergency repair of bridge piers scoured by flood waters. Fabric forms can be positioned and filled with concrete from the surface in shallow water or by divers in deeper water. Unlike quarry stone or precast concrete blocks, they do not require placement by heavy cranes working from the land or from barges. The specially woven double-layer fabric is joined by a perimeter of interwoven and/or sewn seams to form a large fabric form envelope. Fabric used in the construc- tion of armor units shall conform to the physical proper- ties shown in Table 11.0. All sewn seams are folded and sewn with a double line of Type 401 double-lock stitches. The sewing thread used for seaming shall be nylon or polyester. Each fabric form is provided with one or more self-closing inlet valves to accommodate a concrete in- jection pipe. Fabric-formed concrete armor units may be cast in a wide range of sizes and shapes. Geostar’s technical staff ac- curately calculates the length, width and height of the concrete armor unit and the volume of concrete per mea- sure of unit length with the aid of computer programs. Tables 12.0 and 13.0 provide typical dimensions and vol- umes of fabric-formed concrete armor units, both filled and unfilled. HYDROCAST CONCRETE ARMOR UNITS (alternate length/width axis of placement) geotextile Reinforcement bar or dowel. Articulating Block (AB) Concrete Pad and Apron Fine Aggregate Concrete Backfill, if required Articulating Block Concrete Apron HYDROCAST Concrete Armor Units Bridge Pier Geotextile Articulating Block Concrete Cover and Apron HYDROCAST Concrete Armor Units Sand Backfill Underwater Pipeline Page 32 Synthetex cirbaFtinUromrATSACORDYH-stnemeriuqeRytreporP-0.11elbaT 2,1 ytreporPdohteMtseTstinUseulaV :lacisyhP snraYfonoitisopmoC retseylopronolyN )reyal-elbuod(aerAtinUrePssaM1625DMTSAdy/zo 2 m/g(2))074(41 ssenkcihT9915DMTSA)mm(slim)7.0(82 htdiWlliM )m(ni)29.1(67 :lacinahceM htgnertSelisneTpirtShtdiW-ediWssorC/enihcaM-5954DMTSA)m/Nk(ni/fbl)5.42(041/)2.33(091 kaerBtanoitagnolEssorC/enihcaM-5954DMTSA% 03/02 htgnertSraeTladiozeparTssorC/enihcaM-3354DMTSA)N(fbl)015(511/)008(081 :ciluardyH )SOA(eziSgninepOtnerappA1574DMTSA)mm(eveiSdradnatS.S.U)052.0(06 etaRwolF1944DMTSAtf/nim/lag 2 m/nim/l(2))5302(05 In addition to the wide range of standard rectangular fabric formed concrete armor units, Geostar’s designers can also design custom shaped forms to accommodate un- derwater pipelines, footers and other objects (Fig. 60). Notes: 1. Conformance of fabric to specification property requirements shall be based on ASTM D 4759, “Practice for Determining the Specification Conformance of Geotextiles.” 2. All numerical values represent minimum average roll values (i.e., average of test results from any sample roll in a lot shall meet or exceed the minimum values). Lots shall be sampled according to ASTM D 4354, “Practice for Sampling of Geosynthetics for Testing.” 3. Yarns used in fabric construction shall not contain partially oriented (POY), draw-textured, and or staple yarns. Fine Aggregate Concrete Backfill HYDROCAST Concrete Armor Units Reinforcement bar or dowel Reinforcement bar or staples Articulating Block Concrete Apron Geotextile Armor Unit Pipeline Page 33 Synthetex's BBBBBBBBBBBBBBBBBB elbbaT Note: Values shown are typical and will vary with weight of concrete and field conditions. The ordering of fabric forms should be done in advance of the start of the project, to allow time for the preparation, submittal and approval of layout and shop drawings. Project plans and specifications should be submitted to Geostar’s technical support department. Trained tech- nicians translate the site plans, grades, elevations, contours and con- struction details into CAD systems where they develop cost-effective take-offs and fabric-formed concrete armor unit layout drawings, tai- lored to the project’s design requirements. This design technique and CAD layout verification procedure will assure accurate dimensioning and quantity material takeoffs. The forms are over-dimensioned, in both length and width, to make allowance for form contraction as they are filled with fine aggregate concrete. Contraction factors are a function of site conditions and fin- ished armor unit dimensions. The definition of “contraction factor” is the length or width of fabric form required divided by the correspond- ing length or width of the area to be covered by the concrete armor Page 34 tinUromrAfohtgneL/htdiWdnassenkcihTdelliFothtgneL/htdiWmroFcirbaFdellifnU-0.21elbaT tinUromrAfohtgneL/htdiWdnassenkcihTdelliFothtgneL/htdiWmroFcirbaFdellifnU-0.21elbaT tinUromrAfohtgneL/htdiWdnassenkcihTdelliFothtgneL/htdiWmroFcirbaFdellifnU-0.21elbaT tinUromrAfohtgneL/htdiWdnassenkcihTdelliFothtgneL/htdiWmroFcirbaFdellifnU-0.21elbaT tinUromrAfohtgneL/htdiWdnassenkcihTdelliFothtgneL/htdiWmroFcirbaFdellifnU-0.21elbaT delliFdelliFdelliFdelliFdelliF ssenkcihTssenkcihTssenkcihTssenkcihTssenkcihT smroFcirbaFdellifnUfohtgneL/htdiWsmroFcirbaFdellifnUfohtgneL/htdiW smroFcirbaFdellifnUfohtgneL/htdiW smroFcirbaFdellifnUfohtgneL/htdiWsmroFcirbaFdellifnUfohtgneL/htdiW sehcnisehcnisehcnisehcnisehcni 42 03 63 24 84 45 06 66 27 87 48 09 69 201 801 411 021 sehcnI-smroFcirbaFdelliFfohtgneL/htdiWsehcnI-smroFcirbaFdelliFfohtgneL/htdiW sehcnI-smroFcirbaFdelliFfohtgneL/htdiW sehcnI-smroFcirbaFdelliFfohtgneL/htdiWsehcnI-smroFcirbaFdelliFfohtgneL/htdiW 66666 12 72 33 93 54 15 75 36 96 57 18 78 39 99 501 111 711 99999 91 52 13 73 34 94 55 16 76 37 97 58 19 79 301 901 511 2121212121 71 32 92 53 14 74 35 95 56 17 77 38 98 59 101 701 311 5151515151 12 72 33 93 54 15 75 36 96 57 18 78 39 99 501 111 8181818181 62 23 83 44 05 65 26 86 47 08 68 29 89 401 011 1212121212 03 63 24 84 45 06 66 27 87 48 09 69 201 801 4242424242 43 04 64 25 85 46 07 67 28 88 49 001 601 7272727272 93 54 15 75 36 96 57 18 78 39 99 501 0303030303 34 94 55 16 76 37 97 58 19 79 301 3333333333 74 35 95 56 17 77 38 98 59 101 6363636363 15 75 36 96 57 18 78 39 99 9393939393 65 26 86 47 08 68 29 89 2424242424 06 66 27 87 48 09 69 5454545454 46 07 67 28 88 49 8484848484 96 57 18 78 39 Synthetex Note: Values shown are typical and will vary with weight of concrete and field conditions. unit. An example contraction factor calculation is given on page 36 of this manual. Layout drawings showing the field assembly of the fabric form armor units for the entire project are prepared. The drawings identify each ar- mor unit, its location and sequence of installation, pertinent elevations and coordinates, direction of flow, anticipated water levels, and struc- tures such as roads, curbs, bridges, intake and discharge pipes, cul- verts, ramps and other existing and future structures that may effect the placement of the fabric-forme d armor units. A submittal package which includes shop and layout drawings, a list of numbered fabric forms, form dimensions and areas, and a manufacturer’s certification is assembled and forwarded to the contractor for submittal to the project engineer. Upon the project engineer’s approval of the sub- mittal package, Geostar’s manufacturing department commences fabric form fabrication and confirms the delivery schedule. Page 35 tinUromrAfoemuloVdelliFothtdiWmroFcirbaFdellifnU-0.31elbaT tinUromrAfoemuloVdelliFothtdiWmroFcirbaFdellifnU-0.31elbaT tinUromrAfoemuloVdelliFothtdiWmroFcirbaFdellifnU-0.31elbaT tinUromrAfoemuloVdelliFothtdiWmroFcirbaFdellifnU-0.31elbaT tinUromrAfoemuloVdelliFothtdiWmroFcirbaFdellifnU-0.31elbaT delliFdelliFdelliFdelliFdelliF ssenkcihTssenkcihTssenkcihTssenkcihTssenkcihT smroFcirbaFdellifnUfohtdiWsmroFcirbaFdellifnUfohtdiWsmroFcirbaFdellifnUfohtdiWsmroFcirbaFdellifnUfohtdiWsmroFcirbaFdellifnUfohtdiW sehcnisehcnisehcnisehcnisehcni 42 03 63 24 84 45 06 66 27 87 48 09 69 201 801 411 021 htgneLfotooFrepteeFcibuC-etercnoCfoemuloVhtgneLfotooFrepteeFcibuC-etercnoCfoemuloV htgneLfotooFrepteeFcibuC-etercnoCfoemuloV htgneLfotooFrepteeFcibuC-etercnoCfoemuloVhtgneLfotooFrepteeFcibuC-etercnoCfoemuloV 66666 8.0 1.1 3.1 6.1 8.1 1.2 3.2 6.2 8.2 1.3 3.3 6.3 8.3 1.4 3.4 4.4 7.4 99999 1.1 4.1 8.1 2.2 6.2 9.2 3.3 7.3 1.4 4.4 8.4 2.5 6.5 9.5 3.6 7.6 1.7 2121212121 2.1 7.1 2.2 7.2 2.3 7.3 2.4 7.4 2.5 7.5 5.6 7.6 2.7 7.7 2.8 7.8 2.9 5151515151 9.1 5.2 1.3 8.3 4.4 0.5 6.5 3.6 9.6 5.7 1.8 8.8 4.9 0.01 6.01 3.11 8181818181 7.2 5.3 2.4 0.5 7.5 5.6 2.7 0.8 7.8 5.9 2.01 0.11 7.11 5.21 2.31 1212121212 7.3 6.4 5.5 3.6 2.7 1.8 0.9 8.9 7.01 6.11 5.21 3.31 2.41 1.51 4242424242 9.4 9.5 9.6 9.7 9.8 9.9 9.01 9.11 9.21 9.31 9.41 9.51 9.61 7272727272 2.6 3.7 4.8 5.9 7.01 8.11 9.21 0.41 2.51 3.61 4.71 5.81 0303030303 6.7 8.8 1.01 3.11 6.21 8.31 1.51 3.61 6.71 8.81 1.02 3333333333 2.9 6.01 9.11 3.31 7.41 1.61 4.71 8.81 2.02 6.12 6363636363 9.01 4.21 9.31 4.51 9.61 4.81 9.91 4.12 9.22 9393939393 8.21 5.41 1.61 7.71 3.91 0.12 6.22 2.42 2424242424 9.41 6.61 4.81 1.02 9.12 6.32 4.52 5454545454 1.71 0.91 8.02 7.22 6.42 5.62 8484848484 4.91 4.12 4.32 4.52 4.72 Synthetex Contractor/manufacturer should submit layout drawings in accordance with this documentation for review. A submittal package in accordance with this documentation should be submitted. If field design/install is proposed, manufacturer should provide minimum specifications. Fabric forms are delivered at the job site in trailers or ocean containers. Fabric forms are stacked in a manner that as- sures ease of unloading. Standard 40 ft (12 m) long trailers or containers hold up to 215,000 ft2 (20,000 m2) of fabric forms per load. Armor unit fabric forms are normally shipped boxed. Alter- natively they may each be wrapped in two layers of protec- tive cover. The first layer (inner layer) is a waterproof, opaque, plastic cover the second (outer layer) is a woven, abrasion resistant, fabric cover. When fabric forms are to be inventoried at the job site, they should be kept dry and remain boxed so that they are pro- tected from the elements during storage and handling. If stored outdoors, they should be elevated and protected with a waterproof cover that is opaque to ultraviolet light. Care should be taken not to damage the fabric forms during un- loading, storage and handling. The definition drawing, Figure 61, illustrates the change in width that occurs when a fabric form is filled with concrete to form an armor unit. Table 12.0 is a guide in determining the required dimensions of an unfilled fabric form for cast- ing a given concrete armor unit size. Table 13.0 is a guide in determining the volume of concrete required to fill a fab- ric form of given dimensions. The dimensions and volumes are calculated from dimensional equation and may not re- flect field conditions. Equations for determining the filled width and length of HYDROCAST Fabric Forms: W = Wf + 0.57T L = Lf+ 0.57T Where: W = Width of unfilled fabric form Wf= Width of filled fabric form L = Length of unfilled fabric form Lf = Length of filled fabric form T = Thickness of filled fabric form Equations for determining the volume of concrete re- quired for filling HYDROCAST Fabric Forms: Vf = 0.785 T2 + T (Wf - T) Vt = (Vf)(Lf) Where: Vf = Volume of concrete per unit length of filled armor unit Vt = Total Volume of the filled armor unit Example Calculation: Determine the unfilled dimensions and filled volume for a 10 ft (3 m) long by 62 inches (1.57 m) wide by 18 inches (0.46 m) thick armor unit. From equations: W = Wf + 0.57T = 62 in + 0.57 x 18 in = 72 in (1.83 m) L = Lf + 0.57T = 10 in x 12in/ft + 0.57 x 18 in = 130 in or 11 ft V = Vf Lf = 7.3 ft2 x 10 ft = 73 ft3 or 2.7 yd3 ( 2.1 m3) From tables: From Table 12.0 - For a filled width of 62 in (1.57 m), with a thickness of 18 in (0.46 m) and a length of 10 ft (3 m), a fabric form 11 ft long by 72 in wide would be selected. From Table 13.0 - The volume of a 62 in (1.57 m) wide, by 18 in (0.46 m) thick and 10 ft (3 m) long fabric form would be approximately 72 ft3 or 2.7 yd3. R= 0.5T T Width (filled) Width (unfilled) Page 36 Because of the simple installation procedure for HYDROCAST Armor Units, a nominal amount of tools and equipment are required. We suggest that the contractor have on hand the following: Tools: Surveyor’s level and rod Shovels Rakes Hammers Stakes String line Rubber boots and gloves Pail Safety glasses or goggles Scissors Trowels Equipment: Small line concrete pump Concrete pump hose - 2 inch (50 mm) diameter Injection pipe - 2 inch (50 mm) diameter Hand-held sewing machine (electric or air powered) with speed control Extension cord (if electrical equipment is used) Electric generator with ground fault circuit breaker Air compressor (for air powered sewing machine) Small, walk-behind flat or vibratory compactor for soil compaction Once the area to be protected has been excavated, graded and compacted to the lines and grades specified in the Con- tract Drawings and Specifications, an installation crew, filter fabric (if required), fabric forms, and the tools and equipment listed above should be mobilized to the job site. Depending on the location of the area, dimensions, and the rate of subgrade preparation, installation rates of as much as 15 yd3 (11.5 m3) of fine aggregate concrete per hour can be achieved by a crew of 3 or 4 laborers, a concrete pump op- erator and a supervisor. Establish the starting point. The first step in the installation of fabric-formed concrete ar- mor units is to establish a starting point. If a working point and direction of placement are shown on the Contract Draw- ings this should be the starting point. If this is not the case, it is the customary practice for channels, streams and rivers to work from the upstream end of the project to the downstream end. In this manner the flow of the water will tend to spread Page 37 the fabric forms out ahead of the finished work and the finished concrete armor unit is protected from undercutting. For inland and coastal shorelines it is customary practice to install the first course of ar- mor units then proceed to succeeding courses. Establish the alignment lines Once a starting point has been established a surveyor’s level should be used to determine the lon- gitudinal and slope alignment lines of the fabric- formed concrete armor units. String lines should then be placed along the respective alignment lines and staked. Generally, the alignment lines are offset, by a measured distance, to the opposite side of any trench or a minimum of 5 feet (1.5 m) in order not to interfere with the work area. Placement of the filter fabric, if required Under certain soil conditions or if called for in the Contract Drawings and Specifications, it will be nec- essary to place filter fabric and/or a granular sublayer under the fabric forms to guarantee that soil is not piped through any spaces between the armor units. Filter fabric should be selected and placed in accor- dance with the Contract Drawings and Specifications or in the absence of such directions in accordance with the manufacturer’s guidelines. Placement of the first course of armor unit fab- ric forms The prefabricated armor unit forms are folded and marked with the appropriate form numbers and di- mensions at the factory for easy identification, loca- tion and installation. The first armor unit fabric form, in the first course, should be carefully placed at the designated starting point and unfolded into position (Fig 62). Special care should be taken to assure than the sides and ends of the form are exactly parallel to their respec- tive alignment lines. Armor unit fabric forms should be placed loosely, but without folds, to allow for proper filling with fine ag- gregate concrete. The extra fabric provided for form contraction should be extended, Forms that are stretched or taut will not permit the required form contraction, therefore the fabric forms will not fill to their required thicknesses. For example, a 72 inch by 120 inch (183 cm x 305 cm) form is to be filled to a thickness of 30 inches (76 cm). When filled with fine aggregate concrete to this thickness, the width and length of the form will contract by approximately 57% of the thickness, giving a finished armor unit dimension of 55 inches x 103 inches (139 cm x 261 cm). Adjacent armor units (of the same dimensions Alignment Line Surveyor’s Level Armor Unit form offset 5 ft. from alignment lines Page 38 used in this example) should therefore be placed with their centers 17 inches (43 cm) closer together than called for by the unfilled form dimensions. The second armor unit form in the first course should be placed alongside the first form so that the centerline to centerline distance equals that of the calculated armor unit width after contraction, as shown in Figure 63. After the second armor unit form has been positioned, the alignment of the forms should be checked. The remaining armor unit forms in the first course should be placed side-by-side in the same manner. The alignment of the forms should be checked peri- odically since small errors in alignment can progress in severity. Armor unit form alignment is important in providing a uniform and attractive appearance in the finished installation. Placement of the second course of armor unit fabric forms The second course of armor unit forms should be placed atop the fine aggregate concrete filled first course. (See Sequence of Fine Aggregate Concrete Pumping.) The center line of the first form in the sec- ond course is positioned directly over the abutting edges of the first two armor units in the first course, as shown in Figure 64. The staggering of the centerlines of the armor units in vertically adjacent courses encourages “nesting” of armor units and facilitates alignment. The remaining forms in the sec- ond course should be placed side-by-side in the same manner as the first course. Once again, check alignment periodically since small errors can progress in severity. When constructing structures subject to wave ac- tion, the armor units should be aligned with their long axis facing the principal direction of wave attack. Underwater placement of fabric-formed armor units may require the use of divers. The divers can pre- pare the finished grading, inspect the area to be pro- tected, and position and secure the filter fabric and fabric forms. The securing of the forms may require sand bags or weights. A small quantity of bulk (uncut and unassembled) form fabric should be ordered for each project. The fabric can be used for special field tailoring. At least one half a roll, about 900 ft2 (84 m2) of bulk fabric, is recommended. Centerline to centerline distance Second form overlaps first to compensate for narrowing during filling. Second course units are centered over the abutting edges of the units in the first course. CL dowel staple Page 39 Ordering fine aggregate concrete Fine aggregate concrete is generally delivered to the job site in ready-mix trucks. The order for concrete should be placed a least one day prior to its sched- uled delivery to the job site. The concrete supplier should be instructed to fill the water tank of each truck with mix water. In order to avoid presetting of the fine aggregate concrete it is recommended that the concrete be de- livered in loads of no more than 8 yd3 (6 m3). At a minimum, the first load of each day should be checked with a standard flow cone for consistency, in accordance with ASTM D 6449. Securing the armor unit forms Beginning at the designated staring point the instal- lation crew should check and adjust the armor unit forms to assure that they are in alignment. After the forms have been properly adjusted, fine aggregate concrete is pumped into forms. Inserting the fine aggregate concrete injection pipe Fine aggregate concrete should be pumped into the fabric form armor unit by inserting the injection pipe through a self-closing “pocket type” filling valve in the upper layer of the fabric. A tight seal is made when the injection pipe is inserted into the valve. When the pipe is withdrawn, the valve shuts. Filling the first fabric form armor unit with fine aggregate concrete Starting at the first fabric form armor unit, the injec- tion pipe should be inserted into the self closing fill- ing valve. The form should be filled by pumping fine aggregate concrete into the form. The fine aggre- gate concrete should fill the center and corners of the form, proceeding gradually to the specified ar- mor unit thickness. The injection pipe should then be moved to the adja- cent armor unit form and inserted into the filling valve. Once again, the previous pumping procedure should be repeated until this form has been filled to its speci- fied thickness. Armor Units may be joined to concrete backfill or to each other, vertically or horizontally, with standard reinforcing bars or dowels. Unfilled Bag Width = W 25 50 75 100 Permissible Fabric Stress (%) Bag Thickness = (T)* Filled Bag Width = Wf *Recommended maximum T is 0.5 W Page 40 Overpressuring of fabric forms Care must be taken when pumping fabric forms to assure that the fabric is not over pressurized. Over pressurization may cause bursting of seams. Please refer to Table 12.0 for recommended filling thick- nesses per width. See also Figure 65 for fabric stress at differing fill geometries. Connecting fine aggregate concrete armor units Armor units are easily joined by inserting steel rein- forcement bars, “dowels” or “staples” as suggested in Figures 66 and 67. When connecting vertically ad- jacent courses of armor units by inserting dowels, first force the pointed ends of the reinforcement bars through the fabric and into the fresh concrete of the filled armor units. Dowels or staples shall be inserted into the filled unit(s) not less than one half hour and not more than one hour after filling of the unit, un- less directed otherwise by the Engineer. The forms in the succeeding course are then threaded over the exposed reinforcement bar ends. The dowels are then forced through the bottom layer of the vertically adjacent fabric form (Fig. 68), and the form is then filled with fine aggregate concrete. Armor units may be connected side-by-side by in- serting staples; bend the reinforcement bars into an elongated “U” shape and force the pointed ends of the reinforcement bars through the fabric and into the fresh concrete of the filled armor units. The dow- els and staples assist in holding the forms in place during filling and maintaining the alignment of the armor unit structure. Abutting armor units, if placed laterally, may be installed immediately after place- ment of the preceding unit(s). If an armor unit is to bear on previously installed units, the lower units must be allotted a minimum of four hours of cure time before beginning installation of a succeeding, vertically adjacent course of armor units. Where required, reinforcement bar cages are in- stalled in the forms through openings in the forms. The form opening is closed before filling by means of a zipper or a portable sewing machine. Reinforce- ment bar cages are suspended by tie wires from the upper side of the form to assure centering. Circumferential straps may be attached to armor unit forms as thickness indicators to facilitate the filling of forms underwater. Slight depressions formed by the straps in the surface of the armor unit indicate to the diver, working by touch, that the form has been filled to the specified thickness. Circumferential straps of predetermined circumfer- ences and spacing, with or without external restrain- ing reinforcement bars, permit the casting of taper- ing or irregularly shaped armor units. joining dowel joining staple Page 41 Requirements for joining dowel size, location, and frequency should be specified. Filling remaining fabric form armor units with fine aggregate concrete If care has been taken in positioning the forms and in concrete filling the first course of armor unit forms, little, if any, adjustment of subsequent courses should be re- quired. However, form alignment should be checked pe- riodically since small errors in alignment can progress in severity. Periodically check the location of the forms with an instrument to assure that proper alignment is being maintained. Pipes, piles, culverts, trees, and other appurte- nances Armor unit forms should be tailored in the field to fit around pipes, culverts, trees, and other appurtenances. A form may be field cut and sewn or bulk fabric may be fabri- cated to fit snugly around the object. Backfilling and compaction of trenches The backfilling and compaction of open excavations should not begin until at least one hour after filling the adjacent concrete armor unit. Backfill material may be either select bedding materials or fine aggregate con- crete. The excavations should be backfilled as shown on the Contract Drawings. Foot traffic Foot traffic on the freshly pumped fine aggregate con- crete armor unit should be avoided for a period of not less than one hour after concrete injection or until the concrete is resistant to indentation. Should traffic be un- avoidable, the contractor should place board walks along the finished filled concrete areas. This will reduce the amount of objectionable indentation. Cleanup Any fine aggregate concrete that may spill on top of the fabric-formed concrete armor unit should be picked up by hand or trowel and the surface smoothed by cloth or broom. Such unnecessary spillage of concrete will cause an unsightly appearance. This is particularly important along the top of the final course of armor units. The freshly pumped fabric-formed concrete units should never be washed (sprayed) under pressure with water in an effort to clean or remove spills from its surface. A wet cloth should be used for clean up and spill removal. The cement film that impregnates the fabric forms pro- vides a bond between the fabric form and the concrete fill and a degree of protection against ultraviolet degra- dation of the fabric. Should this film be removed by wash- ing the uncured concrete armor units, cement may be also washed out from beneath the layer of fabric. The result would be a loss of concrete-to-fabric bond, a sandy, low strength outer surface of concrete and a concrete armor units which will exhibit low abrasion resistance and durability. Page 42 Information should be provided on the relation of the grout bags with the helical piles and caps, and whether the units will connected to or installed around the piles. Information on materials and methods for grouting the void spaces under the foundation should be provided and reviewed/approved by the structural engineer.