03 01 00.pdf

USACE / NAVFAC / AFCEC UFGS-03 01 00 (February 2018)

Preparing Activity: USACE Superseding UFGS-03 01 30.71 (April 2006) UFGS-03 01 30 (November 2009) UFGS-03 01 32 (November 2009)

UNIFIED FACILITIES GUIDE SPECIFICATIONS

References are in agreement with UMRL dated July 2025

SECTION TABLE OF CONTENTS

DIVISION 03 - CONCRETE

SECTION 03 01 00

REHABILITATION OF CONCRETE

02/18

PART 1 GENERAL

1.1 SCOPE

1.2 DEFINITIONS

1.2.1 Bracing

1.2.2 Delamination

1.2.3 Rehabilitation

1.2.4 Repair

1.2.5 Shoring

1.2.6 Termination Joint

1.2.7 Unsound Concrete

1.3 REFERENCES

1.4 SUBMITTALS

1.5 QUALITY ASSURANCE

1.5.1 General Requirements

1.5.2 Quality Control Plan

1.5.3 Qualifications

1.5.3.1 Testing Agencies

1.5.3.2 Quality Control Personnel

1.5.3.3 Contractor Qualifications

1.5.3.4 Worker Qualifications

1.5.3.5 Regulatory Requirements

1.5.4 Pre-Construction Conference

1.5.5 Work Plan

1.6 ACCEPTANCE OF REHABILITATION WORK

1.6.1 General Requirements

1.6.2 Tolerances

1.6.3 Appearance

1.7 PROTECTION OF COMPLETED REHABILITATION WORK

PART 2 PRODUCTS

2.1 MATERIALS FOR SHORING AND BRACING

SECTION 03 01 00 Page 1

2.1.1 Shoring and Bracing Systems

2.1.2 Design Requirements

2.2 EQUIPMENT FOR CONCRETE PREPARATION

2.2.1 Equipment for Concrete Removal

2.2.1.1 Cutting Equipment

2.2.1.2 Concrete Breakers

2.2.1.3 Hydromilling Equipment

2.2.2 Surface preparation and cleaning equipment

2.2.2.1 Abrasive Blasting

2.2.2.2 Low Pressure Water Cleaning

2.2.2.3 Other Cleaning Equipment

2.3 MATERIALS FOR FORMWORK AND EMBEDDED ITEMS

2.4 REINFORCEMENT AND REINFORCEMENT SUPPORTS

2.4.1 Steel Bars, Wires, and Fiber-reinforced Concrete

2.4.2 Fiber-Reinforced Polymers

2.5 CONVENTIONAL CONCRETE

2.6 POLYMERS

2.6.1 Epoxies

2.6.2 Latexes

2.6.3 Methacrylates

2.6.4 Other Polymers

2.6.5 Aggregate

2.7 MISCELLANEOUS MATERIALS AND EQUIPMENT

2.7.1 Packaged and proprietary materials

2.7.2 Bond Breakers

2.7.3 Structural steel

2.7.4 Concrete Accessories

2.7.5 Miscellaneous Equipment

2.8 MIXTURE PROPORTIONING

PART 3 EXECUTION

3.1 GENERAL REQUIREMENTS

3.1.1 Examination

3.1.2 Protection

3.1.3 Formwork and Shoring

3.1.3.1 Formwork

3.1.3.2 Shoring

3.1.4 Concrete preparation

3.1.5 Quality Control

3.1.5.1 Quality control of surface preparation

3.1.5.2 Quality control of repair overlays

3.1.6 Curing

3.1.7 Clean up

3.1.8 Safety

3.2 CRACK REPAIR

3.2.1 Preparation

3.2.1.1 General Requirements

3.2.1.2 Crack routing

3.2.1.3 Sealing

3.2.2 Application

3.2.2.1 Epoxy Injection

3.2.2.2 Gravity fill

3.2.3 Quality Control

3.2.4 Acceptance Criteria

3.2.4.1 Core Sampling

3.2.4.2 Core Testing

3.2.4.3 Acceptance

3.3 CORROSION AND SURFACE REPAIR

SECTION 03 01 00 Page 2

3.3.1 Preparation

3.3.1.1 Identification of Extent of Concrete Removal

3.3.1.2 Shoring and Formwork

3.3.1.3 Concrete Removal

3.3.1.4 Preparation of Concrete Substrate Surface

3.3.2 Application

3.3.2.1 Existing Reinforcement Preparation

3.3.2.2 Placement of New Reinforcement

3.3.2.3 Placement of Concrete

3.3.2.4 Placement of Other Repair Materials

3.3.3 Quality Control

3.4 OVERLAYS

3.4.1 Preparation

3.4.1.1 Bonded Overlays

3.4.1.2 Unbonded Overlays

3.4.2 Application

3.4.2.1 Portland Cement Concrete

3.4.2.2 Polymer-modified Portland Cement Concrete

3.4.2.3 Polymer Concrete/Mortar

3.4.2.4 Bonding Agents

3.4.3 Quality Control

3.4.4 Joints

3.5 CONCRETE STRENGTHENING

3.5.1 Preparation

3.5.2 Application

3.5.2.1 Section enlargement

3.5.2.2 Externally bonded systems

3.5.2.2.1 Steel Plates

3.5.2.2.2 Fiber-reinforced Polymer Laminates

3.5.3 Quality Control

-- End of Section Table of Contents --

SECTION 03 01 00 Page 3

USACE / NAVFAC / AFCEC UFGS-03 01 00 (February 2018)

Preparing Activity: USACE Superseding UFGS-03 01 30.71 (April 2006) UFGS-03 01 30 (November 2009) UFGS-03 01 32 (November 2009)

UNIFIED FACILITIES GUIDE SPECIFICATIONS

References are in agreement with UMRL dated July 2025

SECTION 03 01 00

REHABILITATION OF CONCRETE

02/18

NOTE: This guide specification covers the requirements for repair of portland cement concrete using epoxy resin grouts, mortars and concretes.

Adhere to UFC 1-300-02 Unified Facilities Guide Specifications (UFGS) Format Standard when editing this guide specification or preparing new project specification sections. Edit this guide specification for project specific requirements by adding, deleting, or revising text. For bracketed items, choose applicable item(s) or insert appropriate information.

Remove information and requirements not required in respective project, whether or not brackets are present.

Comments, suggestions and recommended changes for this guide specification are welcome and should be submitted as a Criteria Change Request (CCR) .

PART 1 GENERAL

1.1 SCOPE

This specification governs the rehabilitation of structural concrete.

1.2 DEFINITIONS

1.2.1 Bracing

Temporary supplemental members used to avoid local or global instability during construction, evaluation, or repair that are intended to be removed after completion of construction.

SECTION 03 01 00 Page 4

1.2.2 Delamination

A planar separation in a material that is roughly parallel to the surface of the material.

1.2.3 Rehabilitation

Repairing or modifying an existing structure to a desired useful condition.

1.2.4 Repair

The reconstruction or renewal of concrete parts of an existing structure for its maintenance or to correct deterioration, damage, or faulty construction of members or systems of a structure.

1.2.5 Shoring

Props or posts of timber or other material in compression used for the temporary support of excavations, formwork, or unsafe structures; the process of erecting shores.

1.2.6 Termination Joint

The interface where a placement of repair material meets existing concrete, the edge of an expansion joint, or other existing surfaces.

1.2.7 Unsound Concrete

Concrete that is fractured, delaminated, spalled, deteriorated, defective, contaminated or otherwise damaged.

1.3 REFERENCES

NOTE: This paragraph is used to list the publications cited in the text of the guide specification. The publications are referred to in the text by basic designation only and listed in this paragraph by organization, designation, date, and title.

Use the Reference Wizard's Check Reference feature when you add a Reference Identifier (RID) outside of the Section's Reference Article to automatically place the reference in the Reference Article. Also use the Reference Wizard's Check Reference feature to update the issue dates.

References not used in the text will automatically be deleted from this section of the project specification when you choose to reconcile references in the publish print process.

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

SECTION 03 01 00 Page 5

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS

(AASHTO)

AASHTO M 288 (2021) Standard Specification for Geosynthetic Specification for Highway Applications

AMERICAN CONCRETE INSTITUTE (ACI)

ACI 117 (2010; R 2015) Specifications for Tolerances for Concrete Construction and Materials and Commentary

ACI 440.5 (2008) Specification for Construction with Fiber-Reinforced Polymer Reinforcing Bars

ACI 440.6 (2008) Specification for Carbon and Glass Fiber-Reinforced Polymer Bar Materials for Concrete Reinforcement

ACI 440.8 (2013) Specification for Carbon and Glass Fiber-Reinforced Polymer (FRP) Materials Made by Wet Layup for External Strengthening of Concrete and Masonry Structures

ACI 503.2-503.4 (2010, R 2003) Three Epoxy Specifications

ACI 503.3 (2010) Specification for Producing a Skid-Resistant Surface on Concrete by the Use of Epoxy and Aggregate

ACI 503.7 (2007) Specification for Crack Repair by Epoxy Injection

ACI 548.4 (2011) Standard Specification for Latex-Modified Concrete (LMC) Overlays

ACI 548.8 (2007) Specification for Type EM (Epoxy Multi-Layer) Polymer Overlay for Bridge and Parking Garage Decks

ACI 548.9 (2008) Specification for Type ES (Epoxy Slurry) Polymer Overlay for Bridge and Parking Garage Decks

ACI 548.10 (2010) Specification for Type MMS (Methyl Methacrylate Slurry) Polymer Overlays for Bridge and Parking Garage Decks

ACI 548.12 (2012) Specification for Bonding Hardened Concrete and Steel to Hardened Concrete with an Epoxy Adhesive

AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE)

ASCE/SEI 37 (2015) Design Loads on Structures During Construction

SECTION 03 01 00 Page 6

ASTM INTERNATIONAL (ASTM)

ASTM A775/A775M (2022) Standard Specification for Epoxy-Coated Steel Reinforcing Bars

ASTM A780/A780M (2020) Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings

ASTM A934/A934M (2022) Standard Specification for Epoxy-Coated Prefabricated Steel Reinforcing Bars

ASTM C33/C33M (2024a) Standard Specification for Concrete Aggregates

ASTM C42/C42M (2020) Standard Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete

ASTM C387/C387M (2023) Standard Specification for Packaged, Dry, Combined Materials for Concrete and High Strength Mortar

ASTM C496/C496M (2017) Standard Test Method for Splitting Tensile Strength of Cylindrical Concrete Specimens

ASTM C881/C881M (2020a) Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete

ASTM C882/C882M (2024) Standard Test Method for Bond Strength of Bonding Systems Used With Concrete by Slant Shear

ASTM C928/C928M (2020a) Standard Specification for Packaged, Dry, Rapid-Hardening Cementitious Materials for Concrete Repairs

ASTM C1059/C1059M (2024) Standard Specification for Latex Agents for Bonding Fresh to Hardened Concrete

ASTM C1077 (2024) Standard Practice for Agencies Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Testing Agency Evaluation

ASTM C1438 (2013; R 2017) Standard Specification for Latex and Powder Polymer Modifiers for use in Hydraulic Cement Concrete and Mortar

ASTM C1583/C1583M (2013) Standard Test Method for Tensile Strength of Concrete Surfaces and the Bond Strength or Tensile Strength of Concrete Repair and Overlay Materials by Direct Tension (Pull-off Method)

SECTION 03 01 00 Page 7

ASTM C1600/C1600M (2017) Standard Specification for Rapid Hardening Hydraulic Cement

ASTM C1602/C1602M (2022) Standard Specification for Mixing Water Used in Production of Hydraulic Cement Concrete

ASTM D93 (2019) Standard Test Methods for Flash-Point by Pensky-Martens Closed Cup Tester

ASTM D226/D226M (2017) Standard Specification for Asphalt-Saturated Organic Felt Used in Roofing and Waterproofing

ASTM D323 (2015a) Vapor Pressure of Petroleum Products (Reid Method)

ASTM D450/D450M (2007; R 2018) Standard Specification for Coal-Tar Pitch Used in Roofing, Dampproofing, and Waterproofing

ASTM D542 (2014) Index of Refraction of Transparent Organic Plastics

ASTM D1078 (2011) Standard Test Method for Distillation Range of Volatile Organic Liquids

ASTM D2103 (2015) Standard Specification for Polyethylene Film and Sheeting

ASTM D2822/D2822M (2005; R 2011; E 2011) Standard Specification for Asphalt Roof Cement, Asbestos-Containing

ASTM D3418 (2015) Transition Temperatures of Polymers by Differential Scanning Calorimetry

ASTM D4016 (2014) Viscosity of Chemical Grouts by Brook field Viscometer (Laboratory Method)

ASTM D4580/D4580M (2012) Standard Practice for Measuring Delaminations in Concrete Bridge Decks by Sounding

ASTM D4869/D4869M (2016a) Standard Specification for Asphalt-Saturated Organic Felt Underlayment Used in Steep Slope Roofing

ASTM E329 (2023) Standard Specification for Agencies Engaged in Construction Inspection, Testing, or Special Inspection

INTERNATIONAL CONCRETE REPAIR INSTITUTE (ICRI)

ICRI 310.2R (2013) Selecting and Specifying Concrete Surface Preparation for Sealers, Coatings, Polymer Overlays, and Concrete Repair

SECTION 03 01 00 Page 8

1.4 SUBMITTALS

NOTE: Review submittal description (SD) definitions in Section 01 33 00 SUBMITTAL PROCEDURES and edit the following list, and corresponding submittal items in the text, to reflect only the submittals required for the project. The Guide Specification technical editors have classified those items that require Government approval, due to their complexity or criticality, with a "G." Generally, other submittal items can be reviewed by the Contractor's Quality Control System. Only add a “G” to an item, if the submittal is sufficiently important or complex in context of the project.

For Army projects, fill in the empty brackets following the "G" classification, with a code of up to three characters to indicate the approving authority. Codes for Army projects using the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO" for District Office (Engineering Division or other organization in the District Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project Office. Codes following the "G" typically are not used for Navy and Air Force projects.

The "S" classification indicates submittals required as proof of compliance for sustainability Guiding Principles Validation or Third Party Certification and as described in Section 01 33 00 SUBMITTAL

PROCEDURES.

Government approval is required for submittals with a "G" or "S" classification. Submittals not having a "G" or "S" classification are for Contractor Quality Control approval. Submittals not having a "G" or "S" classification are for information only. When used, a code following the "G" classification identifies the office that will review the submittal for the Government. Submit the following in accordance with Section

01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Qualifications ; G, [_____]

Work Plan ; G, [_____]

Quality Control Plan ; G, [_____]

SD-03 Product Data

Conventional Concrete

Polymers

Miscellaneous Materials And Equipment

SECTION 03 01 00 Page 9

SD-04 Samples

Reinforcement And Reinforcement Supports

[Polymers ]

[Miscellaneous Materials And Equipment]

SD-05 Design Data

Formwork And Shoring ; G, [_____]

Repair Procedures ; G, [_____]

Mixture Proportioning ; G, [_____]

SD-06 Test Reports

Mixture Proportioning

Quality Control

[Tolerence Report]

[Reinforcement And Reinforcement Supports]

[Conventional Concrete]

[Polymers]

[Miscellaneous Materials And Equipment]

SD-07 Certificates

Qualifications

Reinforcement And Reinforcement Supports

[Conventional Concrete]

[Polymers]

SD-08 Manufacturer's Instructions

[Equipment For Concrete Preparation]

[Conventional Concrete]

[Polymers]

[Miscellaneous Materials And Equipment]

1.5 QUALITY ASSURANCE

1.5.1 General Requirements

a. Follow the requirements of Section 03 30 00 CAST-IN-PLACE CONCRETE for Work involving portland cement concrete.

SECTION 03 01 00 Page 10

b. To protect personnel from overexposure to toxic materials, conform to the applicable manufacturer's Safety data sheets or local regulations.

Submit manufacturer's Safety Data Sheets for all polymers as well as other potentially hazardous materials.

c. Submit the repair procedures for executing the work as well as the test data and documentation on materials used for repair. Submittal must include component materials, mixture proportions, and supplier's quality control program.

d. Inspection and testing of surface preparation as well as placement of reinforcing steel must be in accordance with provisions included herein and the Contract Document.

e. Sampling and testing of materials, as well as inspection and testing of work, must be in accordance with established procedures, manufacturer's instructions, specific instructions from the Contracting Officer if given, or recommended practices as referenced herein and the Contract Documents.

f. Trial batches and testing requirements for various repair materials specified are the responsibility of the Contractor.

g. The testing agency must inspect, sample, and test repair materials and concrete production as required. When it appears that material furnished or work performed by Contractor fails to conform to Contract Documents the testing agency will immediately report such deficiency.

1.5.2 Quality Control Plan

Submit a quality control plan as specified in Sections 01 45 00 QUALITY CONTROL [and] [ 03 30 00 CAST-IN-PLACE CONCRETE].

1.5.3 Qualifications

The submittals must where applicable, identify agencies and individuals who will be working on this contract and their relevant experience. Do not make changes in approved agencies or personnel without prior approval of the Contracting Officer.

1.5.3.1 Testing Agencies

In addition to the requirements of Section 01 45 00 QUALITY CONTROL, agencies that test concrete materials must meet the requirements of ASTM C1077. Testing agencies that test or inspect placement of reinforcing steel must meet the requirement of ASTM E329. Submit data on qualifications of Contractor's proposed testing agency for acceptance.

1.5.3.2 Quality Control Personnel

Field tests of repair materials required must be made by an ICRI Concrete Surface Repair Technician Tier 2. Submit resumes, pertinent information, past experience, training and education of all operators of specialized demolition equipment if needed for this and the three paragraphs above.

1.5.3.3 Contractor Qualifications

The contractor performing the repair work must have been involved in a

SECTION 03 01 00 Page 11 minimum of [three][_____] concrete repair projects similar in size and scope to this project for at least [five][_____] years. Submit information, including name, dollar value, date, and point-of-contact for similar projects which demonstrates the required experience and/or training.

1.5.3.4 Worker Qualifications

a. Each worker engaged in the use of specialized removal or application equipment, including [saw operators] [milling machine operators,] [hydromilling equipment operators,] [epoxy injection] [_____], must have satisfactorily completed an instruction program and three years of experience in the operation of the equipment. [The worker must have active experience with the equipment within five years of the project.]

b. Workers installing adhesive anchors must be ACI Adhesive Anchor Installer certified or equivalent.

NOTE: Add worker qualification requirements for the usage of specialized equipment if needed. The instruction program for workers engaged in the use of grout injection equipment must have included theory on the nature and causes of cracking in concrete, the technical aspects of correct material selection and use, and the operation, maintenance, and troubleshooting of equipment used in the repair work.

1.5.3.5 Regulatory Requirements

Perform all work in accordance with applicable Federal, State, and local safety, health, and environmental requirements. The Contractor is responsible for obtaining all permits required by Federal, State, and local agencies for the performance of the work.

[ 1.5.4 Pre-Construction Conference

NOTE: Appropriate technical representatives for specialized repair materials should be required to meet with the Government and Contractor representatives to ensure that all parties involved are knowledgeable of the material properties and application requirements.

[Conduct a pre-construction conference to discuss repair materials performance requirements, control provisions, and roles and responsibilities for the Work to ensure that the Contractor's personnel understand all aspects of the repair material, its properties and application procedures. The conference must include the Contracting Officer or authorized representative, the Contractor's field superintendent and foreman, and a competent Technical Representative of the material manufacturer, and other involved trades or supplier representatives. The Technical Representative must be fully qualified to perform the work.]

SECTION 03 01 00 Page 12

] 1.5.5 Work Plan

Prepare a work plan describing the methods of concrete removal and repair, including methods, equipment and materials to be used for each feature.

Submit the work plan for approval at least 30 days prior to the start of the work. The plan must include, but not be limited to, repair materials to be used with specific information on products and/or constituents, and requirements for handling, storage, etc., equipment to be used, surface preparation, and requirements for placement, finishing, curing and protection specific to the materials used. Include a description of field demonstrations in the work plan. Do not commence work until the work plan and field demonstration representative of the type of work are approved.

1.6 ACCEPTANCE OF REHABILITATION WORK

1.6.1 General Requirements

a. Completed concrete rehabilitation work must conform to applicable requirements of Contract Document and this specification. The Contractor is responsible to bring Work into compliance with requirements of Contract Documents if the Concrete repair work fails to meet one or more requirements of Contract Documents.

b. Correct rejected repair work by removing and replacing or by strengthening with additional construction acceptable to the Contracting Officer. Use repair methods that meet applicable requirements for function, durability, dimensional tolerances, and appearance.

c. Submit proposed work plan , repair methods, materials, and modifications to the Work needed to correct rejected repair work to meet the requirements of Contract Documents.

1.6.2 Tolerances

a. Construction tolerances for repairs must conform to [ ACI 117 ][_____].

Where existing conditions do not allow tolerances to conform to [ ACI 117 ][_____], use the details and materials for such conditions as indicated in the Contract Documents. For conditions not shown or that are different than indicated in the Contract Documents, notify the Contracting Officer before proceeding with the work at those locations.[Provide a tolerence report as required by Section 03 30 00

CAST-IN-PLACE CONCRETE.]

b. Inaccurately formed concrete surfaces resulting in concrete members with dimensions that exceed [ ACI 117 ][_____] tolerances are subject to rejection.

1.6.3 Appearance

Concrete surfaces not meeting the requirements of the Contract Documents must be brought into compliance.

1.7 PROTECTION OF COMPLETED REHABILITATION WORK

a. Do not allow construction loads to exceed the loads that a structural member or structure is safely capable of supporting without damage.

Provide supplemental support if construction loads are expected to exceed safe load capacity.

SECTION 03 01 00 Page 13

b. Protect repaired and adjacent areas from damage by construction traffic, equipment, and materials. During the curing period, protect repair materials from damage by mechanical disturbances, including load-induced stresses, shock, and vibration.

c. Protect repair materials from environmental damage by weather events during the length of the curing period.

PART 2 PRODUCTS

NOTE: Unconventional products and materials could sometimes be the best solutions for repairs. Since the repair industry is evolving, products and materials not listed in this document that have had a record of success in the field could be allowed on a project. The Contracting Officer must permit the usage of those materials prior to application.

Additional submittals for those materials should also be requested as needed.

Products or materials used must conform to the requirements included herein as well as the Contract Documents. The usage of other products or materials not covered by this requirement or specified in the Contract Documents are permitted upon approval by the Contracting Officer.

Additional information and submittals for products and materials not included in this document including product data, samples, design data, test reports, certificates, manufacturer's instructions, and field reports must be submitted as requested by the Contracting Officer.

2.1 MATERIALS FOR SHORING AND BRACING

2.1.1 Shoring and Bracing Systems

Use commercially manufactured and engineered shoring and bracing systems and components, except where custom built assemblies of lumber or other suitable materials are permitted by the Contracting Officer.

2.1.2 Design Requirements

The design of the bracing and shoring must be based on ASCE/SEI 37 .

a. Non-manufactured shoring and bracing systems must have calculations signed and sealed by a Licensed Design Professional.

b. Members of non-manufactured shoring systems, must be designed in accordance with the provisions of the governing building code for the specific material of the member.

c. Members of manufactured shoring systems, consisting of pre-engineered components designed and produced specifically for structural shoring, must be used in accordance with the manufacturer's recommendations.

2.2 EQUIPMENT FOR CONCRETE PREPARATION

NOTE: Refer to ACI 546R and ICRI 310.2R for more

SECTION 03 01 00 Page 14 detail guidance on methods discussed in this paragraph.

Means and methods used for concrete removal and surface preparation must be selected and used such as to minimize damage to the structure and to the concrete substrate that remains.

2.2.1 Equipment for Concrete Removal

Removal equipment and techniques must be suitable to produce concrete surface profiles and level of cleanliness in designated areas as required by this specification and the contract Documents.

[ 2.2.1.1 Cutting Equipment

NOTE: Cutting equipment and methods are used to cut and remove concrete sections. Include this paragraph if cutting equipment and methods are required or permitted for concrete removal.

a. The following cutting equipment are permitted: [High-pressure water jet without abrasives][Saw cutting][Diamond wire cutting][Mechanical shearing][Stitch drilling][_____].

NOTE: Refer to ACI 546R for details on selecting the different equipment and methods for cutting concrete.

b. Cutting, lifting, and transporting equipment must be adequate to cut, support, and transport concrete sections without incurring any damage to the existing structure.

] 2.2.1.2 Concrete Breakers

NOTE: concrete breakers are also known as impact methods. These are the most commonly used methods for concrete removal.

a. Provide sharp tips on breaker equipment to minimize microcracking damage in partial depth removal.

NOTE: Sharp-pointed tools tend to reduce the potential for microcracking of the surface concrete left in place.

b. The use of the following impact equipment and methods is permitted:

[Hand-held breakers][Boom-mounted breakers][Scabblers][Needle scalers][Scarifiers][Milling methods][_____].

c. [The maximum breaker size is [_____]][_____].

SECTION 03 01 00 Page 15

NOTE: Use the information provided in this note and ACI 546R to select the suitable type and size of impact breakers allowed on the project (bullet point b and c). Note that you can include different types and sizes of breakers for a job and specify where each should be used. Using large breakers increases the potential for microcracking, and that is why a suitable size (or limits) should be specified.

Hand-held breakers (chipping hammers): size ranges from 8 to 90 lbs (3.5 to 41 kg). Smaller hand-held breakers are commonly used in partial depth removal of sound and unsound concrete and concrete removal around reinforcing steel because they minimize damage to the existing concrete and reinforcing steel. Larger breakers are used for removal of large volumes of concrete. For example, a 14 kg (30 lbs) breaker can be specified for removal of concrete above reinforcing steel while a smaller 7 kg (15 lbs) hammer can be specified to remove concrete around reinforcing steel.

Boom-mounted breakers: is like the hand-held breaker except that it is mechanically operated and considerably larger than a handheld breaker.

Boom-mounted breakers differ from hand-held breakers as they function on the principle of high energy and low frequency rather than low energy and high frequency, and are driven by compressed air or hydraulic pressure. The reach of the hydraulic arm enables the breaker to be used on vertical or overhead surfaces at a considerable distance above and below the machine level.

The boom-mounted breaker is a highly productive means of removing concrete; however, the high-cycle impact energy delivered to a structure by the breaker generates forces that may damage the existing concrete and reinforcing steel and adversely affect the integrity of the structure.

For boom-mounted breakers, limits specified are based on energy not weight (example 205 N-m or 150 ft-lbs).

Milling methods can remove a specified amount of concrete from large areas of horizontal or vertical surfaces. The removal depth typically ranges from 1/4 to 4 in. (6 to 100 mm). Removal depth is determined by the number and size of teeth. Milling operations typically leave a sound surface with fewer microfractures than impact methods.

Rotary head milling equipment is used for uniform depth removal on horizontal or vertical surfaces.

Boom-mounted milling head are used typically for vertical surfaces.

For information on Scabblers, Needle scalers, and Scarifiers refer to ACI 546R.

SECTION 03 01 00 Page 16

[ 2.2.1.3 Hydromilling Equipment

NOTE: Delete this paragraph if water blasting equipment is not allowed on the job. For more information on hydrodemolition refer to ACI 546R and

ICRI 310.3R.

a. Hydromilling equipment must include a trailer-mounted water tank, pumps, high-pressure hose, wand with safety release cutoff control, nozzle, and auxiliary water re-supply equipment. The water tank and auxiliary re-supply equipment must be of sufficient capacity to permit continuous operations.

b. Hydrodemolition for concrete removal is permitted in the following locations: [_____]

NOTE: Specify where (the locations) hydrodemolition is permitted to be used for concrete removal.

c. Use protective covers and barriers to protect adjacent surfaces not intended to be repaired from water blasting and over-spray.

d. Use equipment capable of delivering pressures of 35 MPa 5000 psi to 275 MPa 40,000 psi at 7.5 liters/min 2 gal/min to 190 liters/min 50 gal/min for concrete removal and surface preparation.

e. [Noise resulting from hydrodemolition operations must be at a noise level of less than [90 decibels][_____] at a distance of [ 15 m 50 ft.

NOTE: Hydrodemolition does not produce significant sound that is transmitted through a structure;

however, the noise from the hydrodemolition unit in the work area is sufficiently loud and may be objectionable to the public. If noise resulting from hydrodemolition operations need to be controlled, then add the above requirement and make changes to it as needed

] 2.2.2 Surface preparation and cleaning equipment

[ 2.2.2.1 Abrasive Blasting

a. Use [dry][wet][dry or wet] oil-free abrasive blasting capable of removing loose micro-fractured (bruised) or otherwise damaged or pulverized concrete surfaces, and rust from exposed steel reinforcement, and providing a surface profile in compliance with the Contract Documents.

NOTE: Choose if dry or wet abrasive blasting can be

SECTION 03 01 00 Page 17 used. Refer to ACI 546R for more information on the topic.

b. [Use the following abrasive blasting methods: [Sandblasting] [Shotblasting] [_____]]

NOTE: Add this requirement if methods of abrasive blasting need to be specified. This requirement can be expanded to include locations where certain methods of abrasive methods should be used. If this is needed, then specify the method along with the location that it should be used.

][ 2.2.2.2 Low Pressure Water Cleaning

Use equipment capable of delivering 7 MPa 1000 psi to 35 MPa to 5000 psi at

7.5 liters/min 2 gal/min to 38 liters/min 10 gal/min for cleaning loose material from repair areas.

] 2.2.2.3 Other Cleaning Equipment

Use equipment that delivers oil free air capable of cleaning loose material and debris from repair areas. If necessary to dry the concrete surface, [gas-fired torches or] clean, dry, compressed air may be used.

Also, use vacuums capable of removing loose material and debris.

2.3 MATERIALS FOR FORMWORK AND EMBEDDED ITEMS

a. Formwork and embedded items must meet the requirements specified in Section [ 03 30 00 CAST-IN-PLACE CONCRETE] [ 03 30 53 MISCELLANEOUS

CAST-IN-PLACE CONCRETE][_____].

NOTE: Formwork requirements for repairs are similar to requirements for new construction. Formwork should be designed to support repair material pressures as well as pressure resulting from placement and consolidation vibrations. Formwork should also be designed to maintain specified dimensional tolerances.

b. Install and remove formwork without damaging or staining the existing structure or repair material.

c. Forms used for polymer concrete/mortars must be tight enough to hold the material that is used without leaking. All surfaces where bond is not desired, but which are exposed to the monomer or resin, must be treated with a form release agent.

NOTE: Some polymers/resins/monomers have low viscosity and might require tighter forms than what is usually used for portland cement concrete.

SECTION 03 01 00 Page 18

2.4 REINFORCEMENT AND REINFORCEMENT SUPPORTS

2.4.1 Steel Bars, Wires, and Fiber-reinforced Concrete

a. Reinforcement and reinforcement support must meet the requirements specified in Section [ 03 30 00 CAST-IN-PLACE CONCRETE] [ 03 30 53

MISCELLANEOUS CAST-IN-PLACE CONCRETE][_____].

NOTE: Conventional reinforcement used for repairs is no different than reinforcement used for new construction.

b. Repair coating damage incurred during shipment, storage, handling, and placing of reinforcing bars in accordance with [the appropriate ASTM standard practices for repair of damaged reinforcement][ ASTM A780/A780M ][ ASTM A775/A775M ][ ASTM A934/A934M ][_____]. Damaged areas must not exceed 2 percent of surface area in each linear foot of each bar.

NOTE: Coated reinforcing bars often incur damage during transportation and handling. Coated reinforcing bars are used to mitigate corrosion and that is why it is important to ensure that they are not damaged and the cause of future localized corrosion failures.

ASTM has several documents that discuss practices for repair of damaged bars. ASTM A780/A780M discusses the repair Zinc-coated reinforcing bars, while ASTM A775/A775M and ASTM A934/A934M discuss practices for repair of epoxy-coated bars (See ASTM standards for other types of bar repairs). Specify a standard for repair of bars as needed in your project. If the statement "...in accordance with the appropriate ASTM standard practices for repair of damaged reinforcement" is selected, then it will be up to the Contractor to choose the ASTM standard for repair when multiple standards exist.

c. Mechanical splices for coated reinforcement must have compatible coatings, in accordance with manufacturer's instructions. Splices for galvanized reinforcement must be galvanized or coated with dielectric material. Splices used with epoxy-coated or dual-coated reinforcement must be coated with dielectric material.

d. Submit mill certificates and shop drawings as requirement by Section [

03 30 00 CAST-IN-PLACE CONCRETE] [ 03 30 53 MISCELLANEOUS CAST-IN-PLACE

CONCRETE][_____].

2.4.2 Fiber-Reinforced Polymers

NOTE: Fiber-Reinforced Polymers (FRP) include FRP bars and FRP laminates. FRP bars are used inside (and sometimes outside) the concrete to replace

SECTION 03 01 00 Page 19 conventional steel reinforcement. FRP laminates are attached outside concrete members mainly for strengthening purposes. For more information on FRP bars and laminates, refer to ACI 440 documents.

a. Fiber-Reinforced Polymers (FRP) bars used as internal reinforcement in concrete and their supports must meet the product requirements of ACI 440.5 and conform to [ ACI 440.6 ][_____].

NOTE: ACI 440.5 and ACI 440.6 are two ACI specifications related to the use of FRP bars in concrete. ACI 440.5 is a construction standard, while ACI 440.6 is a material standard. ACI 440.6 was written by an ACI committee as the basis of a future ASTM standard. If ACI 440.6 is withdrawn and adopted by ASTM, refer to the ASTM material standard instead of ACI 440.6.

b. Submit test reports and certificates for FRP bars as required by ACI 440.5 and the Contract Documents.

c. Fiber-Reinforced Polymer (FRP) laminate materials externally bonded to concrete made by wet layup must meet the requirements of ACI 440.8 and the Contract Documents. Submit product data sheets for materials used for FRP layup systems as described in ACI 440.8 .

d. The use of externally bonded FRP systems other than wet layup systems are permitted upon approval by the Contracting Officer. Submit product and materials data, design data, test reports, certificates, manufacturer's instructions, and field reports for those systems as requested by the Contracting Officer and required by Contract Documents.

NOTE: To learn more about commercially available externally bonded FRP systems refer to ACI 440.2R.

2.5 CONVENTIONAL CONCRETE

NOTE: Conventional concrete used for repairs has the same base requirements as concrete used for new construction.

Additional requirements to consider in material selection include:

- Good tensile bond, to have a strong bond between the repair and substrate.

- Modulus of elasticity similar to substrate.

- Low drying shrinkage so that the material does not lose volume over time.

- Matching coefficient of thermal expansion with the substrate by using similar coarse aggregate type.

Materials with different coefficients of thermal expansion will shrink/expand at different rates and cause cracking or spalling.

SECTION 03 01 00 Page 20

- Low creep so that the repair does not relax over time due to loads.

Note that these material requirements and properties should have been considered in the design phase.

Refer to ACI 546R, ACI 546.3R, and ICRI 320.2R. for more information the selection of materials for repair.

a. Portland cement concrete materials must meet the requirements specified in Section [ 03 30 00 CAST-IN-PLACE CONCRETE] [ 03 30 53

MISCELLANEOUS CAST-IN-PLACE CONCRETE][_____].

b. Materials for shotcrete must meet the requirements of Section 03 37 13

SHOTCRETE.

c. [For cement based bonding systems use neat portland cement or a blend of portland cement and an ASTM C33/C33M fine aggregate filler proportioned one to one by mass. The water-to-cement ratio of the bonding mixture must be [equal to the water-to-cement ratio of concrete used as a repair or overlay material][_____]. Water used must meet ASTM C1602/C1602M requirements.]

NOTE: If the use of cement based bonding agent is not permitted, delete this requirement. If it is permitted, then specify the water-to-cement ratio for that mixture.

d. [Use cementitious materials indicated in the Contract Documents.][Use cementitious materials of the same brand and type from the same manufacturing plant as the cementitious materials used in the concrete represented by the submitted field test records or used in trial mixtures.][_____]

NOTE: If information on cementitious materials is provided in the Contract Documents, then the first part of the requirement should be sufficient. If the information on cementitious materials is not provided, the second part of the requirement will require the use of materials that match the existing concrete (substrate).

Using similar cementitious materials is prescribed to have compatibility between the repair material and the existing substrate. The use of incompatible materials can cause deterioration at the interface between the existing and new concrete due to differential volume changes.

Note that this requirement is only applicable if the materials originally used for the substrate were adequate and not the cause of deterioration.

Material selection should have been considered in the design phase of the repair.

e. Aggregates used in concrete must be obtained from the same sources [,be of the same type][and have the same size range] as aggregates

SECTION 03 01 00 Page 21 used in the concrete represented by submitted historical data or used in trial mixtures.

NOTE: Like cementitious materials requirements, aggregates used for concrete need to be compatible with the existing concrete.

Only require the same size range of aggregate if it is appropriate for the repair. Remember that the maximum coarse aggregate size should not exceed three-fourths of the minimum clear spacing between reinforcing bars, one-fifth of the narrowest dimension between sides of forms, or one-third of the thickness of slabs, overlays, or partial depth repairs.

f. Refer to Section [ 03 30 00 CAST-IN-PLACE CONCRETE] [ 03 30 53 MISCELLANEOUS CAST-IN-PLACE CONCRETE][03 37 13 SHOTCRETE][_____] for details on submittals involving conventional concrete.

2.6 POLYMERS

NOTE: For more information on polymers and their use in repair, refer to ACI 503, 546, 548, RAP (Repair Application Procedures) documents and ICRI 320.2R.

When selecting polymers for repairs, select the material based on the desired properties. Some polymers like epoxies are well defined and standardized which makes specifying them much easier. Other materials like urethanes are not well standardized for usage in construction. These should only be specified after reviewing information obtained from the material manufacturer and comparing that to the desired properties needed for the repair.

Some of the properties to consider when specifying these materials are: working time of the material, curing times and requirements, viscosity and the ability to penetrate cracks, resistance to temperature changes, sensitivity to light (UV rays) and other exposures, thickness of material required, strength, flexibility and rigidity, and compatibility with other materials.

a. The requirements for the properties of polymers and aggregates used in polymers must meet the requirements specified in this paragraph as well as the properties specified in the referenced specifications and the Contract Documents.

b. Polymers used must be compatible with other polymers and materials used on the project. Unless repair materials are specified in the

SECTION 03 01 00 Page 22 contract documents, the Contractor is responsible for verifying material compatibilities.

NOTE: Material compatibility is vital in repairs.

Make sure that you specify materials that will work well together and work well with concrete.

c. Submit product data, manufacturer's Safety Data Sheets,samples, design data, test reports, certificates, manufacturer's instructions, and field reports for materials as required by this document as well as the referenced specifications and the Contract Documents.

2.6.1 Epoxies

NOTE: Epoxy mortars and concrete do not have thermal characteristics compatible with portland cement concrete. This thermal incompatibility should be carefully considered before specifying epoxy mortar or concrete for exterior concrete surface repairs.

For example, when used to repair cracks, limit their use to cracks ranging from 0.002 to 0.25 in. (0.05 to 6 mm) wide; a thicker cross section of the epoxy in a crack exposed to large temperature variations can cause internal stresses in the repaired concrete. Moreover, epoxy should not be used to repair active cracks (still moving) because cracks parallel to the original cracks are likely to occur.

For more information on epoxies and crack repair refer to ACO 546R, ACI 546.3R, and ACI 548.1R.

a. Epoxy mortars and epoxy compounds must conform to ASTM C881/C881M [.][,Type [_____]; Class [_____]; Grade [_____]; [_____].]

b. Epoxy mortars used for repairing defects in hardened portland cement concrete must meet the requirements of ACI 503.2-503.4 .

c. Epoxy used for crack repair must meet the requirements of ACI 503.7 .

NOTE: Epoxy is one of the main polymer materials used for crack repairs. Crack repair are usually either for structural purposes (strength related) or for sealing cracks (stop water and other materials from passing through). Because of their bond strength, epoxies are the main materials used for structural crack repairs. They should however not be used with active cracks. Refer to ACI 546R and 546.3R for more details.

Also, note that ASTM C881/C881M, Type IV, Grade 1 is good for repairing crack sizes from 0.005 to 0.010

in. (0.13 to 0.25 mm). Smaller cracks may not need

SECTION 03 01 00 Page 23 repair. For larger cracks, a more viscous epoxy may be appropriate (ACI RAP 1 and ACI 503.7).

d. Epoxy used to produce a skid-resistant surface on hardened concrete must meet the requirements of ACI 503.3 .

e. Epoxy used for overlays must meet the requirements of [ ACI 548.8 ][

ACI 548.9 ].

NOTE: ACI 548.8 covers Epoxy multi-layer overlays while ACI 548.9 covers epoxy slurry overlays (for Bridge and Parking Garage Decks). Refer to those documents for more details.

f. Epoxy used for bonding freshly mixed concrete and hardened concrete must meet the requirements of ASTM C881/C881M, Type [II][V], Grade [2][3], Class [A][B][C].

NOTE: Type II adhesives are used in non-load-bearing applications, whereas Type V are for load-bearing uses. Grade 1 materials are low viscosity (not to be used for this application).

Grade 2 materials are medium viscosity. Grade 3 materials have a non-sagging consistency. Class A materials are used when temperatures are below 40°F (4°C), Class B materials are used when temperatures are typically between 40 and 60°F (4 and 16°C), and Class C materials are used when temperatures are above 60°F (16°C) with upper limits set by the manufacturer.

Refer to ASTM C881/C881M for more information about types, grades, and classes of epoxies.

Refer to ACI 548.11R for more information about epoxy used as bonding agent.

g. Epoxy used for bonding hardened concrete and steel to hardened concrete must meet the requirements of ACI 548.12 .

2.6.2 Latexes

a. Latex used in polymer modified portland cement concrete/mortar must meet the requirements of ASTM C1438.

b. Latex used in polymer modified portland cement concrete overlays must meet the requirements of ACI 548.4 .

c. Latex used for bonding freshly mixed concrete and hardened concrete must meet the requirements of ASTM C1059/C1059M , Type II.

NOTE: Refer to ASTM C1059 for more information

SECTION 03 01 00 Page 24 about latex used as bonding agent. Also, refer to ACI 548.12 for information about use and application of this material.

2.6.3 Methacrylates

NOTE: Per ACI 546R, methacrylates have high adhesive strength and can bond cracks as a structural repair. Methacrylates can therefore be used to restore strength (like epoxies) to a structural as well as for sealing cracks.

a. Methyl methacrylate slurry (MMS) used for overlays must meet the requirements of ACI 548.10 .

b. High molecular weight methacrylate (HMWM) must be a 2-component, rapid curing, and solvent-free system.

c. HMWM monomers must be a high molecular weight or substituted methacrylate that conforms the following properties:

d.

Physical Properties of HMWM Monomer

Property Test Method Criteria

Vapor Pressure Flash Point Density

ASTM D323

ASTM D93

Less than 133 Pa at 25 degrees C Greater than 93 degrees C Greater than 1.0 g per cubic cm at 25 degrees C Less than 0.02 psi at 77 degrees F Greater than 200 degrees F Greater than 8.4 lbs. per gal. at 77 degrees F

Viscosity Index of Refraction Boiling point @ 133 Pa 0.02 psi Shrinkage on cure

ASTM D4016

ASTM D542

ASTM D1078

0.012 + 0.004 Pas at 23 degrees C;

1.470 + 0.002 70 degrees C Less than 11 percent 12 + 4 cps at 73 degrees F

1.470 + 0.002 158 degrees F Less than 11 percent

Glass Transition Temperature (DSC)

ASTM D3418 57.2 degrees C 158 degrees F

Curing Time (100 g mass)

ASTM D3418 Greater than 40 minutes at 25 degrees C, with 4 percent cuemene hydroperoxide Greater than 40 minutes at 73 degrees F, with 4 percent cuemene hydroperoxide

SECTION 03 01 00 Page 25

Physical Properties of HMWM Monomer

Bond Strength ASTM C882/C882M Greater than 10.3 mPa Greater than 1,500 psi

e. The initiator/promoter system for HMWM must be capable of providing a surface cure time of not less than 40 minutes nor more than 3 hours at the surface temperature of the concrete during application. The initiator/promoter system must be such that the gel time may be adjusted to compensate for changes in temperature that may occur throughout the treatment application.

f. The initiator/promoter system for HMWM must meet the following criteria:

(1)

Initiator Cuemene Hydroperoxide 78 percent

Promoter Cobalt Napthenate 6 percent

[ 2.6.4 Other Polymers

NOTE: There are many types of polymers that could be used for concrete repair. Some of them however can vary a lot in properties and are not well defined or standardized in the construction industry. These materials should only be used after understanding their properties. Refer to ACI 546R and 546.3R for more information.

Note that not all polymers have similar properties and thus are usage specific. For example, while a polyurethane grout could be used to seal cracks, it will not restore structural strength like epoxies or methacrylates do. The polyurethane however could be a better choice than an epoxy if a crack is active and the only reason for using the polyurethane is to seal cracks and stop water from going through.

The use of [urethanes][silicones][acrylics][_____] is permitted.

NOTE: Choose the types of polymers (other than epoxies, latexes, and methacrylates) that can be used on your project. You could also add to this the locations where those materials could be used and where they should not.

Submit [product data], [samples], [design data], [test reports], [certificates], [manufacturer's instructions] for acceptance by the Contracting Officer.

SECTION 03 01 00 Page 26

NOTE: Based on the materials being specified, specify the submittals required by the Contractor.

] 2.6.5 Aggregate

a. Unless otherwise specified or recommended by the polymer material manufacturer, aggregate used with polymers must meet ASTM C33/C33M requirements.

b. Aggregate properties and proportions used with polymers must meet the requirements of the polymer material manufacturer, the requirements of the referenced polymer standard, and the Contract Documents.

c. Aggregate used with polymers must be dry and free of dirt, asphalt, and other organic materials. Aggregate moisture content must be less than [0.2][1][_____] percent by weight.

NOTE: If a specific moisture content for aggregate is required, add this requirement in c. ACI 548.1R recommends a moisture content of less than 1 percent for use with polymers. Note that some referenced standards do have limits specified.

d. For patch repairs, the maximum-sized aggregate must not be greater than one third the depth of the patch…