09672340 RES 4.docx

01-01-21

SECTION 09 67 23.40

Resinous Poured in place resilient flooring (RES-4)

GENERAL

1.1 DESCRIPTION

This section specifies resinous, poured in place resilient urethane flooring with integral cove base:

Res-4 specifically designed for sterile fields and clean room type spaces.

1.2 SUBMITTALS

Submit in accordance with Section 01 33 23, SHOP DRAWINGS, PRODUCT DATA, AND SAMPLES.

Manufacturer's Literature and Data:

Description of each product to be provided.

Application and installation instructions.

Maintenance Instructions: Submit manufacturer’s written instructions for recommended maintenance practices.

Qualification Data: For Installer.

Sustainable Submittal:

Product data for products having recycled content, submit documentation indicating percentages by weight of post-consumer and pre-consumer recycled content.

Include statements indicating costs for each product having recycled content.

Product data for field applied, interior, paints, coatings, and primers, include printed statement of VOC content indicating compliance with environmental requirements.

Samples:

Each color and texture specified in Section 09 06 00, SCHEDULE FOR FINISHES.

Samples for verification: For each (color and texture) resinous flooring system required, 6 inches (152 mm) square, applied to a rigid backing by installer for this project.

Sample showing construction from substrate to finish surface in thickness specified and color and texture of finished surfaces. Finished flooring must match the approved samples in color and texture.

Shop Drawings: Include plans, sections, component details, and attachment to other trades. Indicate layout of the following:

Patterns.

Edge configuration Certifications and Approvals:

Manufacturer's certification of material and substrate compliance with specification.

Manufacturer's approval of installer Contractor's certificate of compliance with Quality Assurance requirements.

Warranty: As specified in this section.

1.3 QUALITY ASSURANCE

Manufacture Certificate: Manufacture shall certify that a particular resinous flooring system has been manufactured and in use for a minimum of five (5) years.

Installer Qualifications: Engage an experienced installer (applicator) who is experienced in applying resinous flooring systems similar in material, design, and extent to those indicated for this project for a minimum period of five (5) years, whose work has resulted in applications with a record of successful in-service performance, and who is acceptable to resinous flooring manufacturer.

Engage an installer who is certified in writing by resinous flooring manufacturer as qualified to apply resinous flooring systems indicated.

Contractor shall have completed at least ten (10) projects of similar size and complexity. Include list of at least five (5) projects. List must include owner (purchaser); address of installation, contact information at installation project site; and date of installation.

Installer's Personnel: Employ persons trained for application of specified product.

Source Limitations:

Obtain primary resinous flooring materials including primers, resins, hardening agents, grouting coats and finish or sealing coats from a single manufacturer.

Provide secondary materials, including patching and fill material, joint sealant, and repair material of type and from source recommended by manufacturer of primary materials.

Pre-Installation Conference:

Convene a meeting not less than thirty days prior to starting work.

Attendance:

Contractor

VA COR

Manufacturer and Installer's Representative Review the following:

Environmental requirements Air and surface temperature Relative humidity Ventilation Dust and contaminates Protection of surfaces not scheduled to be coated Inspect and discus condition of substrate and other preparatory work performed Review and verify availability of material; installer’s personnel, equipment needed Design and patter and edge conditions.

Performance of the coating with chemicals anticipated in the area receiving the resinous (urethane and epoxy mortar/cement) flooring system Application and repair Field quality control Cleaning Protection of coating systems One-year inspection and maintenance Coordination with other work Manufacturer’s Field Services: Manufacturer’s representative shall provide technical assistance and guidance for surface preparation and application of resinous flooring systems.

Contractor Job Site Log: Contractor shall document daily; the work accomplished environmental conditions and any other condition event significant to the long term performance of the urethane and epoxy mortar/cement flooring materials installation. The Contractor shall maintain these records for one year after Substantial Completion.

1.4 MATERIAL PACKAGING DELIVERY AND STORAGE

Deliver materials to the site in original sealed packages or containers, clearly marked with the manufacturer's name or brand, type and color, production run number and date of manufacture.

Protect materials from damage and contamination in storage or delivery, including moisture, heat, cold, direct sunlight, etc.

Maintain temperature of storage area between 60 and 80 degrees F (15 and 26 degrees C).

Keep containers sealed until ready for use.

Do not use materials beyond manufacturer’s shelf life limits.

Package materials in factory pre-weighed and in single, easy to manage batches sized for ease of handling and mixing proportions from entire package or packages. No On site weighing or volumetric measurements are allowed.

1.5 PROJECT CONDITIONS

Environmental Limitations: Comply with resinous flooring manufacturer's written instructions for substrate temperature, ambient temperature, moisture, ventilation, and other conditions affecting resinous flooring application.

Maintain material and substrate temperature between 65 and 85 degrees F (18 and 30 deg C) during resinous flooring application and for not less than 24 hours after application.

Concrete substrate shall be properly cured per referenced section 03 30 00, CAST-IN-PLACE CONCRETE. Standard cure time a minimum of 30 days. A vapor barrier must be present for concrete subfloors on or below grade.

Resinous flooring applications where moisture testing resulting in readings exceeding limits as defined in this specification under part 3, section 3.4, paragraph B, shall employ an multiple component 15 mil thick system designed to suppress excess moisture in concrete.

Application at a minimum thickness of 15 mils, over properly prepared concrete substrate as defined in section 3.4.

Moisture suppression system must meet the design standards as follows:

Tensile Strength

Volatile Organic Compound Limits (V.O.C.)

Lighting: Provide permanent lighting or, if permanent lighting is not in place, simulate permanent lighting conditions during resinous flooring application.

Close spaces to traffic during resinous flooring application and for not less than 24 hours after application, unless manufacturer recommends a longer period.

1.6 WARRANTY

Warranty: Manufacture shall furnish a single, written warranty covering the full assembly (including substrata) for both material and workmanship for a extended period of three (3) full years from date of installation, or provide a joint and several warranty signed on a single document by manufacturer and applicator jointly and severally warranting the materials and workmanship for a period of three (3) full years from date of installation. A sample warranty letter must be included with bid package or bid may be disqualified.

1.7 APPLICABLE PUBLICATIONS

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

ASTM Standard C722-04 (2012), "Standard Specification for Chemical-Resistant Monolithic Floor Surfacings," ASTM International, West Conshohocken, PA, 2006, DOI: 10.1520/C0722-04R12, www.astm.org.

Specification covers the requirements for aggregate-filled, resin-based, monolithic surfacings for use over concrete.

ASTM International(ASTM):

PRODUCTS

1.8 SYSTEM DESCRIPTION FOR RES-4 (poured in place resilient)

System Descriptions:

Monolithic, multi-component urethane chemistry resinous flooring system. Multi step concrete sealing primer with resilient poured in place urethane resin base, optional decorative aggregates, High performance polyaspartic undercoats (pigment and clear options), and High performance polyurethane low VOC sealers.

Products: Subject to compliance with applicable fire, health, environmental, and safety requirements for storage, handling, installation, and clean up.

System Components: Verify specific requirements as systems vary by manufacturer. Verify build up layers and installation method. Verify compatibility with substrate. Use manufacturer’s standard components, compatible with each other and as follows:

Primers:

Resin: epoxy or urethane.

Formulation Description: Multiple component high solids.

Application Method: squeegee, backroll, double step second coat with squeegee application.

Thickness of coat(s): 4-6mil.

Number of Coats: Two wet on wet.

Mortar (Base):

Resin: Urethane.

Formulation Description: Multiple component resilient mortar.

Application Method: Rake and spike roll.

Thickness of coat: Verify thickness as systems vary by manufacturer; approximately from 1/8 to 3/16 inch (3 to 5 mm).

Aggregate: Optional aggregates to achieve aesthetics, and design requirements.

Requires additional sanding steps.

Undercoat:

Resin: Poly-aspartic Urethane.

Formulation Description: Pigmented, or clear options, multi-component, high solids.

Application Method: Notched squeegee and Back roll Number of Coats: One or two per requirements.

Number of Coats: One.

Sealer coat:

Resin: Urethane.

Formulation Description: High performance polyurethane low VOC sealer.

Type/Finish: Clear flat.

Thickness of coat(s): 2-3mil.

Number of Coats: (2) two.

Application: Squeegee and finish roll.

System Characteristics:

Color and Pattern: As selected by COR from manufacturer's standard colors.

Integral cove base: 1 inch (25.4 mm) radius epoxy mortar cove keyed into concrete substrate and or resinous flooring mortar system. No fillers integral cove base must be troweled in place with specified resinous mortar base.

Overall System Thickness: Nominal 1/8 to 3/16 inches (3 to 5 mm).

Flooring systems used in sterile fields, operating suites, procedure rooms, or clean room spaces must comply with resistance to VHP processes, and exhibit Betadyne staining resistance. Written published documentation of compliance is to be submitted during bid process. Failure to submit will result in disqualification of bid. Temperature Range: Systems vary by manufacturer; approximate range from a minimum of 45 to 150 degrees F.

Physical Properties:

Physical Properties of flooring system when tested as follows:

Or equal to

0.14 % thickness (140 lb./64kg.load)

(125lb./57kg. load) Or equal to 0.001in./0.025mm (250lb./113kg.load)

Chemical Resistance in accordance ASTM D1308 - 02(2007) “Standard Test Method for Effect of Household Chemicals on Clear and Pigmented Organic Finishes”. ASTM International, West Conshohocken, PA, 2006, DOI: 10.1520/D1308-02R07, www.astm.org. No effect to the following exposures:

Acetic acid (5 percent) Ammonium hydroxide (10 percent) Citric Acid (50 percent) Fatty Acid Motor Oil, 20W Hydrochloric acid (20 percent) Sodium Chloride Sodium Hypochlorite (10 percent) Sodium Hydroxide (30 percent) Sulfuric acid (25 percent) Urine, Feces Hydrogen peroxide (10 percent)

1.9 SUPPLEMENTAL MATERIALS

Textured Top Coat: Type recommended or produced by manufacturer of seamless resinous flooring system, type and profile of for desired final finish.

Joint Sealant: Type recommended or produced by resinous flooring manufacturer for type of service or joint conditioned indicated.

Waterproof Membrane: Type recommended or produced by manufacturer of resinous floor coatings for type of service and conditions

Crack Isolation Membrane: Type recommended or produced by manufacturer of resinous flooring for conditions Anti-Microbial Additive: Incorporate anti-microbial chemical additive to prevent growth of most bacteria, algae, fungi, mold, mildew, yeast, etc.

Patching and Fill Material: Resinous product of or approved by resinous coating manufacturer for application indicated. Resinous based materials only. Cementitous or single component product are not expectable

1.10 BASE CAP STRIP

Zinc cove strip.

Shape for 2mm depth of base material, "J" or “L” configuration.

Finish:

Finish exposed surfaces in accordance with NAAMM Metal Finishes Manual.

EXECUTION

1.11 INSPECTION

Examine the areas and conditions where monolithic resinous system with integral base is to be installed with the VA COR.

Moisture Vapor Emission Testing: Perform moisture vapor transmission testing in accordance with ASTM F1869 to determine the MVER of the substrate prior to commencement of the work. See section 3.4, 3.

1.12 PROJECT CONDITIONS

Maintain temperature of rooms (air and surface) where work occurs, between 70 and 90 degrees F (21 and 32 degrees C) for at least 48 hours, before, during, and 24 hours after installation. Maintain temperature at least 70 degrees F (21 degrees C) during cure period.

Maintain relative humidity less than 75 percent.

Do not install materials until building is permanently enclosed and wet construction is complete, dry, and cured.

Maintain proper ventilation of the area during application and curing time period.

Comply with infection control measures of the VA Medical Center.

1.13 INSTALLATION REQUIREMENTS

The manufacturer's instructions for application and installation shall be reviewed with the VA COR for the seamless resinous flooring system with integral cove base Substrate shall be approved by manufacture technical representative.

1.14 PREPARATION

General: Prepare and clean substrates according to resinous flooring manufacturer's written instructions for substrate indicated. Provide clean, dry, and neutral Ph substrate for resinous flooring application.

Concrete Substrates: Provide sound concrete surfaces free of laitance, glaze, efflorescence, curing compounds, form-release agents, dust, dirt, grease, oil, and other contaminants incompatible with resinous flooring.

Prepare concrete substrates as follows:

Shot-blast surfaces with an apparatus that abrades the concrete surface, contains the dispensed shot within the apparatus, and re circulates the shot by vacuum pickup.

Comply with manufacturer's written instructions.

Repair damaged and deteriorated concrete according to resinous flooring manufacturer's written recommendations.

Verify that concrete substrates are dry.

Perform anhydrous calcium chloride test, ASTM F 1869. Proceed with application only after substrates have maximum moisture-vapor-emission rate of [3 lb of water/1000 square feet. (1.36 kg of water/92.9 square meters) in 24 hours.

MVT threshold for monolithic resinous flooring shall not exceed 3 lbs/1000 square feet (0.0001437 kPa) in a 24 hour period.

When MVT emission exceeds this limit, apply manufacturer’s recommended vapor control primer or other corrective measures as recommended by manufacturer prior to application of flooring or membrane systems.

Perform in situ probe test, ASTM F2170. Proceed with application only after substrates do not exceed a maximum potential equilibrium relative humidity of 85 percent.

Provide a written report showing test placement and results.

Verify that concrete substrates have neutral Ph and that resinous flooring will adhere to them. Perform tests recommended by manufacturer. Proceed with application only after substrates pass testing.

Resinous Materials: Mix components and prepare materials according to resinous flooring manufacturer's written instructions.

Use patching and fill material to fill holes and depressions in substrates according to manufacturer's written instructions.

Treat control joints and other nonmoving substrate cracks to prevent cracks from reflecting through resinous flooring according to manufacturer's written recommendations. Allowances should be included for flooring manufacturer recommended joint fill material, and concrete crack treatment.

Prepare wall to receive integral cove base Verify wall material is acceptable for resinous flooring application, if not, install material (e.g. cement board) to receive base.

Fill voids in wall surface to receive base, install undercoats (e.g. water proofing membrane, and/or crack isolation membrane) as recommended by resinous flooring manufacturer.

Install base prior to flooring if required by resinous flooring manufacturer.

Grind, cut or sand protrusions to receive base application.

1.15 APPLICATION

General: Apply components of resinous flooring system according to manufacturer's written instructions to produce a uniform, monolithic wearing surface of thickness indicated.

Coordinate application of components to provide optimum adhesion of resinous flooring system to substrate, and optimum intercoat adhesion.

Cure resinous flooring components according to manufacturer's written instructions. Prevent contamination during application and curing processes.

Apply joint sealant to comply with manufacturer's written recommendations.

Apply Primer: over prepared substrate at manufacturer's recommended spreading rate for all areas to receive integrated cove base.

Apply cove base: Trowel to wall surfaces at a 1 inch radius, before applying flooring. Apply according to manufacturer's written instructions and details including those for taping, mixing, priming, and troweling, sanding, and top coating of cove base. Round internal and external corners.

Apply Primer: over prepared substrate at manufacturer's recommended spreading rate.

Mortar base: Mix mortar material according to manufacturer's recommended procedures. Application should be based upon the following: Screed Rake, free-flowing mortar. Uniformly spread mortar over substrate using manufacturer's specially designed screed rake adjusted to manufacturer's recommended height. Spike-roll the mortar to remove any rake lines.

Aggregates: For applications with aggregate follow manufactures installation procedures, that includes sanding steps to expose aggregates pre-mixed into mortar base.

Under-Coat: Mix and apply sealer with strict adherence to manufacturer's installation procedures. Options for pigmented or clear undercoats depending on design type choice.

First Sealer: Mix and apply sealer with strict adherence to manufacturer's installation procedures.

Second Sealer: Mix and apply second sealer coat with strict adherence to manufacturer's installation procedures.

1.16 TOLERANCE

From line of plane: Maximum 1/8 inch (3.18 mm) in total distance of flooring and base. Broadcast resinous flooring system will contour substrate. Deviation and tolerance are subject to concrete tolerance.

From radius of cove: Maximum of 1/8 inch (3.18 mm) plus or 1/16-inch (1.59 mm) minus.

1.17 ENGINEERING DETAILS

Chase edges to “lock” the flooring system into the concrete substrate along lines of termination.

Penetration Treatment: Lap and seal resinous system onto the perimeter of the penetrating item by bridging over compatible elastomer at the interface to compensate for possible movement.

Trenches: Continue flooring system into trenches to maintain monolithic protection. Treat cold joints to assure bridging of potential cracks.

Treat floor drains by chasing the flooring system to lock in place at point of termination.

Treat control joints to bridge potential cracks and to maintain monolithic protection. Treat cold joints and construction joints to bridge potential cracks and to maintain monolithic protection on horizontal and vertical surfaces as well as horizontal and vertical interfaces.

Discontinue Resinous floor system at vertical and horizontal contraction and expansion joints by installing backer rod and compatible sealant after coating installation is completed. Provide sealant type recommended by manufacturer for traffic conditions and chemical exposures to be encountered.

1.18 CURING, PROTECTION AND CLEANING

Cure resinous flooring materials in compliance with manufacturer's directions, taking care to prevent contamination during stages of application and prior to completion of curing process.

Close area of application for a minimum of 24 hours.

Protect resinous flooring materials from damage and wear during construction operation.

Cover flooring with kraft type paper.

Optional 6 mm (1/4 inch) thick hardboard, plywood, or particle board where area is in foot or vehicle traffic pattern, rolling or fixed scaffolding and overhead work occurs.

Remove temporary covering and clean resinous flooring just prior to final inspection. Use cleaning materials and procedures recommended by resinous flooring manufacturer.

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