B08_Attach_152_REV_030130_Maintenance_Cast-in-Place_Concrete_0007.pdf

INDE-391-186336 03 01 30 - 1

PMIS 245589 MAINTENANCE OF CAST-IN-PLACE CONCRETE

SECTION 03 01 30 - MAINTENANCE OF CAST-IN-PLACE CONCRETE

PART 1 - GENERAL

1.1 SUMMARY

A. Hand patching of cracks and spalls in interior concrete surfaces and roof deck

B. Patching of interior concrete slabs after completion of mechanical, plumbing and electrical work

1. Placement of sand fill and concrete topping at existing utility trenches

2. Trenching of existing concrete slabs for new electrical conduits in exhibit area

3. Patching of trenches after installation of new conduits in exhibit area

C. Fill in existing floor drains not to be reused.

D. Stripping, cleaning and removal of efflorescence deposits from interior concrete floor surfaces in basement

E. Infill concrete slab as required after dismantling of elevator shaft. See Section 03 30 00 “Cast in Place Concrete.”

F. For repairs in excess of 1 cubic yard, see Section 03 30 00, “Cast-in-Place Concrete.”

1.2 RELATED WORK

A. Division 1 requirements.

B. Section 03 30 00, “Cast-in-Place Concrete”

C. Section 09 30 13, “Ceramic Tile”

D. Section 09 65 19, “Vinyl Tile”

E. Section 09 66 23, “Resin Matrix Terrazzo”

F. Section 09 68 16, “Carpeting”

G. Section 32 13 13, “Field Quality Control Requirements”

H. Section 32 14 00, “Unit Paving”

1.3 REFERENCES

INDE-391-186336 03 01 30 - 2

A. Concrete repairs shall conform to the Guidelines of the Secretary of the Interior for Historic Preservation. Techniques employed for concrete patching and repair shall be as outlined in “Preservation Brief No. 15 (2007) as published by the National Park Service.

B. American Concrete Institute and the International Concrete Repair Institute.

1. ACI562-19 Code Requirements for Assessment, Repair and Rehabilitation of Existing Concrete Structures

2. ACI563-18 Specifications for Repair of Concrete in Buildings

1.4 SUBMITTALS

A. Product literature

1. The Contractor shall submit manufacturer’s product literature for all generic and proprietary concrete cleaning and repair materials including, but not limited to, cement, sand, aggregate, admixtures, bonding agents, primers and proprietary patching products. Product literature shall demonstrate material compliance with these specifications and the standards referenced herein.

1.5 QUALITY ASSURANCE

A. The Contractor performing the work of this Section shall have at least ten (10) years experience in the restoration of concrete surfaces and shall have completed at least three projects of similar scale and scope within the previous five (5) years.

B. The Contractor shall prepare test panels of the following types of work at locations designated by the Contracting Officer:

1. Concrete spall repairs, One location, not to exceed 6 inches square.

2. Concrete cleaning: One location, not to exceed 50 square feet. Concrete cleaning mock-up will be used to verify concentration and dwell time for full cleaning.

3. Test panels for patching work shall be inspected twice. The first inspection shall occur after the test area has been cleaned and prepped for patching. Prep work shall include cutting out of damaged material, prepping and priming of reinforcement to remain and/or installation of new reinforcement if required. The second inspection shall occur after installation and curing of the patching material.

3. More than one test panel may be required to obtain approval. The Contractor shall prepare up to three test panels of each type, if required to obtain approval, without further compensation. Approved test panels shall become a part of the finished work and shall serve as the standard for all subsequent repairs.

C. For concrete placements in excess of 1 cubic yard, see section 03 30 00, “Cast-in-Place Concrete” for concrete inspection and testing requirements.

INDE-391-186336 03 01 30 - 3

1.6 DELIVERY, STORAGE AND HANDLING

A. Concrete repair materials shall be delivered to the site in original packaging, unopened, with manufacturer’s name and product identification thereon. Cementitious materials shall be protected from contamination by foreign matter and deterioration by moisture or temperature. Contaminated or deteriorated material shall not be used. Products stored longer than six months shall not be used.

B. Concrete materials shall be stored in such a manner as not to interfere with the work of other trades involved in the project. The Contracting Officer (CO) shall review proposed storage locations prior to the delivery of materials.

1.7 PROJECT / SITE CONDITIONS

A. Normal conditions for the work of this Section shall be when the air and surface temperatures are 40 degrees F and rising or less than 90 degrees F and falling. Outside this temperature range, hot or cold weather procedures as defined by the American Concrete Institute shall be followed.

B. The Contractor is responsible for protecting existing adjacent materials during the execution of the work. Provide all necessary protection and work procedures to avoid damage to existing material assemblies not a part of the work of this Section. At a minimum, the Contractor shall:

1. Minimize levels of dust during surface preparation operations including drilling, chipping and grinding. Where such operations are planned, install temporary sealants, coverings, curtains or temporary partitions as required to prevent dust penetration around the building interior or into mechanical equipment.

2. Concrete scrap, excess mortar, waste material, packaging and other debris associated with the repair and preparation work shall be disposed of in accordance with local, state and federal environmental regulations. Remove debris from concrete repair work from the site on a timely basis and at the completion of the work.

3. The Contractor shall coordinate concrete repair and preparation operations with the other trades involved in interior restoration work including, but not limited to, masonry restoration, roofing, floor finish, electrical and mechanical trades.

4. Access to interior work areas must be coordinated with Contracting Officer (CO).

PART 2 - PRODUCTS

2.1 FIELD-MIXED CONCRETE PATCHING MATERIALS

A. Job-mixed concrete

1. Portland Cement: ASTM C 150, Type I

INDE-391-186336 03 01 30 - 4

2. Aggregate: ASTM C 33, maximum size ¾ inch

3. Water: Potable and free from organic materials, oils or other contaminants

B. Mix Design: 3500 psi

C. Trench Fill: Fine, sharp, washed, natural sand or crushed stone with 100 percent passing No. 16 sieve and no more than 10 percent passing No. 200 sieve

D. Drainage Geotextile: Nonwoven needle-punched geotextile fabric, manufactured for subsurface drainage applications, made from polyolefins or polyesters; with elongation greater than 50 percent; complying with AASHTO M 288.

E. Reinforcing steel:

1. Reinforcing Bars: ASTM A615, Grade 60

2. Welded Wire Fabric: ASTM A 1064

F. Form Release Agent: Soy-based

1. Inviro-Gold RO-427, Romix Chemical

2. Crete-Release Bio-True, Cresset Chemical

3. Blue Bear 805 RG, Franmar Chemical

4. Contracting Officer-approved equivalent

2.2 PROPRIETARY PATCHING MATERIALS

A. Cementitious repair mortar for hand-patching existing concrete shall be a factory-mixed product formulated for crack and spall patching.

1. Edison Coatings System 44

2. SikaQuick EZ Patch

3. W R Meadows Meadow-Patch T1

4. Contracting Officer approved equivalent.

2.3 ACCESSORY PRODUCTS

A. Anti-corrosion coating and bonding agent for concrete patches shall be one of the following products:

1. Armatec 110 as manufactured by Sika Corporation, Lyndhurst, NY

2. B-1 Rebar Coating & Bonding Agent, J.E. Tomes, Blue Island, IL

INDE-391-186336 03 01 30 - 5

3. ECB (Electro-Chemical Barrier), as manufactured by Conproco Corporation

4. Contracting Officer-approved equivalent.

2.4 CONCRETE STRIPPING

A. Paint stripper for concrete masonry shall be a commercial grade thixotropic solution suitable for spray application and containing no wax, no NMP and no chlorinated solvents. Acceptable paint strippers are as follows:

1. Light Duty Paint Remover, Cathedral Stone Products

2. Smart Strip Advanced Paint Remover, Dumond Chemicals

3. Paint Stripper for Concrete, Rustoleum, Vernon Hills, IL

4. Contracting Officer-approved equivalent.

2.5 CONCRETE CLEANING

A. ProSoCo Consolideck Concrete Floor Restorer

B. Chemique Bac-2-Nu Heavy Duty Restoration Cleaner

C. Zep Driveway & Concrete Cleaner

D. Contracting Officer-approved equivalent.

E. Prepare concrete cleaning mock-up using a concentration of 1 part cleaner to 6 parts water or as recommended by manufacturer. Solution strength may be increased up to a ratio of one part cleaner to 3 parts water if required to remove soiling.

PART 3 - EXECUTION

3.1 GENERAL

A. For concrete placements in excess of 1 cubic yard, see section 03 30 00, “Cast-in-Place Concrete” for concrete inspection and testing requirements.

3.2 HAND-APPLIED CEMENTITIOUS REPAIRS

A. Surface Preparation

1. Remove damaged concrete, corrosion products and debris from the area to be patched. Cut back patch area to sound concrete or to a minimum depth of 3/8 inch or as specified by manufacturer of patching mortar. Do not feather-edge patching material. Rout cracks to a uniform minimum width of ¼ inch and a uniform minimum depth of ½ inch.

INDE-391-186336 03 01 30 - 6

2. Where reinforcing bars are present in the area to be patched, remove concrete behind bars to a minimum depth of 3/8 inch behind bars.

3. After chipping and cutting is completed, remove all loose material, corrosion products and debris using a non-ferrous wire brush. Flush away remaining dust and debris with clean water.

4. Exposed reinforcing bars shall be cleaned of corrosion products and coated with 2 coats of specified anti-corrosion coating applied in accordance with manufacturer’s instructions. Take special care to coat the undersides of exposed bars for a continuous coating.

B. Concrete Patching

1. Place concrete patching mortar within 7 days of coating exposed reinforcing bars.

2. Apply specified bonding agent to concrete substrate with a stiff-bristle brush, working material well into surface. Apply patching mortar wet on wet over bonding agent. Do not allow bonding agent to dry. Apply only as much bonding agent as can be covered before coating dries.

3. Mix specified repair mortar in accordance with Manufacturer’s instructions. Mix only enough mortar as can be applied prior to achieving initial set. Do not re-temper.

4. Place mortar over wet bonding agent, working material into the roughened surface and filling voids behind reinforcing bars.

5. After filling cracked or spalled area completely, level patching material and allow to desired stiffness. Finish to match adjacent surfaces.

3.3 TRENCHING OF EXISTING CONCRETE

A. Coordinate layout of trench locations with exhibit design and electrical contractor. Group conduits together where possible to minimize the size, depth and extent of trenching in the existing slab.

B. Cut trenches for electrical conduits using a masonry saw and/or grinder to produce straight lines and smooth curves as required to accommodate conduits. Loosen material to be removed using a pneumatic chisel or similar tool. Clean trenches to a uniform width and depth.

C. Coordinate with electrical contractor to ensure that all electrical work is complete prior to filling trenches in accordance with Article 3.3 below.

3.4 POURED CEMENTITIOUS REPAIRS

A. Do not begin preparation for in-fill repairs until all MEP installation work has been completed. Coordinate with mechanical trades to install any embedded sleeves required for new work, if applicable.

INDE-391-186336 03 01 30 - 7

B. Remove trash and loose debris from trenches to be filled. Square off all sides of area to be filled and hand-excavate trenches to uniform depth for installation of new MEP work.

Install and compact at least 1 inch of sand fill to cover bottom of trench.

C. After completion of MEP installations, install sand fill around and over installed piping and screed level. Cover with a layer of geotextile fabric prior to installing concrete topping.

D. Where space permits, install welded-wire reinforcement, anchored into or otherwise tied to edges of existing slab and allowing depth for required cover at top of infill.

E. Install new concrete to match depth of existing trench topping and vibrate to ensure full embedment of reinforcing. Trowel flat to match finish of surrounding material as required.

3.5 CONCRETE STRIPPING

A. Apply paint stripper to concrete surfaces using roller or low-pressure hand sprayer. Allow to dwell in accordance with manufacturer’s recommendations until existing coatings are loosened.

B. Lift loosened paint with scrapers and/or stiff, non-metallic bristle brushes. Dispose collected residue in accordance with Federal, state and local environmental regulations.

C. Rinse stripped surfaces with clean, low-pressure water, vacuuming effluent.

3.6 CONCRETE CLEANING

A. Apply cleaning solution to dry concrete using a low-pressure hand sprayer.

D. Allow cleaning solution to dwell on the floor surface 3 to 5 minutes or as determined during mock-up preparation. Agitate with non-metallic scrub brush to loosen soiling.

E. Rinse surface with clean low-pressure water (not to exceed 400 psi), vacuuming effluent as work progresses. Continue rinsing until rinse water tests near neutral (no less than 6) using a pH meter or test papers.

3.7 CLEAN-UP

A. Immediately remove all excess concrete from concrete surfaces surrounding the spall or crack to prevent staining.

END OF SECTION 03 01 30

D. Drainage Geotextile: Nonwoven needle-punched geotextile fabric, manufactured for subsurface drainage applications, made from polyolefins or polyesters; with elongation greater than 50 percent; complying with AASHTO M 288.