B08_Attach_158_REV__096623_Resin_Matrix_Terrazzo_Flooring_0007.pdf

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PMIS 245589 RESIN MATRIX TERRAZZO FLOORING

SECTION 09 66 23A - RESIN-MATRIX TERRAZZO FLOORING

1.1 SUMMARY: The work of this Section includes, but is not necessarily limited to, the following:

A. New thin-set epoxy terrazzo flooring over concrete slab substrates

1. Assume a 2-color scheme. Pattern as indicated on the Drawings.

B. Leveling of concrete floor slabs in existing building to receive new terrazzo

C. Moisture-resistant membrane over concrete substrates at first floor level

D. Epoxy terrazzo base where indicated.

E. Precast epoxy terrazzo stair treads with non-skid inserts

F. The work of the Section is included in both the Base Bid and specific Contract Line Items. See Section 01 27 00, “Definition of Contract Line Items” for additional information.

1.2 RELATED WORK

A. Division 1 requirements

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

C. Section 05 51 13, “Metal Pan Stairs”

D. Section 07 95 13, “Expansion Joint Covers”

E. Division 22 requirements

1.3 REFERENCE STANDARDS

A. American Society for Testing and Materials (ASTM) Publications:

1. C-307 Test Method for Tensile Strength of Chemical-Resistant Mortars.

2. C-501 Test Method for Relative Resistance to Wear Unglazed Ceramic Tile by the Taber Abraser.

3. C-531 Test Method for Linear Shrinkage and Coefficient of Thermal Expansion of Chemical- Resistant Mortars, Grouts, and Monolithic Surfacing.

4. C-579 Test Methods for Compressive Strength of Chemical-Resistant Mortars and Monolithic Surfaces.

5. C-580 Test Method for Flexural Strength and Modulus of Elasticity of Chemical-Resistant Mortars, Grouts, and Monolithic Surfacing.

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6. C-884 Test Method for Thermal Compatibility Between Concrete and an Epoxy Resin Overlay.

7. D-570 Water Absorption of Plastics.

8. D-695 Compression Properties of Rigid Plastic.

1.4 SUBMITTALS

A. Shop Drawings: Shop Drawings shall be furnished showing installation of cove base and termination details, and details at floor material transitions and where adjoining equipment.

1. Locate and provide detailing for flexible joints required for flooring in area of installation.

2. Precast epoxy terrazzo stair tread inserts

B. Product data: Submit manufacturer’s product data for new epoxy terrazzo flooring and accessory materials. Submit descriptive data and specific recommendations for mixing, application, curing including any precautions of special handling instructions required to comply with the Occupational Safety and Health Act

C. Selection Samples: Manufacturer’s full color range for selection of colors by Contracting Officer Submit selection samples as described in Paragraph 2.1.D. for selection of matrix and aggregate combinations for field and border.

D. Moisture testing reports: Submit for information and record only.

1.5 CLOSEOUT SUBMITTALS

A. Maintenance information: Submit terrazzo manufacturer’s maintenance recommendations for cleaning and repair of epoxy resin terrazzo flooring.

1.6 QUALITY ASSURANCE

A. Materials used in the floor surfacing shall be the products of a single manufacturer.

B. Installation shall be performed by an applicator with minimum 3 years’ experience in work of similar nature and scope. Installer must be approved by the manufacturer of the floor surfacing materials.

The contractor shall furnish a written statement from the manufacturer that the installer is acceptable.

C. Installer to verify locations of all flexible joints required by the provisions of this Section and by the recommendations of the related material manufacturers.

1. Joint locations may or may not be shown in drawings.

2. Refer to drawings required under SUBMITTALS above.

D. Installer to keep daily log of the date of installation, room number, type, color, and method of application of product being installed. Log must be available for inspection by the Contracting Officer upon request.

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E. Contractor to have proven experience with specified system.

F. Portable mock-up: Prior to starting application of flooring, provide full scale portable mock-up to establish acceptable quality, durability, and appearance. Mock-up size must not be less than 4 square feet.

1. Acceptable mock-up to be standard of quality for installed work.

2. Unacceptable installed work to be removed and replaced until acceptable. Aesthetically unacceptable but well bonded work may be overlaid or recoated per Manufacturer’s instructions if thickness clearances permit.

G. Contractor to guarantee work under this Section to be free from defects of material and installation for the duration of the warranty period. Defects occurring during warranty period shall be repaired, in a manner satisfactory to the Contracting Officer, at no additional cost to the Government.

1. Warranty Period: One (1) Year

1.7 PRODUCT DELIVERY, STORAGE, AND HANDLING

A. All materials shall be delivered to project site in original manufacturer's sealed containers including type of material, batch numbers, date of manufacture, and pertinent labels intact and legible.

B. Store materials in dry protected area at a temperature between 60° F to 80° F.

C. Follow all manufacturer's specific instructions and prudent safety practices for storage and handling.

1.8 PROJECT CONDITIONS

A. Maintain the ambient room and the floor temperatures at 60 degrees Fahrenheit, or above, for a period extending from 72 hours before, during and after floor installation. Concrete to receive surfacing shall have cured for at least 28 days and shall have been free of water for at least 7 days.

B. Dew Point: Substrate temperature must be minimum of 5 degrees above dew point prior to, during or up to 24 hours after application of flooring system.

C. Illumination: Apply flooring system only where a minimum of 30 footcandles exist when measured 3 feet from surface.

D. Advise other trades of fixtures and fittings not to be installed until flooring is cured and protected.

1.9 PROTECTION

A. Protect adjacent surfaces not scheduled to receive the flooring by masking, or by other means, to maintain these surfaces free of the flooring material.

B. Provide adequate ventilation and fire protection at all mixing and placing operations. Prohibit smoking or use of spark or flame producing devices within 50 feet of any mixing or placing operation.

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PART 2 - PRODUCTS

2.1 EPOXY TERRAZZO

A. Physical Properties

1. Weight:

a. 1.50 lbs/sq.ft. per 3/16 inch thickness.

2. Compressive Strength:

a. ASTM C-579

b. 10,000 psi or better

3. Tensile Strength:

a. ASTM C-307

b. 2,400 psi or better

4. Flexural Strength:

a. ASTM C-580

b. 3,000 psi or better

5. Indentation:

a. MIL-D-3134F Sec. 4.7.4

b. Withstands 2,000 psi for 30 mins. without indentation

6. Impact Resistance:

a. MIL-D-3134F, Sec. 4.7.3

b. 16 ft/lbs.; no chipping, cracking, or delamination

7. Adhesive Strength to Concrete:

a. ACI Committee 403/503

b. 250 psi minimum (100% concrete failure)

8. Abrasion Resistance:

a. ASTM-C-501

b. 32 mg. max.

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9. Thermal Shock Resistance:

a. Passes ASTM-C-884

B. Epoxy-Resin Matrix: Two-part pourable low-VOC epoxy resin

1. Basis of Design: Groutless EZ-Pour Epoxy 158, Terrazzco

a. White

b. Gray Matters

c. Functional Gray

2. Alternate Manufacturers: Provide one of the following products:

a. Cheminert Epoxy Terrazzo, Dex-O-Tex

b. Key Epoxy Terrazzo, Key Resin Company

c. Morricite Epoxy Matrix Terrazzo, Master Terrazzo Technologies

d. Contracting Officer-approved equivalent.

C. Aggregate: Crushed natural stone and/or glass, Color(s) to be selected by Contracting Officer.

1. Basis of Design: Terrazzco

a. Northern White

b. Pearl Gray

2. Alternate manufacturers:

a. Key Resin Company

b. Dex-O-Tex

c. Master Terrazzo Technologies

d. Contracting Officer-approved equivalent

3. Aggregate Size:

a. Existing building: Sizes 0 and 1.

b. New addition: Sizes 0, 1 and 2.

D. Selection samples: The Contractor shall prepare samples of the following matrix and aggregate combinations for selection by the Contracting Officer:

1. Field

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a. #F1: Aggregate – Northern White; Matrix – White

b. #F2: Aggregate – Pearl Gray; Matrix – Gray Matters

2. Border

a. #B1: Aggregate – Northern White; Matrix – Functional Gray

b. #B2: Aggregate – Pearl Gray; Matrix – Gray Matters

3. Samples to be a minimum of 6 inches square

2.2 ACCESSORY MATERIALS

A. Thin-Set Divider Strips: 1/8-inch, brass, L-type angle in depth required for topping thickness indicated.

B. Moisture-Vapor-Emission-Control Membrane: Two-component, high-solids, high-density, low-odor, epoxy-based membrane-forming product produced by epoxy terrazzo manufacturer that reduces moisture emission from concrete substrate to not more than 3 lb of water/1000 sq. ft. in 24 hours.

1. Moisture Mitigation System MMS 950, Terrazzco

2. Key Urecon SLT Moisture Control, Key Resin Systems

3. VaporControl FC, Dex-O-Tex

4. Morricite 350, Master Terrazzo Technologies, Inc.

5. Contracting Officer-approved equivalent

C. Non-skid Inserts: Manufacturer’s standard epoxy with abrasive aggregate fill.

PART 3 - EXECUTION

3.1 PREPARATION

A. Clean substrates of substances, including oil, grease, and curing compounds, that might impair terrazzo bond. Provide clean, dry, and neutral substrate for terrazzo application.

B. Concrete Slabs:

1. Provide sound concrete surfaces free of laitance, glaze, efflorescence, curing compounds, form-release agents, dust, dirt, grease, oil, and other contaminants incompatible with terrazzo.

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

b. Repair damaged and deteriorated concrete according to terrazzo manufacturer's written instructions.

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

2. Verify that concrete substrates are dry and moisture-vapor emissions are within acceptable levels according to manufacturer's written instructions.

3. Preinstallation Moisture Testing:

a. Testing Agency: Engage a qualified testing agency to perform tests.

b. Moisture Testing: Perform tests so that each test area does not exceed 100 square feet, and perform no fewer than three tests in each installation area and with test areas evenly spaced in installation areas.

i. Moisture-Vapor-Emission Test: Maximum moisture-vapor-emission rate of 3 lb of water/1000 sq. ft. in 24 hours when tested according to ASTM F 1869 using anhydrous calcium chloride.

ii. Relative Humidity Test: Maximum 75 percent relative humidity measurement when tested according to ASTM F 2170 using in-situ probes.

c. Proceed with terrazzo installation only after concrete substrates pass moisture testing or after installation of moisture-vapor-emission-control membrane on substrate areas that fail testing.

d. Moisture-Vapor-Emission-Control Membrane: Install according to manufacturer's written instructions.

i. Install concrete substrates that fail preinstallation moisture testing on all first-floor areas to receive epoxy terrazzo.

e. Substrate-Crack-Suppression Membrane: Install to isolate and suppress substrate cracks according to manufacturer's written instructions.

i. Prepare and prefill substrate cracks with membrane material.

ii. Install membrane to produce full substrate coverage in areas to receive terrazzo.

f. Protect other work from water and dust generated by grinding operations. Control water and dust to comply with environmental protection regulations.

i. Erect and maintain temporary enclosures and other suitable methods to limit water damage and dust migration and to ensure adequate ambient temperatures and ventilation conditions during installation.

3.2 EPOXY-RESIN TERRAZZO INSTALLATION

A. Comply with NTMA's written recommendations for terrazzo and accessory installation.

B. Strip Materials:

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1. Divider and Control-Joint Strips:

a. Locate divider strips in locations indicated on approved shop drawings.

b. Install control-joint strips back to back and directly above concrete-slab control joints.

c. Install strips in adhesive setting bed without voids below strips, or mechanically anchor strips as required to attach strips to substrate, as recommended by strip manufacturer.

2. Accessory Strips: Install as required to provide a complete installation.

3. Abrasive Strips for precast stair inserts: Rout tread surface as indicated and fill with abrasive material to 1/16” above finish surface of tread.

C. Apply primer to terrazzo substrates according to manufacturer's written instructions.

D. Place, rough grind, grout, cure grout, fine grind, and finish terrazzo according to manufacturer's written instructions.

1. Installed Thickness:

a. New addition: ⅜ inch nominal.

b. Existing historic structure: ¼ inch nominal

2. Terrazzo Finishing: Ensure that matrix components and fluids from grinding operations do not stain terrazzo by reacting with divider and control-joint strips.

a. Rough Grinding: Grind with 24-grit or finer stones or with comparable diamond abrasives. Follow initial grind with 60/80-grit stones or with comparable diamond abrasives.

b. Grouting: Before grouting, clean terrazzo with water, rinse, and allow to dry. Apply and cure epoxy grout.

c. Fine Grinding/Polishing: Delay fine grinding until heavy trade work is complete and construction traffic through area is restricted. Grind with 80-grit stones or with comparable diamond abrasives until grout is removed from surface.

3. Installation Tolerance: Limit variation in terrazzo surface from level to 1/4 inch in 10 feet;

noncumulative.

4. Install and finish poured-in-place terrazzo base at the same time the adjacent terrazzo flooring is installed.

5. Cut out and replace terrazzo areas that evidence lack of bond with substrate. Cut out terrazzo areas in panels defined by strips and replace to match adjacent terrazzo, or repair panels according to NTMA's written recommendations, as approved by Contracting Officer.

E. Cleaning:

1. Remove grinding dust from installation and adjacent areas.

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2. Wash surfaces with cleaner according to NTMA's written recommendations and manufacturer's written instructions; rinse surfaces with water and allow them to dry thoroughly.

F. Sealing:

1. Seal surfaces according to NTMA's written recommendations.

2. Apply sealer according to sealer manufacturer's written instructions.

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c. Proceed with terrazzo installation only after concrete substrates pass moisture testing or after installation of moisture-vapor-emission-control membrane on substrate areas that fail testing.

3. Installation Tolerance: Limit variation in terrazzo surface from level to 1/4 inch in 10 feet; noncumulative.