03 01 30 Maintenance of Cast-In-Place Concrete.pdf

Veteran Benefits Administration August 21st, 2023

36C10E22N0069 | OIG Houston VARO Space Renovation

Specifications –Bid Documents

MAINTENANCE OF CAST-IN-PLACE CONCRETE

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SECTION 03 01 30

MAINTENANCE OF CAST-IN-PLACE CONCRETE

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary

Conditions and Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. Section Includes:

1. Selective removal of existing concrete and subsequent replacement and patching.

2. Floor joint repair.

3. Epoxy crack injection.

4. Corrosion-inhibiting treatment.

5. Polymer sealers.

1.3 PREINSTALLATION MEETINGS

A. Preinstallation Conference: Conduct conference at Project site.

1. Review methods and procedures related to concrete repair including, but not limited to, the following:

a. Verify concrete-repair specialist's personnel, equipment, and facilities needed to make progress and avoid delays.

b. Materials, material application, sequencing, tolerances, and required clearances.

c. Quality-control program.

d. Coordination with building occupants.

1.4 ACTION SUBMITTALS

A. Product Data: For each type of product.

1. Include construction details, material descriptions, chemical composition, physical properties, test data, and mixing, preparation, and application instructions.

1.5 INFORMATIONAL SUBMITTALS

A. Qualification Data: For concrete-repair specialist and manufacturers.

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B. Product Test Reports: For manufactured bonding agent, cementitious patching mortar, joint-filler, crack-injection adhesive, and polymer sealer, for tests performed by manufacturer and witnessed by a qualified testing agency.

C. Field quality-control reports.

D. Quality-Control Program: Submit before work begins.

1.6 QUALITY ASSURANCE

A. Manufacturer Qualifications: Each product manufacturer shall employ factory-authorized service representatives who are available for consultation and Project-site inspection and on-site assistance.

B. Concrete-Repair Specialist Qualifications: Engage an experienced concrete-repair firm that employs installers and supervisors who are trained and approved by materials manufacturers to perform work of this Section. Firm shall have completed work similar in material, design, and extent to that indicated for this Project with a record of successful in-service performance.

Experience in only installing or patching new concrete is insufficient experience for concrete-repair work.

1. Field Supervision: Concrete-repair specialist firm shall maintain experienced full-time supervisors on Project site during times that concrete-repair work is in progress.

C. Quality-Control Program: Prepare a written plan for concrete repair to systematically demonstrate the ability of personnel to properly perform repair work, including each phase or process, protection of surrounding materials during operations, and control of debris and runoff during the Work. Describe in detail materials, methods, equipment, and sequence of operations to be used for each phase of the Work.

1.7 DELIVERY, STORAGE, AND HANDLING

A. Comply with manufacturer's written instructions for minimum and maximum temperature requirements and other conditions for storage.

B. Store cementitious materials off the ground, under cover, and in a dry location.

C. Store aggregates covered and in a dry location; maintain grading and other required characteristics and prevent contamination.

1.8 FIELD CONDITIONS

A. Environmental Limitations for Epoxies: Do not apply when air and substrate temperatures are outside limits permitted by manufacturer. During hot weather, cool epoxy components before mixing, store mixed products in shade, and cool unused mixed products to retard setting. Do not apply to wet substrates unless approved by manufacturer.

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1. Use only Class A epoxies when substrate temperatures are below or are expected to go below 40 deg F (5 deg C) within eight hours.

2. Use only Class A or B epoxies when substrate temperatures are below or are expected to go below 60 deg F (16 deg C) within eight hours.

3. Use only Class C epoxies when substrate temperatures are above and are expected to stay above 60 deg F (16 deg C) for eight hours.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Source Limitations: For repair products, obtain each color, grade, finish, type, and variety of product from single source and from single manufacturer with resources to provide products of consistent quality in appearance and physical properties.

2.2 BONDING AGENTS

A. Epoxy-Modified, Cementitious Bonding and Anticorrosion Agent: Manufactured product that consists of water-insensitive epoxy adhesive, portland cement, and water-based solution of corrosion-inhibiting chemicals that forms a protective film on steel reinforcement.

B. Epoxy Bonding Agent: ASTM C881/C881M, bonding system Type II and free of VOCs.

C. Latex Bonding Agent, Redispersible: ASTM C1059/C1059M, Type I for use at nonstructural and interior locations unless otherwise indicated.

D. Mortar Scrub Coat: Mix consisting of 1 part portland cement and 1 part fine aggregate complying with ASTM C144 except 100 percent passing a No. 16 (1.18-mm) sieve.

2.3 PATCHING MORTAR

A. Patching Mortar Requirements:

1. Only use patching mortars that are recommended by manufacturer for each applicable horizontal, vertical, or overhead use orientation.

2. Color and Aggregate Texture: Provide patching mortar and aggregates of colors and sizes necessary to produce patching mortar that matches existing, adjacent, exposed concrete.

Blend several aggregates if necessary to achieve suitable matches.

3. Coarse Aggregate for Patching Mortar: ASTM C33/C33M, washed aggregate, Size

No. 8, Class 5S. Add to patching-mortar mix only as permitted by patching-mortar manufacturer.

B. Job-Mixed Patching Mortar: 1 part portland cement and 2-1/2 parts fine aggregate complying with ASTM C144, except 100 percent passing a No. 16 (1.18-mm) sieve.

C. Cementitious Patching Mortar: Packaged, dry mix for repair of concrete.

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1. Compressive Strength: Not less than 4000 psi (27.6 MPa) at 28 days when tested according to ASTM C109/C109M.

D. Rapid-Strengthening, Cementitious Patching Mortar: Packaged, dry mix, ASTM C928/C928M for repair of concrete.

1. Compressive Strength: Not less than 3000 psi (21.0 MPa) within three hours when tested according to ASTM C109/C109M.

E. Polymer-Modified, Cementitious Patching Mortar: Packaged, dry mix for repair of concrete and that contains a non-redispersible latex additive as either a dry powder or a separate liquid that is added during mixing.

1. Compressive Strength: Not less than 4000 psi (27.6 MPa) at 28 days when tested according to ASTM C109/C109M.

F. Polymer-Modified, Silica-Fume-Enhanced, Cementitious Patching Mortar: Packaged, dry mix for repair of concrete and that contains silica fume complying with ASTM C1240 and a non-redispersible latex additive as either a dry powder or a separate liquid that is added during mixing.

1. Compressive Strength: Not less than 4000 psi (27.6 MPa) at 28 days when tested according to ASTM C109/C109M.

2.4 PREPLACED CONCRETE MATERIALS

A. Preplaced Aggregate: Washed aggregate, ASTM C33/C33M, Class 5S, with 95 to 100 percent passing a 1-1/2-inch (37.5-mm) sieve, 40 to 80 percent passing a 1-inch (25-mm) sieve, 20 to 45 percent passing a 3/4-inch (19-mm) sieve, zero to 10 percent passing a 1/2-inch (12.5-mm) sieve, and zero to 2 percent passing a 3/8-inch (9.5-mm) sieve.

B. Fine Aggregate for Grout: Fine aggregate according to ASTM C33/C33M, but with 100 percent passing a No. 8 (2.36-mm) sieve, 95 to 100 percent passing a No. 16 (1.18-mm) sieve, 55 to 80 percent passing a No. 30 (0.6-mm) sieve, 30 to 55 percent passing a No. 50 (0.3-mm) sieve, 10 to 30 percent passing a No. 100 (0.15-mm) sieve, zero to 10 percent passing a No. 200 (0.075-

mm) sieve, and having a fineness modulus of 1.30 to 2.10.

C. Grout Fluidifier for Grout: ASTM C937.

D. Pozzolans for Grout: ASTM C618.

2.5 JOINT FILLER

A. Epoxy Joint Filler: Two-component, semirigid, 100 percent solids, epoxy resin with a Type A

Shore durometer hardness of at least 80 according to ASTM D2240.

B. Polyurea Joint Filler: Two-component, semirigid, 100 percent solids, polyurea resin with a

Type A Shore durometer hardness of at least 80 according to ASTM D2240.

C. Color: As selected by Architect from full range of industry colors.

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2.6 EPOXY CRACK-INJECTION MATERIALS

A. Epoxy Crack-Injection Adhesive: ASTM C881/C881M, bonding system Type I, free of VOCs.

1. Capping Adhesive: Product manufactured for use with crack-injection adhesive by same manufacturer.

2. Color: Provide epoxy crack-injection adhesive and capping adhesive as selected by

Architect from full range of industry colors.

2.7 CORROSION-INHIBITING MATERIALS

A. Corrosion-Inhibiting Treatment: Waterborne solution of alkaline corrosion-inhibiting chemicals for concrete-surface application that penetrates concrete by diffusion and forms a protective film on steel reinforcement.

2.8 POLYMER-SEALER MATERIALS

A. Epoxy Polymer Sealer: Low-viscosity epoxy, penetrating sealer and crack filler recommended by manufacturer for penetrating and sealing cracks in exterior concrete traffic surfaces; VOC content 400 g/L or less.

1. Color: As selected by Architect from full range of industry colors.

2. Basis of Design: Ardex CG Concrete Guard, High Performance, High Solids concrete

Sealer.

2.9 MISCELLANEOUS MATERIALS

A. Portland Cement: ASTM C150/C150M, Type I, II, or III unless otherwise indicated.

B. Water: Potable.

2.10 MIXES

A. General: Mix products, in clean containers, according to manufacturer's written instructions.

1. Do not add water, thinners, or additives unless recommended by manufacturer.

2. When practical, use manufacturer's premeasured packages to ensure that materials are mixed in proper proportions. When premeasured packages are not used, measure ingredients using graduated measuring containers; do not estimate quantities or use shovel or trowel as unit of measure.

3. Do not mix more materials than can be used within time limits recommended by manufacturer. Discard materials that have begun to set.

B. Mortar Scrub Coat: Mix dry ingredients with enough water to provide consistency of thick cream.

C. Dry-Pack Mortar: Mix required type(s) of patching-mortar dry ingredients with just enough liquid to form damp cohesive mixture that can be squeezed by hand into a ball but is not plastic.

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D. Grout for Use with Preplaced Aggregate: Proportion according to ASTM C938. Add grout fluidifier to mixing water followed by portland cement, pozzolan, and fine aggregate.

PART 3 - EXECUTION

3.1 CONCRETE REPAIR

A. Have concrete-repair work performed only by qualified concrete-repair specialist.

B. Comply with manufacturers' written instructions for surface preparation and product application.

3.2 EXAMINATION

A. Notify Architect seven days in advance of dates when areas of deteriorated or delaminated concrete and deteriorated reinforcing bars will be located.

B. Locate extent of concrete removal. Mark areas for removal by simplifying and squaring off boundaries. At columns and walls make boundaries level and plumb unless otherwise indicated.

C. Perform surveys as the Work progresses to detect hazards resulting from concrete removal and repair work.

3.3 PREPARATION

A. Ensure that supervisory personnel are on-site and on duty when concrete repair work begins and during its progress.

B. Protect persons, motor vehicles, surrounding surfaces of building being repaired, building site, plants, and surrounding buildings from harm resulting from concrete repair work.

1. Comply with each product manufacturer's written instructions for protections and precautions. Protect against adverse effects of products and procedures on people and adjacent materials, components, and vegetation.

2. Use only proven protection methods appropriate to each area and surface being protected.

3. Provide temporary barricades, barriers, and directional signage to exclude public from areas where concrete repair work is being performed.

4. Erect temporary protective covers over walkways and at points of pedestrian and vehicular entrance and exit that must remain in service during course of concrete repair work.

5. Contain dust and debris generated by concrete repair work and prevent it from reaching the public or adjacent surfaces.

6. Use water-mist sprinkling and other wet methods to control dust only with adequate, approved procedures and equipment that ensure that such water will not create a hazard or adversely affect other building areas or materials.

7. Protect floors and other surfaces along haul routes from damage, wear, and staining.

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8. Provide supplemental sound-control treatment to isolate removal and dismantling work from other areas of the building.

9. Protect adjacent surfaces and equipment by covering them with heavy polyethylene film and waterproof masking tape. If practical, remove items, store, and reinstall after potentially damaging operations are complete.

10. Neutralize and collect alkaline and acid wastes for disposal off Owner's property.

11. Dispose of debris and runoff from operations by legal means and in a manner that prevents soil erosion, undermining of paving and foundations, damage to landscaping, and water penetration into building interiors.

C. Existing Drains: Prior to the start of work in an area, test drainage system to ensure that it is functioning properly. Notify Architect immediately of inadequate drainage or blockage. Do not begin work in an area until the drainage system is in working order.

1. Prevent solids such as aggregate or mortar residue from entering the drainage system.

Clean out drains and drain lines that become sluggish or blocked by sand or other materials resulting from concrete repair work.

2. Protect drains from pollutants. Block drains or filter out sediments, allowing only clean water to pass.

D. Preparation for Concrete Removal: Examine construction to be repaired to determine best methods to safely and effectively perform concrete repair work. Examine adjacent work to determine what protective measures will be necessary. Make explorations, probes, and inquiries as necessary to determine condition of construction to be removed in the course of repair.

1. Verify that affected utilities have been disconnected and capped.

2. Inventory and record the condition of items to be removed for reinstallation or salvage.Provide and maintain shoring, bracing, and temporary structural supports as required to preserve stability and prevent unexpected or uncontrolled movement, settlement, or collapse of construction being demolished and construction and finishes to remain. Strengthen or add new supports when required during progress of removal work.

3. Where section loss of reinforcing bar is more than 25 percent, or 20 percent in two or more adjacent bars, cut bars and remove and replace as indicated on Drawings.

4. Remove additional concrete as necessary to provide at least 3/4-inch (19-mm) clearance at existing and replacement bars.

5. Splice replacement bars to existing bars according to ACI 318 (ACI 318M) by lapping, welding, or using mechanical couplings.

E. Preparation of Floor Joints for Repair: Saw-cut joints full width to edges and depth of spalls, but not less than [3/4 inch (19 mm)] [1 inch (25 mm)] [2 inches (50 mm)] <Insert dimension> deep.

Clean out debris and loose concrete; vacuum or blow clear with compressed air.

F. Surface Preparation for Overlays:

1. Sweep and vacuum roughened surface to remove debris followed by low-pressure water cleaning.

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G. Acidic Surface Preparation for Sealers: Acid etch surface of concrete to produce a surface profile matching CSP 1 according to ICRI 310.2. Prepare surface for acid etching by detergent scrubbing to remove oils and films that may prevent acid penetration.

1. Remove excess acid solution, reaction products, and debris by squeegeeing or vacuuming.

2. Scrub surface with an alkaline detergent, rinse, and squeegee or vacuum.

3. Check acidity of surface with pH test paper and continue rinsing until pH is acceptable according to sealer manufacturer's written instructions.

4. When pH is acceptable according to sealer manufacturer's written instructions and surface is clean, vacuum dry.

H. Nonacidic Surface Preparation for Sealers: Clean concrete to remove dirt, oils, films, and other materials detrimental to sealer application.

1. Use low-pressure water cleaning or detergent scrubbing.

I. Surface Preparation for Composite Structural Reinforcement: Clean concrete where reinforcement and epoxy patching mortar is to be placed by low-pressure water cleaning or detergent scrubbing to remove dirt, oils, films, and other materials detrimental to epoxy patching mortar.

1. Sweep and vacuum roughened surface to remove debris followed by low-pressure water cleaning.

3.4 REMOVAL OF CONCRETE

A. Do not overload structural elements with debris.

B. Saw-cut perimeter of areas indicated for removal to depth required for item removal.

C. Where half or more of the perimeter of reinforcing bar is exposed, bond between reinforcing bar and surrounding concrete is broken, or reinforcing bar is corroded, remove concrete from entire perimeter of bar and to provide at least 3/4-inch (19-mm) clearance around bar.

D. Provide surfaces with a fractured profile of at least 1/8 inch (3 mm) that are approximately perpendicular or parallel to original concrete surfaces. At columns and walls, make top and bottom surfaces level unless otherwise directed.

E. Thoroughly clean removal areas of loose concrete, dust, and debris.

3.5 APPLICATION OF BONDING AGENT

A. Epoxy-Modified, Cementitious Bonding and Anticorrosion Agent: Apply to reinforcing bars and concrete by stiff brush or hopper spray according to manufacturer's written instructions.

Apply to reinforcing bars in two coats, allowing first coat to dry two to three hours before applying second coat. Allow to dry before placing patching mortar or concrete.

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B. Epoxy Bonding Agent: Apply to reinforcing bars and concrete by brush, roller, or spray according to manufacturer's written instructions, leaving no pinholes or other uncoated areas. Apply to reinforcing bars in at least two coats, allowing first coat to dry before applying second coat. Place patching mortar or concrete while epoxy is still tacky. If epoxy dries, recoat before placing patching mortar or concrete.

C. Latex Bonding Agent, Type I: Apply to concrete by brush roller or spray. Allow to dry before placing patching mortar or concrete.

D. Latex Bonding Agent, Type II: Mix with portland cement and scrub into concrete surface according to manufacturer's written instructions. Place patching mortar or concrete while bonding agent is still wet. If bonding agent dries, recoat before placing patching mortar or concrete.

E. Mortar Scrub Coat for Job-Mixed Patching Mortar and Concrete: Dampen repair area and surrounding concrete 6 inches (150 mm) beyond repair area. Remove standing water and apply scrub coat with a brush, scrubbing it into surface and thoroughly coating repair area. If scrub coat dries, recoat before placing patching mortar or concrete.

F. Slurry Coat for Cementitious Patching Mortar: Wet substrate thoroughly and then remove standing water. Scrub a slurry of neat patching mortar mixed with latex bonding agent into substrate, filling pores and voids.

3.6 INSTALLATION OF PATCHING MORTAR

A. Place patching mortar as specified in this article unless otherwise recommended in writing by manufacture[ or where dry-pack mortar is indicated.

1. Provide forms where necessary to confine patch to required shape.

2. Wet substrate and forms thoroughly and then remove standing water.

B. Pretreatment: Apply specified bonding agent and slurry coat.

C. General Placement: Place patching mortar by troweling toward edges of patch to force intimate contact with edge surfaces. For large patches, fill edges first and then work toward center, always troweling toward edges of patch. At fully exposed reinforcing bars, force patching mortar to fill space behind bars by compacting with trowel from sides of bars.

D. Consolidation: After each lift is placed, consolidate material and screed surface.

E. Multiple Lifts: Where multiple lifts are used, score surface of lifts to provide a rough surface for placing subsequent lifts. Allow each lift to reach final set before placing subsequent lifts.

F. Finishing: Allow surfaces of lifts that are to remain exposed to become firm and then finish surface matching adjacent concrete.

G. Curing: Wet-cure cementitious patching materials, including polymer-modified cementitious patching materials, for not less than seven days by water-fog spray or water-saturated absorptive cover.

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3.7 INSTALLATION OF DRY-PACK-MORTAR

A. Use dry-pack mortar for deep cavities. Place as specified in this article unless otherwise recommended in writing by manufacturer.

1. Provide forms where necessary to confine patch to required shape.

2. Wet substrate and forms thoroughly and then remove standing water.

B. Pretreatment: Apply specified bonding agent.

C. Place dry-pack mortar into cavity by hand, and compact tightly into place. Do not place more material at a time than can be properly compacted. Continue placing and compacting until patch is approximately level with surrounding surface.

D. After cavity is filled and patch is compacted, trowel surface to match profile and finish of surrounding concrete. A thin coat of patching mortar may be troweled into the surface of patch to help obtain required finish.

E. Wet-cure patch for not less than seven days by water-fog spray or water-saturated absorptive cover.

3.8 CONCRETE PLACEMENT

A. Place concrete as specified in this article.

B. Pretreatment: Apply epoxy bonding agent to reinforcement and concrete substrate.

C. Standard Placement: Place concrete by form-and-pump method unless otherwise indicated.

1. Use vibrators to consolidate concrete as it is placed.

2. At unformed surfaces, screed concrete to produce a surface that when finished with patching mortar will match required profile and surrounding concrete.

D. Form-and-Pump Placement: Place concrete by form-and-pump method where indicated.

1. Design and construct forms to resist pumping pressure in addition to weight of wet concrete. Seal joints and seams in forms and where forms abut existing concrete.

2. Pump concrete into place from bottom to top, releasing air from forms as concrete is introduced. When formed space is full, close air vents and pressurize to 14 psi (96 kPa).

E. Wet-cure concrete for not less than seven days by leaving forms in place or keeping surfaces continuously wet by water-fog spray or water-saturated absorptive cover.

F. Fill placement cavities with dry-pack mortar and repair voids with patching mortar. Finish to match surrounding concrete.

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3.9 FLOOR-JOINT REPAIR

A. Cut out concrete and reconstruct sides of joint with patching mortar as indicated on Drawings.

Install joint filler in nonmoving floor joints where indicated and as specified in this article.

B. Depth: Install joint filler to a depth of at least 3/4 inch (19 mm). Use fine silica sand no more than 1/4 inch (6 mm) deep to close base of joint. Do not use sealant backer rods or compressible fillers below joint filler.

C. Top Surface: Install joint filler so that when cured, it is flush at top surface of adjacent concrete.

If necessary, overfill joint and remove excess when filler has cured.

3.10 EPOXY CRACK INJECTION

A. Clean cracks with oil-free compressed air or low-pressure water to remove loose particles.

B. Clean areas to receive capping adhesive of oil, dirt, and other substances that would interfere with bond.

C. Place injection ports as recommended by epoxy manufacturer, spacing no farther apart than thickness of member being injected. Seal injection ports in place with capping adhesive.

D. Seal cracks at exposed surfaces with a ribbon of capping adhesive at least 1/4 inch (6 mm) thick by 1 inch (25 mm) wider than crack.

E. Inject cracks wider than 0.003 inch (0.075 mm) to a depth of 8 inches (200 mm).

F. Inject epoxy adhesive, beginning at widest part of crack and working toward narrower parts.

Inject adhesive into ports to refusal, capping adjacent ports when they extrude epoxy. Cap injected ports and inject through adjacent ports until crack is filled.

G. After epoxy adhesive has set, remove injection ports and grind surfaces smooth.

3.11 APPLICATION OF POLYMER SEALER

A. Apply polymer sealer by brush, roller, or airless spray at manufacturer's recommended application rate.

3.12 FIELD QUALITY CONTROL

A. Product will be considered defective if it does not pass tests and inspections.

B. Prepare test and inspection reports.

C. Manufacturers Field Service: Engage manufacturers' factory-authorized service representatives for consultation and Project-site inspection and to provide on-site assistance when requested by

Architect.

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1. Have manufacturers' factory-authorized service representatives perform the following number of Project-site inspections to observe progress and quality of the Work, distributed over the period of product installation, regardless of on-site assistance requested by Architect:

a. Bonding-Agent and Packaged Patching-Mortar Installation: Three inspections.

b. Joint-Filler Installation: Two inspections.

c. Crack-Injection-Adhesive Preparation and Installation: Four inspections.

d. Polymer Sealer: Two inspections.

END OF SECTION 030130