S02 695-21-110_030130_MaintCIPConcrete-1.pdf

695-21-110: Repair North Campus Steam Tunnel Amendment 3

Milwaukee VAMC

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SECTION 03 01 30

MAINTENANCE OF CAST-IN-PLACE CONCRETE

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Section 01 33 30 Structural Submittals

B. Section 01 45 25 Structural Testing/Inspection Agency Services

C. Section 03 20 00 Concrete Reinforcement

D. Section 03 30 00 Cast-In-Place Concrete

1.2 SUMMARY

A. Section Includes:

1. Removal of deteriorated concrete and subsequent replacement and patching.

2. Composite structural reinforcement.

1.3 PREINSTALLATION MEETINGS

A. Preinstallation Conference: Conduct conference at Project site.

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

a. Verify concrete-maintenance 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 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.

B. Material Certificates: For each type of repair product supplied for mixing or adding to products at Project site.

C. Product Test Reports: For each repair product, for tests performed by manufacturer and witnessed by a qualified testing agency.

D. Field quality-control reports.

1.5 QUALITY ASSURANCE

A. Manufacturer Qualifications: Each composite-structural-reinforcement manufacturer shall employ factory-authorized service representatives

03 01 30 - 2 who are available for consultation and Project-site inspection and on-site assistance.

B. Concrete-Maintenance Specialist Qualifications: Engage an experienced concrete-maintenance firm that employs installers and supervisors who are trained and approved by manufacturer to apply composite structural reinforcement 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-maintenance work.

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

C. Quality-Control Program: Prepare a written plan for concrete maintenance to systematically demonstrate the ability of personnel to properly perform maintenance 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.

1.6 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.

1.7 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.

B. Cold-Weather Requirements for Cementitious Materials: Do not apply unless concrete-surface and air temperatures are above 40 deg F (5 deg C) and will remain so for at least 48 hours after completion of

Work.

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C. Cold-Weather Requirements for Cementitious Materials: Comply with the following procedures:

1. When air temperature is below 40 deg F (5 deg C), heat patching-material ingredients and existing concrete to produce temperatures between 40 and 90 deg F (5 and 32 deg C).

2. When mean daily air temperature is between 25 and 40 deg F (minus

4 and plus 5 deg C), cover completed Work with weather-resistant insulating blankets for 48 hours after repair or provide enclosure and heat to maintain temperatures above 32 deg F (0 deg C) within the enclosure for 48 hours after repair.

3. When mean daily air temperature is below 25 deg F (minus 4 deg C), provide enclosure and heat to maintain temperatures above

32 deg F (0 deg C) within the enclosure for 48 hours after repair.

D. Hot-Weather Requirements for Cementitious Materials: Protect repair work when temperature and humidity conditions produce excessive evaporation of water from patching materials. Provide artificial shade and wind breaks, and use cooled materials as required. Do not apply to substrates with temperatures of 90 deg F (32 deg C) and above.

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 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[ where indicated] that matches existing, adjacent, exposed concrete. Blend several aggregates if necessary to achieve suitable matches.

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3. Coarse Aggregate for Patching Mortar: ASTM C 33/C 33M, washed aggregate, Size No. 8, Class 5S. Add to patching-mortar mix only as permitted by patching-mortar manufacturer.

B. Silica-Fume-Enhanced, Cementitious Patching Mortar. Basis of design shall be SikaCem-226 CI: Packaged, dry mix for repair of concrete and that contains silica fume and is designed for repair of overhead and vertical surfaces.

1. Compressive Strength: Not less than 6000 psi (41.4 MPa)at 28 days when tested according to ASTM C 109/C 109M.

2.3 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.

2.4 COMPOSITE REINFORCEMENT MATERIALS

A. Composite Structural Reinforcement: Manufacturer's system consisting of carbon-fiber reinforcement in the form of tow sheet with field-applied saturant and fillers, adhesives, saturants, and topcoats, designed for use as externally bonded structural reinforcement for concrete.

2.5 MISCELLANEOUS MATERIALS

A. Portland Cement: ASTM C 150/C 150M, Type I, II, or III unless otherwise indicated.

B. Water: Potable.

2.6 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.

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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.

PART 3 - EXECUTION

3.1 CONCRETE MAINTENANCE

A. Have concrete-maintenance work performed only by qualified concrete-maintenance 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 areas of deteriorated or delaminated concrete using hammer or chain-drag sounding and mark boundaries. Mark areas for removal by simplifying and squaring off boundaries. At columns and walls make boundaries level and plumb unless otherwise indicated.

3.3 PREPARATION

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

B. Protect persons and surrounding surfaces of building being repaired from harm resulting from concrete maintenance 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. Contain dust and debris generated by concrete maintenance work and prevent it from reaching the public or adjacent surfaces.

4. 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.

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

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

7. Protect adjacent surfaces and equipment by covering them with heavy polyethylene film.

8. Neutralize and collect alkaline and acid wastes for disposal off

Owner's property.

9. 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. Reinforcing-Bar Preparation: Remove loose and flaking rust from exposed reinforcing bars by high-pressure water cleaning or wire brushing until only tightly adhered light rust remains.

1. 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.

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

3. Splice replacement bars to existing bars according to ACI 318

(ACI 318M) by lapping, welding, or using mechanical couplings.

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

1. Roughen surface of concrete by sand blasting.

2. Remove delaminated material and deteriorated concrete surface material.

3. Sweep and vacuum roughened surface to remove debris.

3.4 PATCHING MORTAR APPLICATION

A. Place patching mortar as specified in this article unless otherwise recommended in writing by manufacturer.

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

B. General Placement: Place patching mortar by troweling toward edges of patch to force intimate contact with edge surfaces. For large patches, 03 01 30 - 7 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.

3.5 CORROSION-INHIBITING-TREATMENT APPLICATION

A. Apply by brush, roller, or airless spray in two coats at manufacturer's recommended application rate. Remove film of excess treatment by high-pressure washing before patching treated concrete.

3.6 COMPOSITE STRUCTURAL REINFORCEMENT APPLICATION

A. Follow manufacturer’s surface preparation and application requirements.

3.7 FIELD QUALITY CONTROL

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

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

C. Prepare test and inspection reports.

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