Attachment 10- UFGS 09 67 2316 5-Coat System.pdf

SECTION 09 67 23.16 Page 1

SECTION TABLE OF CONTENTS

DIVISION 09 - FINISHES

SECTION 09 67 23.16

FUEL RESISTIVE RESINOUS FLOORING, 5-COAT SYSTEM

08/10

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 QUALITY ASSURANCE

1.3.1 Test Reports

1.3.1.1 Joint Sealant

1.3.1.2 Epoxy Mortar Flooring System

1.3.1.3 Primer

1.3.1.4 Grout Coat

1.3.1.5 Urethane Topcoat

1.3.1.6 Daily Inspection Report

1.3.2 Certificates

1.3.2.1 Work Plan

1.3.2.2 Flooring System Applicator Qualifications

1.3.2.3 Joint Sealant

1.3.2.4 Epoxy Mortar Flooring System

1.3.2.5 Warranty

1.3.3 Manufacturer's Instructions

1.3.3.1 Joint Sealant

1.3.3.2 Epoxy Mortar Flooring System

1.3.3.3 Water-Based Alkaline Degreaser

1.4 DELIVERY, STORAGE, AND HANDLING

1.5 COATING HAZARDS

1.6 JOB SITE REFERENCES

1.7 PATCH TEST DEMONSTRATION

PART 2 PRODUCTS

2.1 JOINT SEALANT

2.2 EPOXY MORTAR FLOORING SYSTEM

2.2.1 Primer Coat

2.2.2 Grout Coat

2.2.3 Urethane Topcoat

2.3 WHITE ALUMINUM OXIDE NON-SKID GRIT

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2.4 PREVIOUSLY TESTED MATERIALS

PART 3 EXECUTION

3.1 COATING SAMPLE COLLECTION

3.2 TILE AND TILE ADHESIVE REMOVAL

3.3 JOINT MATERIAL REMOVAL, RE-SAW CUTTING, CRACK CHASING

3.4 DEGREASING

3.5 COATING SYSTEM REMOVAL

3.6 SURFACE PREPARATION

3.6.1 CMU Surface Preparation

3.7 COVE STRIP INSTALLATION

3.8 KEY-IN TERMINATIONS

3.9 CRACK REPAIRS

3.9.1 Install Bondbreaker

3.9.2 Repair Cracks

3.10 PRE-APPLICATION TESTING FOR CONTAMINATION

3.11 COATING APPLICATION

3.11.1 Isolation (Expansion) and Construction Joint Treatment

3.11.2 Contraction Joint Treatment

3.11.3 Primer Application

3.11.4 Epoxy Mortar Application

3.11.5 Primer Application to CMU Walls

3.11.6 Epoxy Mortar Application to CMU Walls

3.11.7 Grout Coat Application

3.11.8 Grout Coat Sanding

3.11.9 Saw Cutting and Sealing Joints

3.11.9.1 Saw Cut Contraction Joints

3.11.9.2 Saw Cut Isolation (Expansion) and Construction Joints

3.11.9.3 Install Backer Rod

3.11.9.4 Joint Sealant Application

3.11.10 Application of Topcoats

3.11.10.1 Non-Skid Grit Broadcast

3.11.10.2 Grout Coat Cleaning

3.11.10.3 First Topcoat

3.11.10.4 Second topcoat

3.11.10.5 Walkway Stripes

3.12 CURING

3.13 FIELD TESTS AND INSPECTION

3.13.1 Coating Inspector

3.13.2 Inspection

3.13.2.1 Daily Inspection Report

3.13.2.2 Inspection Logbook

3.13.2.3 Inspection Equipment

3.13.3 Adhesion Testing

3.14 Final Cleanup

-- End of Section Table of Contents --

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PART 1 GENERAL

1.1 REFERENCES

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

ASTM INTERNATIONAL (ASTM)

ASTM C307 (2018) Standard Test Method for Tensile

Strength of Chemical-Resistant Mortar, Grouts, and Monolithic Surfacings

ASTM C531 (2018) Standard Test Method for Linear

Shrinkage and Coefficient of Thermal Expansion of Chemical-Resistant Mortars, Grouts, and Monolithic Surfacings, and Polymer Concretes

ASTM C579 (2018) Standard Test Methods for

Compressive Strength of Chemical-Resistant Mortars, Grouts, Monolithic Surfacings, and Polymer Concretes

ASTM C679 (2003; E 2009; R 2009) Tack-Free Time of

Elastomeric Sealants

ASTM C884/C884M (2016) Standard Test Method for Thermal Compatibility between Concrete and Epoxy-Resin Overlay

ASTM D412 (2016) Standard Test Methods for

Vulcanized Rubber and Thermoplastic Elastomers - Tension

ASTM D638 (2014) Standard Test Method for Tensile

Properties of Plastics

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ASTM D1308 (2013) Effect of Household Chemicals on Clear and Pigmented Organic Finishes

ASTM D2240 (2015; E 2017) Standard Test Method for

Rubber Property - Durometer Hardness

ASTM D2621 (1987; R 2016) Standard Test Method for

Infrared Identification of Vehicle Solids from Solvent-Reducible Paints

ASTM D2697 (2003; R 2014) Volume Nonvolatile Matter in Clear or Pigmented Coatings

ASTM D3335 (1985a; R 2014) Low Concentrations of

Lead, Cadmium, and Cobalt in Paint by Atomic Absorption Spectroscopy

ASTM D3718 (1985a; R 2015) Low Concentrations of

Chromium in Paint by Atomic Absorption Spectroscopy

ASTM D3925 (2002; R 2015) Sampling Liquid Paints and

Related Pigmented Coatings

ASTM D4541 (2017) Standard Test Method for Pull-Off

Strength of Coatings Using Portable Adhesion Testers

ASTM D6237 (2019) Standard Guide for Painting

Inspectors (Concrete and Masonry Substrates)

ASTM E11 (2016) Standard Specification for Woven

Wire Test Sieve Cloth and Test Sieves

ASTM F1869 (2016) Standard Test Method for Measuring

Moisture Vapor Emission Rate of Concrete Subfloor Using Anhydrous Calcium Chloride

INTERNATIONAL CONCRETE REPAIR INSTITUTE (ICRI)

ICRI 03732 (1997) Selecting and Specifying Concrete

Surface Preparation for Sealers, Coatings, and Polymer Overlays

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC-TU 2/NACE 6G197 (1997) Design, Installation, and

Maintenance of Coating Systems for Concrete Used in Secondary Containment

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE AMS-STD-595A (2017) Colors used in Government

Procurement

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CFR

U.S. NATIONAL

1910.134

ARCHIVES AND RECORDS ADMINISTRATION (NARA)

Respiratory Protection

29 CFR 1910.1000 Air Contaminants

29 CFR 1926.59 Hazard Communication

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submittals with an "S" are for inclusion in the Sustainability eNotebook. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-04 Samples

Joint Sealant; G

Epoxy Mortar Flooring System; G

White Aluminum Oxide Non-Skid Grit; G

SD-06 Test Reports

Primer; G

Grout Coat; G

Urethane Topcoat; G

White Aluminum Oxide Non-Skid Grit; G

Patch Test Demonstration; G

Daily Inspection Report; G

Adhesion Testing; G

SD-07 Certificates

Work Plan; G

Flooring System Applicator Qualifications; G

Warranty; G

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SD-08 Manufacturer's Instructions

Joint Sealant; G

Epoxy Mortar Flooring System; G

Water-Based Alkaline Degreaser; G

SD-11 Closeout Submittals

Inspection Logbook; G

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1.3 QUALITY ASSURANCE

1.3.1 Test Reports

1.3.1.1 Joint Sealant

Submit test results that confirm sealant complies with Table Ia requirements. Samples must have been tested within the last three years.

1.3.1.2 Epoxy Mortar Flooring System

Submit test results that confirm the epoxy mortar flooring system complies with Table Ib requirements. Samples must have been tested within the last three years.

1.3.1.3 Primer

Submit test results that confirm the primer complies with Table Ic

1.3.1.4 Grout Coat

Submit test results that confirm grout coat complies with Table Id

1.3.1.5 Urethane Topcoat

Submit test results that confirm urethane topcoat complies with Table Ie

1.3.1.6 Daily Inspection Report

Submit one copy of the daily inspection report to the Contracting Officer within 24 hours of the date recorded.

1.3.2 Certificates

1.3.2.1 Work Plan

Submit schedule to complete work within approximately twelve (12) consecutive calendar days. Submit a written plan describing in detail all phases of coating operations. Address work sequencing, surface preparation, flooring system application, recoat and cure time projections, as well as how each step will be controlled, tested, and evaluated. Address safety measures, work scheduling around weather, and record keeping. Assign one supervisor to the job who is to remain on site throughout all phases of work and who is to act as the contractor's primary point of contact. Identify this person in the submitted schedule.

1.3.2.2 Flooring System Applicator Qualifications

Minimum requirements for the installation contractor are as follows:

Completed three or more jobs within the past two years applying the specified materials to concrete surfaces in which the total area exceeds 200,000 square feet. Submit documentation listing location of work, point of contact at job site, total square footage of applied materials, listing of both materials and equipment used, and validation from coating manufacturer documenting quality of materials purchased per job for work totaling 200,000 square feet within the past two years. In addition to the above requirements, installation contractor must be certified by the material manufacturer(s) to install the submitted coatings and sealant. Submit copy of certificates.

1.3.2.3 Joint Sealant

Submit literature documenting the sealant's past performance in automotive and aircraft maintenance shops. Minimum requirements are two or more maintenance shops with joint work totaling 10,000 linear feet whereby the sealant has performed for two years with less than one percent combined sealant failures and defects. Include from sealant manufacturer a list of shop locations, total linear feet of sealant applied per shop, shop point of contact, date sealant was applied, and the name of the installed sealant material.

1.3.2.4 Epoxy Mortar Flooring System

Submit literature documenting the coating system's past performance in aircraft maintenance shops and over floors with high Moisture Vapor Emission (MVE) rates. Minimum requirements are two or more aircraft maintenance shops totaling 34,000 square feet where the coating system has performed for two years with less than 0.05 percent combined premature coating failures, material defects and surface discoloration; no more than

0.03 percent discoloration from aviation chemicals, tire plasticizers, and UV exposure. Provide a minimum of two additional case histories where successful installation occurred on floor slabs with no less than

4.5 pounds moisture per 24 hours, 1000 square feet. Include from flooring manufacturer a list of shop locations, total coated area per shop, shop point of contact, date coating system was applied, successful installation to concrete with high MVE, and the names of the installed coating materials.

1.3.2.5 Warranty

Warrantee materials and workmanship for a minimum of one year following completion of flooring and sealant application. The following terms and conditions form a part of the warranty: If the applied coating system develops blisters (chemical), checks, softening, or lifting within one year following application, rework each area by installation contractor at contractor's expense. The following conditions are excluded from the warranty: A) Concrete cracking, flooring system mirrors cracks in concrete, B) cosmetic imperfections due to scratching and gouging, C) application to metallic concrete finishes (Section 09 97 23 METALLIC TYPE CONDUCTIVE/SPARK RESISTANT CONCRETE FLOOR FINISH), and D) application to concrete with a MVE rate greater than 5.0 pounds moisture per 24 hours, 1000 square feet. If the coating system's adhesion is in question, perform one adhesion test per 100 square feet as described in the paragraph ADHESION TESTING. To satisfy the warranty, adhesion testing must produce cohesive failures within the concrete, concrete removal over 95 percent of each pull-off coupon, or adhesion no less than 400 psi.Each area failing to meet adhesion requirements requires two additional adhesion tests to confirm results. Within the warranty period, remove to sound material and rework all areas unable to meet adhesion requirements. Zero percent sealant failures within one year is required. Within the warranty period, remove and rework all sealant material that has chemically attacked surfaces or lifting from joint walls. Topcoat cracking over sealant is excluded from warranty.

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1.3.3 Manufacturer's Instructions

1.3.3.1 Joint Sealant

Submit manufacturer's printed instructions to include detailed application procedures, minimum and maximum application temperatures, and curing procedures. In accordance with 29 CFR 1926.59, include Safety Data Sheets (SDS) for the sealant to be used at the job site.

1.3.3.2 Epoxy Mortar Flooring System

Submit manufacturer's printed instructions to include detailed mixing, minimum and maximum application temperatures, acceptable atmospheric and interior climatic conditions, application procedures, curing procedures, and procedures for flooring system maintenance cleaning. Provide explicit instructions detailing surface preparation, recoat windows and remedial actions in case recoat windows are missed, and, if applicable, solvent-wiping between coats with acceptable types and grades of solvents. In accordance with 29 CFR 1926.59, include SDSs for the coatings to be used at the job site.

1.3.3.3 Water-Based Alkaline Degreaser

Submit manufacturer's printed instructions to include detailed mixing, dilution rate, application procedures, and rinsing procedures. In accordance with 29 CFR 1926.59, include SDSs for the water-based alkaline degreaser to be used at the job site.

1.4 DELIVERY, STORAGE, AND HANDLING

Store coatings and sealant in spaces with temperatures from 40 to 75 degrees F. Inspect materials on site for damage prior to use. Return to manufacturer any packaged materials in dented, rusty, or leaking containers. Return to manufacturer materials with an expired shelf life for testing, and if compliant, reissuing of shelf life extension.

1.5 COATING HAZARDS

Ensure that employees are trained in all safety plan aspects. Follow the coating manufacturer's written safety precautions throughout mixing, application, and curing of coatings. Comply with respiratory protection requirements in 29 CFR 1910.134 and safe levels of airborne contaminants in 29 CFR 1910.1000.

1.6 JOB SITE REFERENCES

Make available to the Contracting Officer at least one copy each of ASTM D4541, ASTM D6237, SSPC-TU 2/NACE 6G197, and ICRI 03732, including replica standards ICRI-CSP 1 through ICRI-CSP 9, at the job site.

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1.7 PATCH TEST DEMONSTRATION

NOTE:

If customer dislikes non-skid grit level, adjustments can be made. Grit coarser than No. 60 aluminum oxide is not recommended. On architectural floors, non-skid grit broadcast rates can range from none to approximately half the specified level. To confirm grit broadcast is acceptable, walk on cured patch test under both dry and wet conditions. Water can be used to simulate the wet condition.

Prior to the submitted flooring system's approval, apply the complete flooring system to a foot by 10 foot square concrete section as prepared in accordance with Part 3 "EXECUTION." Within this area, perform three adhesion tests using procedures as detailed in the paragraph ADHESION TESTING. If adhesion testing produces cohesive failures within the concrete, no less than 40 mils concrete removed over 95 percent of each pull-off coupon,or adhesion more than 400 psi, patch test adhesion is acceptable. If concrete surface preparation was insufficient, apply an additional coating system patch to properly prepared concrete followed by the above adhesion testing. If adhesion results are unacceptable for both the topcoat and the coatings below the grout coat, submit a new coating system manufactured by a different coating vendor. Apply new coating system to a patch and subject this patch to the above requirements for adhesion prior to approval. If customer dislikes non-skid grit application, adjustments to the specifications can be made. Grit coarser than No. 60 aluminum oxide is not recommended. Immediately following "passing" adhesion results, remove urethane topcoats and grout coat by sanding, repair patch test holes using epoxy mortar, and place a "Key-In Termination" adjacent to patch test perimeter. Perform coarse scarification or pneumatic scabbling as required to remove patch tests failing to meet adhesion requirements.

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PART 2 PRODUCTS

2.1 JOINT SEALANT

Formulate the joint sealant to exhibit the properties as listed in Table Ia.

2.2 EPOXY MORTAR FLOORING SYSTEM

A five-coat flooring system consisting of primer, epoxy mortar, grout coat, and two urethane topcoats. Apply the system at a nominal thickness of 1/4 inch and contain an aluminum oxide non-skid grit broadcast.

Formulate the complete flooring system to exhibit the properties listed in Table Ib. Additional requirements for primer coat, grout coat, and urethane top coat are contained in the following sub-paragraphs.

2.2.1 Primer Coat

In addition to the epoxy mortar flooring system requirements, formulate the primer coat to exhibit the properties as listed in Table Ic.

2.2.2 Grout Coat

the grout coat to exhibit the properties as listed in Table Id.

2.2.3 Urethane Topcoat

the urethane topcoat to exhibit the properties as listed in Table Ie.

2.3 WHITE ALUMINUM OXIDE NON-SKID GRIT

Size No. 60, dust-free (washed and dry), minimum 99 percent pure, having the following sieve analysis when tested using a 2.2 pound sample (ASTM E11):

Sieve No. 40 100 percent passing

Sieve No. 50 15-30 percent retained

Sieve No. 60 70-85 percent retained

Sieve No. 70 0-15 percent retained

2.4 PREVIOUSLY TESTED MATERIALS

Table II is a list of vendors products that were tested to the requirements of this specification and passed under a Navy test and evaluation process. These and additional vendors and products may be submitted for review of compliance with test results in accordance with this specification.

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PART 3 EXECUTION

3.1 COATING SAMPLE COLLECTION

The Contracting Officer and QC Manager must witness all material sampling.

Notify the Contracting Officer a minimum of three days in advance of sampling. Obtain liquid samples of each component (eg., primer, intermediate, grout coat, topcoat) by random selection from sealed containers and in accordance with ASTM D3925. Samples may be either individual cans of liquid material or 1.0 quart quantities of properly mixed, extracted, and sealed liquid material. Label samples by designated name, specification number, batch number, project contract number, sample date, intended use, and quantity involved. When the applied epoxy mortar system has met the requirements defined in the paragraph ADHESION TESTING, return coating samples to the installation contractor for proper disposal.

3.3 JOINT MATERIAL REMOVAL, RE-SAW CUTTING, CRACK CHASING

Remove existing material 100 percent in all joints including material bonded to joint walls and base. Rigid material may require saw cutting equipment to remove. Joints may be widened up to 1/8 inch when re-saw cutting. Chase concrete cracks identified for repair and open to a minimum depth of 1/2 inch below crack surface, resulting in crack(s) with smooth vertical walls.

3.4 DEGREASING

On both previously coated and uncoated concrete, degrease entire floor by scrubbing using a hot potable water solution, 120 to 170 degrees F, and a concentrated water-based alkaline degreaser. Perform two complete degreasing cycles on the entire floor surface. Allow solution to soak into surfaces prior to scrubbing and remove using hot potable water under a minimum of 4,000 psi. Rinsing must be complete when the rinse water appears clear. If the industrial detergent is not biodegradable, collect all rinse water and dispose of as hazardous waste. Squeegees and shop vacuums may be used to collect pooling rinse water. Fans may be used to aid drying of floor surfaces.

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3.5 COATING SYSTEM REMOVAL

Remove existing coating system 100 percent employing one or more of the following techniques: shot blasting, chipping, scraping, sanding, scarification, high pressure water blasting, and various hand tools.

Impact tools such as scabblers may be used to remove unsound epoxy mortar flooring systems. In general, a coating system cannot be completely removed by shot blasting and, to attain 100 percent coating removal, requires a combination of the above techniques.

3.6 SURFACE PREPARATION

Shot blast entire floor to produce a level of coarseness equal to ICRI 03732 CSP 3. Overlap each shot blasting pass by 1/4 to 1/2 inch. Add new shot to shot blasting equipment prior to blasting. Prepare concrete surfaces inaccessible to shot blasting, perimeter wall bases and under secured equipment, using a diamond disk grinding or light scarification to produce a level of coarseness equal to ICRI 03732CSP 2, ICRI 03732 CSP 4, respectively. Resulting surfaces shall appear clean and contain the appropriate surface coarseness level. If the resulting cleanliness level cannot be determined, place numerous drops of water on surfaces that appear contaminated. If the water drops soak into concrete, the surfaces are hydrocarbon contamination free (oils, grease, skydrol).

If the water drops bead up and do not flatten out, surfaces require additional degreasing as detailed in the paragraph DEGREASING. Shot blasting coarse concrete or broom finished concrete can produce a coarseness level equal to ICRI 03732 CSP 5: employ a best effort attempt to minimize excessive removal of coarse concrete material. If coarse concrete is encountered, shot blasting to a level of coarseness equal to ICRI 03732 CSP 5 is acceptable: however, extremely coarse concrete can require resurfacing prior to the flooring system's installation. Sweep, vacuum, and run a high powered magnet over all surfaces to be coated, including joints.

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3.7 CRACK REPAIRS

Use the "Elastomeric Underlayer Crack-Bridging Design" as detailed in SSPC-TU 2/NACE 6G197 Figure 7 over the surface of epoxy mortar filled cracks.

3.7.1 Install Bondbreaker

Install bondbreaker, either solvent resistant bondbreaker tape or a 1/8 to 1/4 inch No. 20-No. 40 mesh silica sand layer, to the base of previously chased cracks identified for repair. For cracks without a rigid base, install suitably sized fiberboard to a depth of 1/2 inch below floor level and with bondbreaker over exposed fiberboard. Install bondbreaker to cover the crack's horizontal base and continuously span the entire crack length.Bondbreaker application prevents epoxy mortar from penetrating deep into cracks.Use bondbreaker tape no more than 6 mils thick.In this application, the use of backer rod is prohibited.

3.7.2 Repair Cracks

Using the specified materials, prime interior crack walls and apply epoxy mortar directly into wet primer. Finish epoxy mortar level with floor and without feathered edges. When cured, remove mortar imperfections by sanding flush with adjacent concrete. Apply solvent resistant tape parallel to each side of the mortar filled crack(s) at a minimum inner width of 4 inches between tape. A 4 inch inner tape width is generally suitable for cracks less than 1/2 inch wide whereas cracks more than 1/2 inch wide can require an inner tape width of 6 inches. Apply 1/24 inch of the specified sealant, in one coat, directly over filled crack(s) and spread flush with inner tape edges: a stiff bristled paintbrush can be used to spread the sealant. Use a Wet Film Thickness (WTF) gage to confirm sealant application is between 35 to 40 mils wet. Remove tape and allow sealant to cure a minimum of 24 hours prior to the epoxy mortar flooring system application. Sealant application above 50 mils dry will require removal and reapplication.

3.10 PRE-APPLICATION TESTING FOR CONTAMINATION

Spot check surfaces for oil/grease contamination using the water break test. At a rate of 5 tests per 1000 square feet place one to two water drops onto surfaces and observe for beading. Test all other surfaces that show visible signs of potential contamination.

Perform additional degreasing to surfaces displaying water beading in accordance with the paragraph DEGREASING.

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3.11 COATING APPLICATION

Prior to the flooring system application, vacuum flooring space and mark all joints.

3.11.1 Isolation (Expansion) and Construction Joint Treatment

Install into each isolation (expansion) and construction joint, a continuous length of round polyethylene backer rod flush with the floor's surface and under 30 percent compression. Backer rod placement prevents epoxy mortar from penetrating into isolation and construction joints.

3.11.2 Contraction Joint Treatment

Apply primer and epoxy mortar directly into all contraction joints. This quantity is in addition to the specified 1/4 inch epoxy mortar thickness.

This step may be performed either prior to, or during, the full epoxy mortar application.

3.11.3 Primer Application

Apply primer to flooring space at a minimum of 10.0 mils wet. Do not prime previously installed patch test.

3.11.4 Epoxy Mortar Application

Apply epoxy mortar at 1/4 inch directly into wet primer using a screed box or equal equipment. Finish open areas using a power trowel with stainless steel blades. Perimeter edges and adjacent equipment footings may require finishing by stainless steel hand trowel. Directly above areas with Key-In terminations and at a distance from 1 to 1-1/2 inches away from the mortar's outer edge, slope the mortar down and flush with the concrete's surface. Terminate the resulting angle flush with the each Key-In termination vertical cut. Apply epoxy mortar flush with previously installed patch test. Do not apply epoxy mortar onto patch test surface. When sufficiently cured, sand entire mortar surface. Resulting surface must appear level, contain uniform thickness, and be free of surface imperfections including trowel marks.

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3.11.5 Grout Coat Application

NOTE: Select a grout coat color identical to the selected topcoat color, either white or ultra-light gray. Ultra-light gray is preferred to white.

Sweep and vacuum up residual dust from epoxy mortar sanding. Apply grout coat to epoxy mortar at a minimum of 10 mils wet. Apply grout coat to previously install patch test. If applicable, up CMU wall bases. If the cured grout coat feels oily/greasy, an amine blush has occurred which requires removal. Consult the coating manufacturer to recommend an appropriate blush removal procedure. Epoxy amines can blush during cool temperatures with high humidity.

3.11.6 Grout Coat Sanding

Sand grout coat using 100 grit or finer sandpaper to a dull appearance with visible scratches. Resulting surface must appear 100 percent absent of gloss with zero shiny spots. Lightly sand perimeter edges and around equipment footings.

3.11.7 Saw Cutting and Sealing Joints

Use the "Conventional Sealed Joint" as detailed in Figure 1 of SSPC-TU 2/NACE 6G197 to seal each contraction and expansion joint. Take care to reduce contamination from saw cutting equipment and foot traffic.

Limit floor access to essential contractor personnel. When performing joint work, including saw cutting, suggest placing clean rolled cardboard adjacent joint surfaces to reduce coating system contamination.

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3.11.7.1 Saw Cut Contraction Joints

Place saw cuts directly in the middle of each contraction joint 1/4 inch wide, placed to a minimum depth of 1-1/4 inches, and span the joint's entire length.

3.11.7.2 Saw Cut Isolation (Expansion) and Construction Joints

Place saw cuts to the isolation (expansion) and construction joint's original width and to a minimum depth of 1-1/4 inches.Completely remove the epoxy mortar across the joint's width and further remove the previously installed backer rod.

3.11.7.3 Install Backer Rod

Install a continuous length of round, closed-cell polyethylene backer rod into each saw cut. For 1/2, 3/8 and 1/4 inch wide saw cuts, place backer rod to a depth of 3/8 inch below the grout coat's surface the highest point on the backer rod. For expansion joint saw cuts greater than or equal to 3/4 inch wide, place backer rod to a depth of 5/8 inch below the grout coat's surface. Fit backer rod tight between joint walls under 30 percent compression and place using a backer rod tool. Remove and reinstall all backer rod that is the incorrect size or at the incorrect depth. Following backer rod installation, apply painter's tape to surfaces adjacent joints to protect from sealant.

3.11.7.4 Joint Sealant Application

Apply sealant directly into joints using a bulk-caulking gun. At room temperature, the resulting sealant application must exhibit a concave recess between 1/8 to 1/24 inch below the grout coat's surface. Remove and reapply cured sealant remaining either flush or greater. Following sealant application, remove painter's tape and sealant drips on grout coat. Prior to topcoating, cure sealant a minimum of 24 hours.

3.11.10 Application of Topcoats

Apply two coats of urethane topcoat. Broadcast No. 60, white, aluminum oxide non-skid grit into the second urethane topcoat.

3.11.10.1 Non-Skid Grit Broadcast

Broadcast non-skid grit at a rate of 1.0 pound per 100 square feet into the second urethane topcoat and backroll. Map floor into 600 square foot sections where 9.0 pounds of non-skid grit is pre-weighed, placed into clean buckets and used in its entirety per marked 600 square foot section.

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3.11.10.2 Grout Coat Cleaning

Inspect floor for shiny grease spots and, if detected, spot degrease using manufacturer approved solvent(s) with clean, lint-free rags. Sweep and vacuum up all residual dirt and dust. Solvent wipe all surfaces using solvent(s) and procedures as recommended by manufacturer of epoxy mortar flooring system.

3.11.10.3 First Topcoat

Apply a full coat of urethane topcoat at a spreading rate from 2.5 to 3.2 mils Dry Film Thickness (DFT). Stripe coat perimeter edges and around equipment footings. Monitor and record a minimum of one Wet Film Thickness (WFT) reading per 600 square foot section of floor surface.Sealant is to be lightly coated.

3.11.10.4 Second topcoat

Apply a second coat of urethane topcoat at a spreading rate from 62.5 to

2.5 to 3.2 mils DFT. Stripe coat perimeter edges and around equipment footings. Monitor and record a minimum of one WFT reading per 600 square foot section of floor surface prior to broadcasting non-skid grit. When the correct WFT has been applied per 600 square feet of area, immediately and evenly broadcast non-skid grit into the second urethane topcoat and backroll in two directions.Test the adhesion of the epoxy mortar flooring system in accordance with the paragraph ADHESION TESTING.

3.11.10.5 Walkway Stripes

Place the walkway stripe and grounding rod marker, if applicable, according to Government drawings. When the second topcoat is within its recoat window, apply a walkway stripe of the red/orange urethane topcoat at

3.0 mils DFT. Lightly broadcast non-skid grit into the wet walkway stripe.

Use solvent resistant tape to protect the floor coating against stripe coat bleed. A thin clear coat of either epoxy or urethane may be required to prevent stripe coat bleed prior to the full application of the colored stripe coat. Completely hide the topcoat color with the red/orange stripe, in one coat. If insufficient hiding occurs, apply one additional walkway stripe coat. Apply grounding rod markings using similar procedures, urethane topcoat, and colors and size according to Government drawings.

3.12 CURING

Installed materials must cure and display performance equal to manufacturer's product literature. Remove and reapply improperly cured material.

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3.13 FIELD TESTS AND INSPECTION

3.13.1 Coating Inspector

Consider the Coating Inspector (or designated) a QC Specialist, working for the QC Manager, and be qualified in accordance with Section 01 45 00.00 10 01 45 00.00 20 01 45 00.00 40 QUALITY CONTROL. The Coating Inspector will be present during all field tests, surface preparation, flooring application, initial cure of the flooring system, and during all flooring repair work. The Coating Inspector will provide all tools/equipment necessary to perform field tests and inspection. The Coating Inspector will be responsible for field tests and specified level of inspection.

3.13.2 Inspection

Document weather conditions, job site occurrences, and report conditions and occurrences potentially detrimental to the flooring system. The listed inspection requirements are in addition to the QC inspection and reporting requirements defined in Section 01 45 00.00 10 01 45 00.00 20 01 45 00.00 40 QUALITY CONTROL. The Coating Prepare a project reference sheet outlining all requirements, tests, test methods, and evaluation criteria, and hold regular meetings with contractor personnel, including shot blasting operators and applicators, to review requirements/evaluation criteria for upcoming work prior to execution. At the start of coating operations and every 1.0 hour following until daily work is complete, record air temperature, substrate temperature, and relative humidity.

Following each coat application, inspect surfaces for improperly cured material, blisters, inadequate and excessive coating thickness, and other defects. Document each inspection, test, non-compliant area, and location of each non-compliant area. List evaluation method, evaluation criteria, areas requiring rework, and all other pertinent observations.

3.13.2.1 Daily Inspection Report

Submit to the Contracting Officer one copy of the daily inspection report completed each day when performing work under this Section. Use Appendix X1 "Inspection Checklist" of ASTM D6237 to monitor daily activity and to assist in preparing the daily inspection report. Note each non-compliant issue and each issue identified for rework in accordance with the QC documentation procedures in Section 01 45 00.00 10 01 45 00.00 20 01 45 00.00 40 QUALITY CONTROL. Use of forms containing entry blocks for all required data is encouraged. Present the data in a legible and professional format. Submit report within 24 hours of the report date.

3.13.2.2 Inspection Logbook

Record all daily activity related to this Section in the Inspection Logbook. Record the daily inspection reports, as well as all other pertinent observations and information, in the logbook. Use a hard or

SECTION 09 67 23.16 Page 24 spiral bound book with consecutively numbered pages. Prior to final payment, submit original Inspection Logbook to the Contracting Officer upon completion of project.

3.13.2.3 Inspection Equipment

Use equipment in good condition, operational within its design range, and calibrated as required by the specified standard for each device.

3.13.3 Adhesion Testing

Perform a minimum of three modified adhesion tests (ASTM D4541) on the topcoat no less than forty-eight hours following application. Select three random flooring locations spaced a minimum of 20 feet between each location. Vertically core completely through the epoxy mortar flooring system and a minimum of 3/8 inch into concrete using a suitable drill fitted with a 1 inch diameter core bit.

Throughout coring, employ a best effort attempt to avoid fracturing and overheating both the mortar system and concrete: improper coring can affect adhesion results. Adhere directly to each cored surface's center a 3/4 inch diameter pull-off coupon. Lightly sand test area flooring surface prior to attaching pull-off coupons containing a grit-blasted anchor profile. When pull-off coupon adhesive has sufficiently cured, test adhesion and evaluate results. If testing produces cohesive failures within the concrete, no less than 40 mils concrete removal over 95 percent of each pull-off coupon, or adhesion more than 400 psi mortar system's adhesion is acceptable. If the above requirements are not satisfied, then perform one adhesion test per 100 square feet using the above procedures. Two additional tests will confirm results for each non-compliant area. Remove and rework all areas unable to meet adhesion requirements to sound material. Fill core holes using primer, sand-filled epoxy mortar, grout coat, and urethane topcoats.

Finish resulting repairs flush with adjacent coatings, displaying an equivalent appearance.

3.14 Final Cleanup

Following work completion, remove debris, equipment, and materials from site. Remove temporary connections to Government or contractor furnished water and electrical services. Restore existing facilities in and around the work areas to their original condition.

SECTION 09 67 23.16 Page 25

TABLE I

MATERIAL REQUIREMENTS

Table Ia - Sealant

Test Minimum Requirement (maximum where indicated)

Sealant System (two-pack: self-leveling) Polysulfide (Manganese Cure; MnO2) or Urethane

Percent Volume Solids 100 percent

Chemical Resistance to JP-8 plus 100 Fuel at 70 degrees F (ASTM D1308) (see note 1)

48 hours immersion: 2.0 percent (max) weight increase, 5.0 percent (max) volume increase, 2.0 percent (max) weight loss

Chemical Resistance to Motor Oils at 70 degrees F (ASTM D1308) (see note 1)

48 hours immersion: 2.0 percent (max) weight increase, 5.0 percent (max) volume increase, 2.0 percent (max) weight loss

Chemical Resistance to Skydrols at 70 degrees F (ASTM D1308) (see note 1)

48 hours immersion: 2.0 percent (max) weight increase, 5.0 percent (max) volume increase, 2.0 percent (max) weight loss

Hardness (ASTM D2240: Shore A) 20

Tensile Strength (ASTM D412) (or ASTM D638

150 psi

Percent Elongation (ASTM D412) (or

ASTM D638)

500 percent

Tack Free at 65 degrees F (ASTM C679) 12 hours maximum

Adhesion to Sand Filled Epoxy Polyamine 140 psi

Adhesion to Urethane Topcoats (paintable sealant)

140 psi

NOTES: (1) Immerse and test a minimum three - 2 by 1/2 by 1/2 inch section of cured sealant.

SECTION 09 67 23.16 Page 26

Table Ib - Epoxy Mortar Flooring System

Test Minimum Requirement (maximum where indicated)

Compression Strength )ASTM C579) 7,500 psi

Tensile Strength (ASTM C307) 1,300 psi

Adhesion to Concrete (ASTM D4541) (see note 1)

400 psi or 100 percent failure in concrete

Heat Resistance, continuous exposure 140 degrees F

Heat Resistance, intermittent exposure 200 degrees F

Coefficient of Thermal Expansion 0 - 210 degrees F (ASTM C531)

5.0 minus 33.0 times 10-6in/in degrees F

Thermal Compatibility between Concrete (

ASTM C884/C884M)

"pass"

Chemical Resistance to JP-8 plus 100 Fuel at 70 degrees F (ASTM D1308)(see note 2)

48 hours immersion: 2.0 percent (max) weight increase, 2.0 percent (max) volume increase, 2.0 percent (max) weight loss

Chemical Resistance to Motor Oils at 70 degrees F (ASTM D1308) (see note 2)

48 hours immersion: 2.0 percent (max) weight increase, 2.0 percent (max) volume increase, 2.0 percent (max) weight loss

Chemical Resistance to Skydrols at 70 degrees F (ASTM D1308) (see note 2)

48 hours immersion: 2.0 percent (max) weight increase, 2.0 percent (max) volume increase, 2.0 percent (max) weight loss

Lead (ASTM D3335 0.06 percent (max)

Cadmium (ASTM D3335) 0.06 percent (max)

Chromium (ASTM D3718) 0.00 percent

NOTES:

(1) When tested for adhesion, mortar system must display 400 psi adhesion or remove no less than 40 mils of concrete over 95 percent of each pull-off coupon throughout service.

SECTION 09 67 23.16 Page 27

Table Ib - Epoxy Mortar Flooring System

Test Minimum Requirement (maximum where indicated)

(2) Immediately following immersion, in addition to the listed requirements, mortar system must be evaluated for blisters, checks, discoloration, softening, and lifting. Mortar system must be visually free of blisters, checks, and discoloration, and display both substrate and intercoat adhesion no less than 350 psi (ASTM D4541).

SECTION 09 67 23.16 Page 28

Table Ic - Primer

Test Minimum Requirement (maximum where indicated)

Resin System (ASTM D2621) Epoxy Polyamine (two-pack)

Percent Volume Solids (ASTM D2697) 100 percent

Color Clear to Amber

Hydrolytic Stability (see note 1) No effect: 30 days immersion in Sodium Hydroxide solution with pH no less than 13.5

Moisture Insensitivity Throughout Service ( ASTM F1869, ASTM D4541) (see note 2)

No effect: Insensitive to moisture vapor emission at rates no more than 4.5 pounds moisture/24 hours, 1000 square feet

Adhesion to Concrete Throughout Service ( ASTM D4541) (see note 3)

400 psi or or 100 percent failure in concrete

NOTES:

(1) Immediately following immersion, evaluate primer for blisters, checks, discoloration, softening, and substrate lifting. Primer must be visually free of blisters, checks and moderate discoloration, and display wet adhesion no less than 350 psi (ASTM D4541).

(2) During and following application, primer must remain unaffected by Moisture Vapor Emission (MVE) at rates no more than 4.5 pounds moisture per 24 hours, 1000 square feet: primer must meet the requirements of note 3. Signs of moisture sensitivity include blisters, softening, lifting, and discoloration (whitening).

(3) When tested for in-situ adhesion, primer must display 400 psi adhesion or remove no less than 40 mils of concrete over 95 percent off each pull-off coupon.

SECTION 09 67 23.16 Page 29

Table Id - Grout Coat

Test Minimum Requirement (maximum where indicated)

Resin System (ASTM D2621) Epoxy Polyamine (two-pack)

Percent Volume Solids (ASTM D2697) 100 percent

Color 17925 (white), or 17875 (ultra-light gray)

Hardness (ASTM D2240: Shore D) 80

Adhesion to Epoxy Mortar (ASTM D4541) 400 psi

SECTION 09 67 23.16 Page 30

Table Ie - Urethane Topcoat

Test Minimum Requirement (maximum where indicated)

Resin System (ASTM D2621) Aliphatic Urethane (two-pack)

Percent Volume Solids (ASTM D2697) 51 percent

Topcoat Color (SAE AMS-STD-595A) 17925 (white) or 17875 (ultra-light gray)

Walkway Strip Color: Red/Orange, semi-gloss (SAE AMS-STD-595A)

22197 (red/orange)

Application Thickness per Coat 2.5 to 3.5 mils Dry Film Thickness(DFT)

Hiding Power: Red/Orange Complete hiding of white coatings at 3.2 mils DFT (one coat)

Sunlight Resistance Non-yellowing

Heat Resistance, continuous exposure 140 degrees F

Heat Resistance, intermittent exposure 200 degrees F

Chemical Resistance to JP-8 plus 100 Fuel at 70 degrees F (ASTM D1308)(see note 1)

48 hours immersion: 1.0 percent (max) weight increase, 1.0 percent (max) volume increase, 1.0 percent (max) weight loss

Chemical Resistance to Motor Oils at 70 degrees F (ASTM D1308) (see note 1)

48 hours immersion: 1.0 percent (max) weight increase, 1.0 percent (max) volume increase, 1.0 percent (max) weight loss

SECTION 09 67 23.16 Page 31

Table Ie - Urethane Topcoat

Test Minimum Requirement (maximum where indicated)

Chemical Resistance to Skydrols at 70 degrees F (ASTM D1308) (see note 1)

48 hours immersion: 1.0 percent (max) weight increase, 1.0 percent (max) volume increase, 1.0 percent (max) weight loss

NOTES: (1)Immediately following immersion, in addition to the listed requirements, evaluate urethane topcoat for blisters, checks, discoloration, softening, and lifting. Urethane topcoat must be visually free of blisters, checks, and discoloration, and display adhesion no less than 350 psi ASTM D4541).

SECTION 09 67 23.16 Page 32

TABLE II

PREVIOUSLY TESTED MATERIALS*

Vendors Materials

Stonhard (856) 779-7500 Primer: Standard Primer

Epoxy Mortar: Stonclad GS

Grout Coat: Stonkote GS4

Topcoat: Stonseal GS6

Sealant: Vulkem 245

Polyspec (281) 397-0033 Primer: 300EX

Epoxy Mortar: Tuffrez 200

Grout Coat: Tuffrez 203

Topcoat: Tuffrez 235

Sealant: T-2235SL

Tennant (800) 553-8033 Primer: Eco-MPE

Mortar Coat: Eco-PT 250

Grout Coat: Eco-PT

Topcoat: Eco-HPS100

Sealant: N/A **

Crawford Labs (800) 356-7625 Primer: Florock 4700

Epoxy Mortar: Florock 4700

Grout Coat: Florock 4700

Topcoat: Florock Florothane MC 100

Sealant: N/A **

SECTION 09 67 23.16 Page 33

TABLE II

PREVIOUSLY TESTED MATERIALS*

Vendors Materials

General Polymers (800) 543-7694 Primer: #3578, Universal Primer

Epoxy Coat: #3562, Mortar Binder Resin

Grout Coat: #3744GP, Novo-Flo

Topcoat: #4618, Polyurethane Enamel

Sealant: Cor-Seal PS

NOTES:

* Other products may meet specification requirements. Up to specification's date of issue, previously tested materials met specification requirements. It is the users' responsibility to confirm previously tested material formulations have not changed and specification requirements will be met. **Polyspec T-2235SL sealant may be used.

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