DPSCD

POST MIDDLE SCHOOL

TUNNEL BULKHEAD 262118 AUGUST 6, 2026

CONCRETE 03001-1

SECTION 03001 – CONCRETE

PART 1. GENERAL

1.01 RELATED DOCUMENTS

A. Attention is directed to Division 0, Bidding and Contract Requirements, and to Division 1, General Requirements, which are hereby made a part of this specification.

1.02 SECTION INCLUDES

A. Work included in this section includes furnishing all labor, materials, equipment and incidentals required for complete installation of formwork, reinforcement, accessories, cast-in-place concrete, finishing and curing. This section pertains to building concrete work.

B. Related work specified elsewhere:

1. Section 03300 – Bonding Agents for Concrete

2. Section 03750 – Concrete Rehabilitation

3. Section 05500 - Metal Fabrications

1.03 SUBMITTALS

A. Comply with ACI 315 "Details and Detailing of Concrete Reinforcement”. Indicate reinforcement sizes, spacings, locations, and quantities, bending and cutting schedules, supporting and spacing devices.

B. See Architectural drawings for General Notes and Special Conditions.

C. Provide data on joint devices, attachment accessories, mix design for each type concrete, proportions of all ingredients, admixtures, slump range, expected strength and water cement ratio. Provide historical test data with each proposed mix design.

1.04 QUALITY ASSURANCES

A. Building Code Requirements for Structural Concrete (ACI

318) and latest supplements thereto.

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B. Standard Practice for Selecting Proportions for Normal, Heavy Weight, and Mass Concrete (ACI 211.1).

C. Hot Weather Concreting (ACI-305R).

D. Cold Weather Concreting (ACI-306R).

E. Guide for Measuring, Mixing, Transporting and Placing Concrete (ACI 304R).

F. Guide to Curing Concrete (ACI 308R).

G. Specifications for Structural Concrete (ACI 301).

H. Guide for Concrete Floor and Slab Construction (ACI 302.1R).

I. Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete (ASTM C618).

J. Standard Specification for Preformed Expansion Joint Filler for Concrete (Bituminous Type) - (ASTM D994).

K. Guide to Formwork for Concrete (ACI 347).

L. Concrete Reinforcing Steel Institute (CRSI) "Manual of Standard Practice.

M. Design and workmanship of all concrete shall be in accordance with referenced specifications and code listed above. Quality, tolerances, and level of performance of work shall be as specified therein. Contractor shall keep on file, in project office, current copies of all references listed above.

PART 2. PRODUCTS

2.01 FORM MATERIALS

A. Form Material for Exposed Concrete: Plywood; 5/8" APA B-B plyform Class 1, exterior. Use plywood thickness sufficient to support concrete at temperature and rate of pour. Use only sound, undamaged sheets with clean, true edges. Furnish in largest sizes to minimize joints.

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B. Form Material for Unexposed Concrete: Plywood; 5/8" APA B-B-G-2, exposure 1, exterior, plywood graded per PS-1 standards for construction and industrial plywood. Use plywood thickness sufficient to support concrete at temperature and rate of pour. Use only sound, undamaged sheets with clean, true edges. Lumber shall be standard grade or better.

C. In lieu of "A" above, the material specified under "B" may be used for exposed concrete if a 3/16" smooth one side, treated, pressed fiberboard liner is utilized.

D. Lumber for light framing (less than 6" wide): standard grade and species. Framing (6" wider and from 2" to 4" thick): provide No. 1 grade in one of the following species:

1. Douglas Fir (WWPA).

2. Southern Pine (SPIB).

3. Redwood (RIS).

E. Prefabricated steel or metal shall be minimum 16 ga. as approved to produce surfaces equal to those specified for wood. Forms shall be matched, tight fitting, and stiffened to support weight of concrete.

F. Metal Form Deck: Utilized to support exterior slabs;

shall be S.D.I. approved and equal to Vulcraft. Spacing of slab reinforcing shall be adjusted if required to match corrugations of metal deck.

G. Form Ties: Bolt and rod type so designed that upon removal of the form no metal shall be within 1-1/2" of the concrete surface and no holes larger than 1" in diameter. Concrete exposed to the exterior shall utilize galvanized ties.

H. Dovetail Anchor Slots: Galvanized steel, foam filled, release tape sealed slots, bond tab anchors as manufactured by Heckmann, Hohmann & Barnard, Inc. or approved.

I. Form Release Agent: Colorless mineral oil which will not stain the concrete or impair natural bonding characteristics of coating intended for use on concrete.

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J. Formed Construction Joints for Slab-on-Grade: Galvanized steel, tongue and groove type profile with knockout holes to receive doweling, min. 26 gage unless noted otherwise.

Size and profile as indicated on drawings or as required to fit field conditions.

K. Slab Edge Joint Filler: ASTM D994, premolded asphaltic board, thickness as indicated or (if not indicated, 1/2" thick minimum).

L. 6 mil thick, clear polyethylene film (for bond break between walls and floor), type recommended for below grade application.

N. Nails, spikes, lag bolts, through bolts, anchorages:

Size as required, of sufficient strength and character to maintain formwork in place while placing concrete.

2.02 REINFORCEMENT MATERIALS

A. Reinforcing Bars: ASTM A 615 Grade 60 deformed.

B. Welded Wire Fabric: ASTM A 185, welded steel wire fabric.

C. Supports for Reinforcement: Bolsters, chairs, spacers, and other devices for spacing, supporting, and fastening reinforcing bars and welded wire fabric in place. Use wire bar-type supports complying with CRSI specifications.

1. For slabs-on-grade, use supports with sand plates or horizontal runners where base material will not support chair legs.

2. For exposed-to-view concrete surfaces where legs of supports are in contact with forms, provide supports with legs that are protected by plastic (CRSI, Class

1) or stainless steel (CRSI, Class 2).

D. Inert fiber reinforcement: Polypropylene fiber meeting

ASTM-C1116; Fibermesh, Forta Corporation, or other Architect approved U.L. Listed. Add to plant mixed concrete at a rate of 1.5 lbs. per cubic yard of mix.

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2.03 CONCRETE MATERIALS

A. Cement; controlling specification for Portland Cement, ASTM C150, Type I-Normal or Type II.

B. Aggregates shall conform to ASTM C-33. Maximum size of aggregate shall not be larger than 1/5 of narrowest dimension between forms of member for which concrete is to be used, nor larger than 3/4 of minimum clear spacing between reinforcing bars, nor larger than 1/3 of slab depth.

C. Lightweight aggregates shall conform to ASTM C 330.

D. Water: Clean and potable.

E. Air Entrainment Admixture: ASTM C260, as manufactured by Master Builders, Euclid, or W.R. Grace.

F. Chemical Admixtures: ASTM C494; Type 'A' - water reducing; Type 'B' - retarding, Type 'C' - accelerating, Type 'D' - water reducing and regarding, Type 'E' - water reducing and accelerating, Type 'F' - water reducing high range; Type 'G' - water reducing high range and retarding. Calcium chloride or admixtures containing more than .05 percent chloride ions by weight of admixture shall not be used. Each admixture shall not contribute more than 5 ppm by weight, of chloride ions to the total concrete constituent. Use admixtures in strict compliance with manufacturer's directions.

G. Fly Ash: ASTM C618, Type 'C' or 'F'.

H. Bonding Agent: Refer to Spec Section 03300 “Bonding Agents for Concrete”.

I. Non-Shrink Grout: Non-shrink type, pre-mixed compound consisting of non-metallic aggregate, cement, water reducing and plasticizing agents. Capable of developing a minimum compressive strength of 7000 psi at 28 days.

a. Manufacturer: Dayton Superior Corp. or equal as approved by engineer.

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J. Adhesive Anchoring: Injectable adhesive or self-contained capsule as manufactured by:

1. 'Hilti' HIT System, or Architect approved/reviewed equal.

2.04 CURING COMPOUNDS & SEALERS

A. Curing Compound/Sealer: Liquid curing compound, water base, concrete curing-sealing compound, VOC (volatile organic content) compliant, containing fugitive dye that does not leave residue (resin, varnish, wax, etc.).

Fugitive dye must disappear in 7 days, as manufactured by:

1. Sonneborn Building Products, Kure-N-Seal W.

2. Dayton Superior Corporation, Safe Cure & Seal (J-

18).

3. Burke by EDOCO Spartan-Cote WB Cure Seal Hardener.

4. MasterKure 100W, Master Builders, Inc.

5. Vocomp-20, W.R. Meadows.

B. Absorptive Mats: Burlap cloth, commercial quality suitable for purpose. Constructed of jute or kenaf, weighing approximately 9 oz. per square yard, complying with AASHTO M182, Class 2.

C. Moisture retaining cover, complying with ASTM C171; one of the following: waterproof paper, polyethylene film, or polyethylene coated burlap.

D. Crack Repair Material: Floor slabs - 2 part, 100% solid epoxy adhesive in formulation recommended by manufacturer for application, as manufactured by:

1. W.R. Meadows Reziweld 1000 or Architect approved/reviewed equal.

E. Concrete Densifier/Hardener/Sealants:

Liquid applied, lithium silicate based concrete hardener/sealer. Manufacturers to include:

1. Dayton Superior “Pentra-Hard Densifier”

2. WR Meadows “Liqi-Hard Ultra

3. Laticrete (L+M) “L+M Lion Hard”

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4. Prosoco “Consolideck LS Premium Concrete Sealer, Hardener and Denisfier.

5. Sika “Sikaflorr-956 LD

6. SureCrete “SureCrete LD 1800 Lithium Densifier and

Cement Hardener”

2.05 CONCRETE MIX

A. Mix concrete in accordance with ACI 304 and deliver concrete in accordance with ASTM C94.

B. Quality working stresses for the design of this project shall be based on specific minimum 28-day compressive strength of concrete or on specified minimum compressive strength at earlier age at which concrete may be expected to receive full load. Provide concrete of the following properties:

1. Exterior concrete; i.e. exterior walks, etc. - 4,000 psi. 28-day compressive strength; water-cement ratio, 0.40 maximum (air entrained).

2. Interior slab on ground - 4000 psi. 28-day compressive strength; water-cement ratio, 0.44 maximum (non-air entrained).

3. Footings, walls, stair landing and steps, slabs and all other concrete - 3500 psi. 28-day compressive strength; water-cement ratio, 0.51 maximum (non-air-entrained), 0.46 maximum (air entrained).

C. Slump Limits: Proportion and design mixes to result in concrete slump at the point of placement as follows:

1. Ramps and Sloping Surfaces: Not more than 3".

2. Reinforced Foundation Systems: Not less than 1" and not more than 4".

3. All Other Concrete: Not less than 1" & not more than

4".

4. Concrete containing high-range water-reducing admixture (superplasticizer). Not more than 8 inches after adding admixture to site-verified 2-3 inch slump concrete.

5. Site added water to increase slump is strictly prohibited.

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D. Proportions of aggregate to cement shall be such as to produce a mixture which will work readily into corners, angles of forms, and around reinforcement without permitting materials to segregate. Excess free water shall not collect on concrete surface.

E. Fly ash shall not exceed 25% of cement content by weight.

No fly ash shall be used in slabs.

F. Select admixture proportions for normal weight concrete in accordance with ACI 301, Method 1 and in strict accordance with manufacturer's instructions.

G. Air Entraining Agent: Use in all exterior concrete exposed to weather; i.e. exposed foundation walls, supported slabs, ramps, etc. Air entrainment shall be accomplished by use of approved additives used in accordance with manufacturer's instructions. Limit air to 5% minimum to 8% maximum.

H. Adjustment to concrete mixes: Mix design adjustments may be requested by Contractor when characteristics of materials, job conditions, weather or other circumstances warrant, as accepted by the Architect. Laboratory test data for revised mix design and strength results must be submitted to and accepted by Architect before using in work.

PART 3. EXECUTION

3.01 FORMWORK ERECTION

A. Erect formwork, shoring and bracing to achieve design requirements. Fabricate forms for easy removal without hammering or prying against exposed concrete surfaces.

B. Provide bracing to ensure stability of formwork.

C. Apply form release agent to formwork in accordance with manufacturer's instructions, prior to placing for accessories and reinforcement.

D. Do not apply form release agent where concrete surfaces will receive special finishes or applied coverings which are affected by agent.

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E. Clean forms as erection proceeds, to remove foreign matter.

F. Footings and foundations shall be formed, notched and/or sleeved as indicated to provide for installation of mechanical, electrical or plumbing piping/conduit.

G. Forms shall conform to shape, lines and dimensions of members as called for, substantially and sufficiently tight to prevent leakage of concrete.

H. Forms shall be properly braced, and tied together so as to maintain position and shape. Forms for exposed concrete shall be braced so as to provide dimensions called for, and have taped joints.

I. Construction joints, whether indicated on drawings or not, shall be made or located so as to least impair strength of the structure. Where joint is to be made, the surface of the concrete shall be thoroughly cleaned and all latency removed. In addition, vertical joints shall be keyed.

3.02 INSERTS, EMBEDDED COMPONENTS, AND OPENINGS

A. Provide formed openings where required for work to be embedded in and passing through concrete members.

B. Coordinate work of other Sections in forming and setting openings, slots, recesses, chases, sleeves, bolts, anchors and other inserts.

C. Install concrete accessories straight, level, and plumb.

3.03 REINFORCEMENT PLACEMENT

A. Place reinforcement, supported and secured against displacement.

B. Ensure reinforcing is clean, free of loose scale, dirt, or other foreign coatings.

C. Provide for continuity of reinforcing around corners in footings and walls. Lap corner bars 30 bar diameters.

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D. Install welded wire fabric in lengths as long as practicable. Lap adjoining pieces at least one full mesh and lace splices with wire. Offset laps of adjoining widths to prevent continuous laps in either direction.

3.04 PLACING CONCRETE

A. Prepare previously placed concrete by cleaning with steel brush and applying bonding agent. Apply bonding agent in accordance with manufacturer's instructions.

B. Separate exterior slabs-on-grade from vertical surfaces with ½ inch thick joint filler, extended full thickness of slab. Also, provide filler strips at supported slabs and vertical surfaces. At interior slabs-on-grade locations, provide bond break from vertical surfaces consisting of 6 mil polyethylene film or 15# asphalt building paper and where indicated on plans.

C. Place concrete continuously between predetermined control and construction joints. Do not break or interrupt successive pours such that cold joints occur. Where applicable, construction joints shall occur at control joint locations, unless noted otherwise.

D. Concrete slabs on grade shall be constructed of thickness indicated. If thickness is not indicated, provide a minimum thickness of 6". Minimum thickness at pipes embedded in concrete shall not be less than three times o.d. of the pipe. All buried piping shall have been tested before placement of concrete.

E. Provide interior control joints where called for on drawing as detailed. When interior construction joints occur, they shall also be considered as control joints.

Provide sawed groove similar to a control joint at all construction joints.

F. Concrete shall be conveyed from the mixer to place of final deposit by methods which will prevent separation and loss of material.

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G. All equipment used for transporting equipment shall be cleaned of all debris. Ice shall be removed from all places to be occupied by concrete forms, and masonry fillers shall be thoroughly wetted except where air temperatures are below 40 degrees F.

H. Equipment for chuting, pumping, pneumatically conveying concrete, shall be such size and design as to insure practically continuous flow of concrete at delivery and without separation of materials.

I. Concrete shall be deposited as soon as practicable in its final position to avoid segregation due to re-handling, flowing. Concreting shall be carried on at such rate that concrete is at all times plastic and flow readily into space between bars. No concrete that has partially hardened or has been contaminated by foreign materials shall be deposited on work, nor shall re-tempered concrete be used.

J. Concreting, once started, shall be carried on as a continuous operation until placing of panel or section is completed. Top surface shall be generally level.

K. All concrete shall be thoroughly compacted by suitable means during operation of placing and shall be thoroughly worked around reinforcement, embedded fixtures, and into corners of forms. Vibrator shall not be used to flow concrete.

L. Where new concrete is doweled to existing work, drill holes in existing concrete, insert steel dowels and pack with non-shrink grout or chemical adhesive. Follow manufacturer's recommendations for installation.

M. Screed floors slabs-on-grade and concrete base for toppings level, maintaining surface flatness of maximum 1/8 inch in 10 ft.

N. Construct all concrete site work items to shape, size, thickness and elevations shown. Concrete supported slabs shall be 4" thick on 1” form deck with reinforcing as indicated, unless otherwise shown. Side form all work.

Slope surfaces of supported slabs, 1/4" per foot to low side or as directed by Architect/Engineer.

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O. Provide 1/2" bituminous expansion joint filler along all joints where supported slabs abut other walks, building walls, etc.

P. Protecting and sealing: Protect concrete supported slabs, ramps, platforms, slabs, etc., from pedestrian traffic for three days after pouring. Concrete shall be cured using two layers of burlap kept wet for minimum of 5 days; or at Contractor's option, he may use sprayed-on compound according to manufacturer's recommendations as approved by Architect. Curing method used shall not discolor original color of concrete, nor shall white liquid curing compound be used.

3.05 FORM REMOVAL

A. Do not remove forms or bracing until concrete has gained sufficient strength to carry its own weight and imposed loads.

B. Remove formwork progressively and in accordance with code requirements.

3.06 FLOOR FINISHING

A. Finish concrete floor surfaces in accordance with ACI 301 and ACI 302.

B. Uniformly spread, screed, and float concrete.

C. Maintain surface flatness, with maximum variation of 1/8 inch in 10 ft. Corridor slabs to have overall FF=40, local

FF=20.

D. In areas with floor drain, maintain floor level at walls and pitch surfaces uniformly to drains.

E. Apply concrete densifier/hardener/sealer on all floor surfaces not receiving resilient flooring tile, hard tile, carpet, epoxy flooring, etc. Apply in accordance with manufacturer's instructions.

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F. Floor shall be finished without excessive floating. Delay troweling until concrete is sufficiently hard to prevent water working to surface. Bring finish to smooth level surface with minimum troweling possible.

G. Finishes, other than floors, exposed on exterior or interior shall be formed true, free from marks, irregularities. Remove any loose material, grind all projections, fill any honeycombing or holes, finish smooth. Use carborundum stone to hand rub and provide smooth, even surface where directed.

H. Thoroughly clean and prepare concrete floors scheduled to receive a sealer. Apply in strict accordance with manufacturer's instructions.

3.07 CURING

A. Place absorptive matting and dampen as required.

B. Immediately after placement, protect concrete from premature drying.

C. Maintain concrete with minimal moisture loss at relatively constant temperature for period necessary for hydration of cement and hardening of concrete.

D. Provisions shall be made for maintaining concrete in moist condition for at least (5) five days after placement, except high early concrete which shall be cured for at least (2) two days.

E. Cold Weather Requirements:

1. General: Except as modified herein, all work shall be in accordance with ACI 306R.

2. Adequate equipment shall be provided for heating concrete materials and protecting concrete during freezing or near freezing weather. No frozen materials or materials containing ice shall be used.

3. All concrete materials, all reinforcement, forms, fillers, ground with which concrete is to come in contact shall be free from frost. Whenever temperature of surrounding air is below 40° F., all concrete placed in forms shall have a temperature of

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between 70° F., 80ºF. Adequate means shall be provided for maintaining temperature of not less than 70° F. for 3 days, 50° F. for 5 days, except high-early concrete shall have temperature maintained at not less than 70° F. for 2 days, 50° F. for (3) three days, or for as much more time as necessary to insure proper curing. Housing, covering, other protection used in connection with curing shall remain in place at least (24) hours after artificial heating is discontinued. No dependence shall be placed on salt or other chemicals for prevention of freezing.

F. Weather Conditions:

1. In hot weather, sprinkle and cover all concrete for at least (24) hours longer than specified for normal curing periods. In hot weather work shall be in accordance with ACI 305R.

2. In weather when temperature falls below freezing, and in any event between December 1 and April 1, no concrete shall be poured without adequate frost protection.

3.08 CONCRETE FINISHING

A. Provide concrete surfaces to be left exposed, concrete walls, columns, etc., with smooth rubbed finish not later than one day after form removal.

1. Moisten concrete surfaces and rub with carborundum brick or another abrasive until producing a uniform color and texture. Do not apply cement grout other than that created by the rubbing process.

2. Provide ¾” x ¾” beveled edges at corners of exposed concrete.

3.09 FIELD QUALITY CONTROL

A. Inspection and testing shall be performed by an independent firm selected by the Owner and retained by the Contractor, in accordance with Division 1, Section 01400 “Quality Control”.

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B. The Contractor shall notify the Architect/Engineer and the Testing Lab at least (5) five days prior to the commencement of concrete operations.

C. See Division 1 for inspection and testing allowances, Section 01400 “Quality Control”.

D. Specimens shall be molded and cured as per ASTM C31.

Three specimens per test, not less than one test for each day's pour, each (50) yards concrete poured, each building unit, or each strength concrete. Specimens shall be laboratory cured.

E. Specimens shall be tested in accordance with ASTM C39.

(1) One specimen shall be tested at (7) seven days, (2) two at (28) days.

F. When average strength of laboratory control cylinders fall below required compressive strength, Architect shall have right to order change in proportions and water content for remainder of structure. Architect shall have right to require tests as per ACI Building Code; Chapter 20 where load tests show concrete does not conform with drawings or specifications. Deficiency shall be corrected without additional cost to Owner.

G. A copy of test reports at (7) seven days and (28) twenty eight days, shall be sent directly to the Architect by the Testing Laboratory, with all required information shown.

H. Slump tests per ASTM C-172 and C-143, minimum of (1) one test for each set of cylinders, or more as conditions warrant. Deliveries exceeding specified slump shall be rejected.

3.10 DEFECTIVE CONCRETE

A. Modify or replace concrete not conforming to required lines, details and elevations, as directed by the Architect/Engineer.

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B. Failure of concrete topping to bond to substrate (as evidenced by a hollow sound when tapped), or disintegration or other failure of topping to perform as a floor finish, will be considered failure of materials and workmanship. Repair of replace toppings in areas of such failures, as directed.

END OF SECTION 03001

BONDING AGENTS FOR CONCRETE 03300-1

SECTION 03300 – BONDING AGENTS FOR CONCRETE

1.01 SUMMARY

A. This specification describes the use of a bonding bridge between new portland-cement mortar or concrete and hardened portland-cement mortar or concrete.

1.02 QUALITY ASSURANCE

A. Manufacturing qualifications: The manufacturer of the specified product shall have in existence a recognized quality assurance program and be ISO 9001 Certified, a program of training, certifying and technically supporting a nationally-organized Approved Contractor Program with a re-certification program of its participants for a minimum of 5 years.

B. Contractor qualifications: Contractor shall be an Approved Contractor of the manufacturer of the specified product, who has completed a program of instruction in the use of the specified coating material, and provides a certification from the manufacturer attesting to its Approved Contractor status.

C. Install materials in accordance with all safety and weather conditions required by manufacturer, or as modified by applicable rules and regulations of local, state and federal authorities having jurisdiction.

Consult Material Safety Data Sheets for complete handling recommendations.

1.03 DELIVERY, STORAGE AND HANDLING

A. All materials must be delivered in original, unopened containers with the manufacturer’s name, labels, product identification, and batch numbers. Damaged material must be removed from the site immediately.

B. Store all materials off the ground and protect from rain, freezing or excessive heat until ready for use.

C. Condition the specified product as recommended by the manufacturer.

1.04 JOB CONDITIONS

A. Environmental Conditions: Do not apply material if it is raining or snowing or if such conditions appear to be imminent. Minimum application temperature 40ºF (5ºC) and rising.

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B. Protection: Precautions should be taken to avoid damage to any surface near the work zone due to mixing and handling of the specified coating.

1.05 SUBMITTALS

A. Submit PDF copy of manufacturer’s literature, to include:

Product Data Sheet, System Data Sheet, Application Guide, and appropriate Material Safety Data Sheets (MSDS).

B. Submit copy of Certificate of Approved Contractor status by manufacturer.

1.06 WARRANTY

A. Provide a written warranty from the manufacturer against defects of materials for a period of (5) five years, beginning with date of substantial completion of the project.

PART 2 – PRODUCTS

2.01 MANUFACTURERS

A. Sika Armatec 110 EpoCem, as manufactured by Sika Corporation, 201 Polito Avenue, Lyndhurst, NJ 07071 is considered to conform to the requirements of this specification.

2.02 MATERIALS

A. Epoxy resin/portland cement adhesive shall be Sika Armatec 110 EpoCem.

1. Component “A” shall be an epoxy resin/water emulsion containing suitable viscosity control agents. It shall not contain butyl glycidyl ether.

2. Component “B” shall be primarily a water solution of a polyamine.

3. Component “C” shall be a blend of selected portland cements and sands.

4. The material shall not contain asbestos.

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2.03 PERFORMANCE CRITERIA

A. Properties of the mixed epoxy resin/portland cement adhesive.

1. Pot Life: 90 minutes @ 73ºF.

2. Contact Time: 95ºF (35ºC) 6 hours

68ºF (20ºC) 12 hours 50ºF (10ºC) 16 hours 40ºF (5ºC) 24 hours

3. Color: Dark gray

B. Properties of the cured epoxy resin/portland cement adhesive.

1. Compressive Strength (ASTM C-109)

a. 3 day: 4500 psi (31.0 MPa)

b. 7 day: 6500 psi (44.8 MPa)

c. 28 day: 8500 psi (58.6 MPa)

2. Splitting Tensile Strength (ASTM C-496)

a. 28 days: 600 psi (4.1 MPa)

3. Flexural Strength (ASTM C-348)

a. 1250 psi (8.6 MPa)

4. Bond Strength ASTM C-882 at 14 days

a. Wet on Wet, 0-hr. open time: 2800 psi (19.3

MPa)

b. 24-hr. open time: 2600 psi (17.9 MPa)

5. Bond of Steel Reinforcement to Concrete (Pullout Test)

a. Sika Armatec 110 coated: 625 psi (4.3 MPa)

b. Epoxy coated: 508 psi (3.5 MPa)

c. Plain Reinforcement: 573 psi (3.95 MPa)

6. The epoxy resin/portland cement adhesive shall not produce a vapor barrier.

7. Material must be proven to prevent corrosion of reinforcing steel when tested under the procedures as set forth by the Federal Highway Administration Program Report No. FHWA/RD86/193. Proof shall be in the form of an independent testing laboratory corrosion report showing prevention of corrosion of the reinforcing steel.

Note: Tests above were performed with material and curing conditions at 73ºF and 45-55% relative humidity.

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PART 3 - EXECUTION

3.01 MIXING AND APPLICATION

A. Mixing the epoxy resin: Shake contents of Components “A” and Component “B”. Completely empty both components into a clean, dry mixing pail. Mix thoroughly for 30 seconds using a jiffy paddle with a low-speed (400-600 rpm) drill. Slowly add the entire contents of Component “C’ while continuing to mix for (3) three minutes until uniform with no lumps. Mix only that quantity that can be applied within its pot life.

B. Placement procedure for Bonding bridge:

1. Apply to prepared surface with a stiff-bristle brush, broom or “hopper-type” spray equipment.

a. For hand-applied mortars-Place fresh, plastic concrete/mortar while the bonding bridge adhesive is “wet” or within open times indicated in section 2.03.A.2.

b. For machine-applied mortars-Apply while the bonding bridge adhesive is “wet” or within the open times indicated in section 2.03.A.2.

C. Placement procedures for anti-corrosion coating:

1. Apply to prepared steel surface with a stiff-bristle brush, or “hopper type” spray equipment at 20 mils minimum thickness. Properly coat the underside of the totally exposed steel. Allow to dry (approx 2-3 hours) then apply a second coat at 20 mils minimum thickness. Allow drying again before placing repair mortar.

*During the anti-corrosion coating method, after applying the second coat Sika Armatec 110 EpoCem, a mortar can be applied to “wet” Sika Armatec 110 EpoCem or within open times indicated in section 2.03.A.2 to achieve the benefit of bonding bridge.

D. Adhere to all limitations and cautions for the epoxy resin/portland cement adhesive in the manufacturer’s current printed literature.

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3.02 CLEANING

A. The uncured epoxy resin/portland cement adhesive can be cleaned from tools with water. The cured epoxy resin/portland cement adhesive can only be removed mechanically.

B. Leave finished work and work area in a neat, clean condition without evidence of spillovers onto adjacent areas.

END OF SECTION 03300

CONCRETE REHABILITATION 03730-1

SECTION 03730 – CONCRETE REHABILITATION

1.01 SUMMARY

A. This specification describes the patching or overlay of interior and/or exterior horizontal surfaces with a polymer-modified, portland cement mortar/cement.

1.02 QUALITY ASSURANCE

A. Manufacturing qualifications: The manufacturer of the specified product shall be ISO 9001 certified and have in existence a recognized ongoing quality assurance program independently audited on a regular basis.

B. Contractor qualifications: Contractor shall be qualified in the field of concrete repair and protection with a successful track record of 5 years or more. Contractor shall maintain qualified personnel who have received product training by a manufacturer’s representative.

C. Install materials in accordance with all safety and weather conditions required by manufacturer or as modified by applicable rules and regulations of local, state and federal authorities having jurisdiction. Consult Material Safety Data Sheets for complete handling recommendations.

1.03 DELIVERY, STORAGE AND HANDLING

A. All materials must be delivered in original, unopened containers with the manufacturer’s name, labels, product identification, and batch numbers. Damaged material must be removed from the site immediately.

B. Store all materials off the ground and protect from rain, freezing or excessive heat until ready for use.

C. Condition the specified product as recommended by the manufacturer.

CONCRETE REHABILITATION 03730-2

1.04 JOB CONDITIONS

A. Environmental Conditions: Do not apply material if it is raining or snowing or if such conditions appear to be imminent. Minimum application temperature 45ºF (7ºC) and rising.

B. Protection: Precautions should be taken to avoid damage to any surface near the work zone due to mixing and handling of the specified coating.

1.05 SUBMITTALS

A. Submit PDF copy of manufacturer’s literature, to include:

Product Data Sheets, and appropriate Material Safety Data Sheets (MSDS).

1.06 WARRANTY

A. Provide a written warranty from the manufacturer against defects of materials for a period of (5) five years, beginning with date of substantial completion of the project.

PART 2. PRODUCTS

2.01 MANUFACTURER

A. SikaTop 111 Plus, as manufactured by Sika Corporation, is considered to conform to the requirements of this specification.

2.02 MATERIALS

A. Polymer-modified portland cement mortar:

1. Component A shall be a liquid polymer emulsion of an acrylic copolymer base and additives.

a. pH: 4.5-6.5

b. Film Forming Temperature: 73ºF max.

c. Tear Strength: 950-psi min.

d. Elongation at Break: 500% min.

e. Particle Size: less than 0.1 micron

2. Component A shall contain an organic, penetrating corrosion inhibitor which has been independently proven to reduce corrosion via ASTM G3 (half-cell potential tests). The corrosion inhibitor shall not be calcium nitrite, and shall have a minimum of 5 years of independent field testing to document performance on actual construction projects.

CONCRETE REHABILITATION 03730-3

3. Component B shall be a blend of selected portland cements, specially graded aggregates, admixtures for controlling setting time, water reducers for workability, and an organic accelerator.

4. The materials shall be non-combustible, both before and after cure.

5. The materials shall be supplied in a factory-proportioned unit.

6. The polymer-modified, portland cement mortar must be placeable from ½-in. to 1-in. in depth per lift for horizontal applications.

B. To prepare a polymer-modified portland cement concrete:

aggregate shall conform to ASTM C-33, The factory-proportioned unit shall be extended with 42-lb. max. of a 3/8 in. (No. 8 distribution per ASTM C-33, Table II) clean, well-graded, saturated surface dry aggregate, having low absorption and high density. Aggregate must be approved for use by the engineer.

2.03 PERFORMANCE CRITERIA

A. Typical Properties of the mixed polymer-modified, portland cement mortar:

1. Working Time: Approximately 30 minutes.

2. Finishing Time: 50-120 minutes

3. Color: Concrete gray

B. Typical Properties of the cured polymer-modified, portland cement mortar:

1. Compressive Strength (ASTM C-109 Modified)

a. 1 day: 2500 psi min. (17.2 MPa)

b. 7 day: 5500 psi (37.9 MPa)

c. 28 day: 7000 psi (48.3 MPa)

2. Flexural Strength (ASTM C-293) @ 28 days: 1500 psi (10.3 MPa)

3. Splitting Tensile Strength (ASTM C-496) @28 days 700 psi (4.8 MPa)

4. Bond Strength (ASTM C-882 Modified) @ 28 days: 2500 psi (17.2 MPa)

5. The portland cement mortar shall not produce a vapor barrier.

6. Density (wet mix): 136 lbs./cu. ft. (2.18 kg/l)

CONCRETE REHABILITATION 03730-4

7. Permeability (AASHTO T-277 @ 28 days approximately

500 Coulombs)

Note: Tests above were performed with material and curing conditions at 71ºF - 75ºF and 45-55% relative humidity.

PART 3 - EXECUTION

3.01 SURFACE PREPARATION

A. Areas to be repaired must be clean, sound, and free of contaminants. All loose and deteriorated concrete shall be removed by mechanical means. Mechanically prepare the concrete substrate to obtain a surface profile of +/- 1/16” (CSP 5 or greater as per ICRI Guidelines) with a new exposed aggregate surface. Area to be patched shall not be less than ½” in depth.

B. Where reinforcing steel with active corrosion is encountered, sandblast the steel to a white metal finish to remove all contaminants and rust. Where corrosion has occurred due to the presence of chlorides, the steel shall be high pressure washed after mechanical cleaning.

Prime steel with (2) two coats of Sika Armatec 110 EpoCem as directed by manufacturer. (See Spec Component SC-201- 0699).

3.02 MIXING AND APPLICATION

A. Mechanically mix in appropriate sized mortar mixer or with a Sika jiffy paddle and low-speed (400-600 rpm) drill. Pour approximately 4/5 gal Component A into the mixing container. Add Component B while continuing to mix. Mix to a uniform consistency for a maximum of 3 minutes. Add remaining Component A to mix if a more loose consistency is desired. Should smaller quantities be needed, be sure the components are measured in the correct ratio and that the Component B is uniformly blended before mixing the components together. Mix only that amount of material that can be placed in 30 minutes.

Do not retemper material.

B. Mixing of the polymer-modified portland cement concrete:

Pour all (1-gal) of Component A into the mixing container. Add Component B while continuing to mix. Add correct amount of the pre-approved coarse aggregate, and continue mixing to a uniform consistency. Mixing time should be (3) three minutes maximum.

CONCRETE REHABILITATION 03730-5

C. Placement Procedure: At the time of application, the substrate should be saturated surface dry with no standing water. Mortar and/or concrete must be scrubbed into substrate filling all pores and voids. While the scrub coat is still wet, force material against edge of repair, working toward center. If repair area is too large to fill while scrub coat is still wet use Sika Armatec 110 EpoCem in lieu of scrub coat (See Spec Component SC-200). After filling, consolidate, then screed. Allow mortar or concrete to set to desired stiffness, then finish with trowel, manual or power, for smooth surface. Broom or burlap for rough surface. Areas where the depth of the repair is less than 1-inch shall be repaired with polymer-modified portland cement mortar.

In areas where the depth of the repair is greater than 1 inch, the repair shall be made with polymer-modified portland cement concrete.

D. As per ACI recommendations for portland cement concrete, curing is required. Moist cure with wet burlap and polyethylene, a fine mist of water or a water-based* compatible curing compound. Moist curing should commence immediately after finishing and continue for 48 hours.

Protect newly applied material from rain, sun and wind until compressive strength is 70% of the 28-day compressive strength. To prevent from freezing cover with insulating material. Setting time is dependent on temperature and humidity.

* Pretesting of curing compound is recommended.

E. Adhere to all procedures, limitations and cautions for the polymer-modified portland cement mortar in the manufacturer’s current printed technical data sheet and literature.

3.03 CLEANING

A. The uncured polymer-modified portland cement mortar can be cleaned from tools with water. The cured polymer-modified portland cement mortar can only be removed mechanically.

B. Leave finished work and work area in a neat, clean condition without evidence of spillovers onto adjacent areas.

END OF SECTION 03730

MORTAR & GROUT 04100-1

SECTION 04100 - MORTAR & GROUT

1.01 RELATED DOCUMENTS

A. Attention is directed to Division 0, Bidding and Contract Requirements, and to Division 1, General Requirements, which are hereby made a part of this specification. Refer to Structural Drawings for additional information.

1.02 SECTION INCLUDES

A. Work included in this section consists of furnishing all labor, materials, equipment, and incidentals required for complete installation of mortar and grout for masonry.

B. Related work specified elsewhere:

1. Section 03001 Concrete.

2. Section 04425 Exterior Granite Cladding

1.03 ENVIRONMENTAL REQUIREMENTS

A. Recommended Practices for Hot and Cold Weather Masonry Construction as published by the Masonry Industry Council.

PART 2. PRODUCTS

2.01 MATERIALS

A. Portland Cement: ASTM C150, Type 1 provide natural color or white cement as required to provide mortar color indicated.

B. Mortar Aggregate: ASTM C144, standard masonry type.

C. Hydrated Lime: ASTM C207, Type 'S', or 'N'.

D. Masonry Cement: ASTM C91.

E. Premix Mortar: ASTM C387.

F. Grout Aggregate: ASTM C404.

G. Grout Fine Aggregate: ASTM C144, 100% passing #8 sieve, maximum 5-30% passing #50 sieve.

MORTAR & GROUT 04100-2

H. Water: Clean and potable.

I. Integral water repellant additive meeting ASTM E-514.

J. Plasticizer:

1. SIKA Chemical Corporation "Intraplast Z".

2. Euclid Chemical Co. "Eucon BK-S".

K. Storage of all material shall prevent the intrusion of foreign matter. Store all masonry units on the ground, protected against damage and intrusion of excess moisture.

No damaged or deteriorated materials shall be used.

2.02 MORTAR MIXES

A. Mortar for exterior load bearing walls and all exterior masonry work below grade; ASTM C270, Type ‘M” or 'S', using the property method unless noted otherwise on structural drawings. Use ASTM C270 Type 'N' above grade at exterior veneers.

B. Mortar for interior non-load bearing walls and partitions:

ASTM C270, Type 'S', using the property method.

C. Mortar for reinforced masonry ASTM C270, Type 'S', using the property method.

D. Pointing mortar for masonry veneers ASTM C270, Type 'N', using the property method.

E. Ready-Mixed Mortar: Cementitious materials, water, and aggregate complying with requirements specified in this Article; combined with set-controlling admixtures to produce a ready-mixed mortar complying with ASTM C 1142.

F. Cold-Weather Admixture: Nonchloride, noncorrosive, accelerating admixture complying with ASTM C 494, Type C and ASTM C1384, and recommended by the manufacturer for ues in masonry mortar of composition indicated.

2.03 MORTAR MIXING

A. Thoroughly mix mortar ingredients in approved type mixing machine in quantities needed for immediate use in accordance

MORTAR & GROUT 04100-3

with ASTM C270 or C780. Discharge mixer completely before recharging.

B. All exterior above grade mortar exposed to moisture shall be fabricated with integral water repellant additive.

C. Blend admixtures in accordance with manufacturer's instructions.

D. Do not use anti-freeze compounds to lower the freezing point of mortar.

2.04 GROUT MIXES

A. Bond beams, lintels, engineered masonry, reinforced masonry walls: min. 2500 psi strength at 28 days unless noted otherwise; 8-10 inches slump; pre-mixed grout in accordance with ASTM C94, or batch mixed in accordance with ASTM C476 for fine or course grout.

PART 3. EXECUTION

3.01 EXAMINATION AND PREPARATION

A. Apply bonding agent to existing concrete surfaces.

3.02 INSTALLATION

A. Install pre-mix mortar and grout in accordance with manufacturer's instructions.

B. Work grout into masonry cores and cavities to eliminate voids. Do not displace reinforcement. Reinforcing shall be mechanically anchored in masonry cores to prevent displacement during grouting.

END OF SECTION 04100

TUNNEL BULKHEAD 07131 AUGUST 6, 2026

SHEET MEMBRANE WATERPROOFING 07131 - 1

SECTION 07131 - SHEET MEMBRANE WATERPROOFING

PART 1 GENERAL

1.01 SECTION INCLUDES

A. Sheet membrane B. Flashings C. Insulation installation.

D. Protection board.

1.02 RELATED SECTIONS

A. Section 07600 – Flashing & Sheet Metal B. Section 07920 – Sealants & Caulking

1.03 REFERENCES

A. ACI 301-89 Specifications for Structural Concrete Buildings.

B. ASTM D 6769-02 Standard Guide for Application of fully

Adhered, Cold Applied, Prefabricated Reinforced Modified

Bituminous Membrane Waterproofing Systems1

C. ACI 515.1R-79-A Guide to the Use of Waterproofing, Dampproofing, and Protective Barrier, and Decorative Systems for Concrete.

D. ASTM D41-94 Specification for Asphalt Primer Used in Roofing and Waterproofing.

E. ASTM D1668-95 Specification for Glass Fabrics (Woven and

Treated) for Roofing and Waterproofing.

F. ASTM D4479-93 Specification for Asphalt Roof Coatings.

1.04 SUBMITTALS

A. Submit product data and samples in accordance with Section 01340 “Shop Drawings, Product Data and Samples”.

SHEET MEMBRANE WATERPROOFING 07131 - 2

B. Manufacturer’s Literature: Materials description and installation instructions for systems to be installed.

C. Samples: One (1) 6 inch X 6 inch sample of sheet membrane and ½ pint of adhesive.

1.05 QUALITY ASSURANCE

A. Applicator: Minimum of ( 5) five years experience in the application of waterproofing systems acceptable to Laurenco Incorporated.

B. Submit list of at least (5) five completed projects of a similar nature.

1.06 PRODUCT DELIVERY, STORAGE AND HANDLING

A. Deliver in accordance with Division 1.

B. Deliver in manufacturer’s original containers with labels identifying material name, brand, and date of manufacture. Store materials in strict accordance with manufacturer’s printed instructions to prevent damage from water, mud, debris and construction traffic. Damage materials will not be used.

1.07 WARRANTY

A. Provide a (10) ten year warranty.

B. Warranty: Include coverage of waterproofing failure to resist penetration of water except where such failures are the result of structural failures of substrate.

1.08 ENVIRONMENTAL REQUIREMENTS

A. Install waterproofing sheet type according to the following ambient temperatures:

1. Summer Grade-60°F to 125°F.

2. Winter Grade-0°F to 60°F.

B. Install number of plies and quantity of adhesive applicable to waterheads and soil conditions to be encountered.

SHEET MEMBRANE WATERPROOFING 07131 - 3

PART 2 PRODUCTS

2.01 MANUFACTURER

A. LAURENCO SYSTEMS as manufactured by Laurenco Incorporated, P.O. Box 471, Garrettsville, Ohio;

Phone: 800 321-3337, Fax: (800) 543-3338.

2.02 MATERIALS

A. Sheet Membrane: 50 mils thick +/- 10%, chloroprene modified asphalt filmed onto a woven glass fabric, ASTM D 1668-95.

B. Adhesive: Self-priming, semi-viscous liquid composed of synthetic rubbers to modify the asphalt in cut back form, ASTM D4479-93, Type 1.

C. Primer: Asphalt modified with an aliphatic solvent, ASTM D41-94.

D. Protection Board (for horizontal work):

Asphalt/felt board, 1/8 inch thick; as manufactured by Sealtight Premolded Membrane, W.R.Meadows, Inc., Skokie, Il or Elastibord, The Celotex Corporation, Tampa, FL.

E. Insulation: Match manufacturer’s type and thickness of insulation removed. Insulation manufacturer shall be acceptable to Laurenco.

PART 3 EXECUTION

3.01 PREPARATION

A. Prepare existing concrete substrate surfaces as described below:

1. Remove or grout projections higher than 1/16 inch, i.e., fins.

2. Grout tie-wire holes, honeycombs, and voids larger than 3/4 inch in diameter and deeper than 1/4 inch.

3. Remove latencies, spatters, dirt, etc., by scraping surfaces to be waterproofed. Do not grind.

SHEET MEMBRANE WATERPROOFING 07131 - 4

4. Scrape off knife-like edges of exterior corners and grout to a continuous smooth surface all interior and exterior corners.

5. Remove dirt and debris.

6. Provide ventilation for confined areas.

B. Do not proceed until all piping, conduit, vents, ducts and other projections through the substrate have been repaired/installed (by others).

3.02 APPLICATION ON HORIZONTAL SURFACES

A. Do not apply in wet weather, or when the temperature is below 0°F.

B. Uniformly coat concrete surface with adhesive at 1 ½ gallons per 100 square feet and allow adhesive to “tack” to almost dry.

C. Embed waterproofing sheet in “cap sheet” fashion without wrinkles. Seal laps using ½ gallon adhesive per 100 square feet. Continue sheets 3 inches minimum up the vertical surfaces, [unless otherwise indicated].

Place special attention to angles so that total contract with substrate is maintained (no bridging).

D. Coat first ply of waterproofing sheet with adhesive at 3/4 gallon per 100 square feet and allow to “tack” to ` almost dry.

E. Embed second ply of waterproofing sheet as specified for first ply, staggering and/or centering laps over first sheet. Seal laps uniformly with ½ gallon adhesive per 100 square feet.

F. Flashings shall be 2 plies of waterproofing sheet cut for the height of the design with a minimum 4 inch (first ply) and 6 inch (second ply) lap on horizontals. Embed plies uniformly in adhesive at 2 gallons per 100 square feet first ply, and 1 gallon per 100 square feet second ply. Use pre-cut widths to extend first ply to height less 4 inches, and second ply to height less 2 inches. Strip off top with 1 or 2 plies of 9 inch wide woven glass fabric coated with adhesive until the weave barely shows.

SHEET MEMBRANE WATERPROOFING 07131 - 5

G. Evenly coat horizontal work and flashings with adhesive at 2 gallons per 100 square feet. Strip off termination at flashings using glass fabric coated with adhesive at 2 to 3 gallons per 100 square feet until weave does not show.

H. Apply an additional ply of waterproofing sheet 36 inch X 36 inch at drain flashings firmly embedded in adhesive and coated with adhesive before setting clamping ring in place to tighten. Apply before protection board is put into place.

I. Adhere insulation to final ply of waterproofing sheet in adhesive applied at 2 gallons per 100 square feet, adhere each additional ply of insulation using the same amount of adhesive. Protect insulation with protection board firmly embedded in adhesive applied at 2 ½ to 3 ½ gallons per 100 square feet.

J. Cut protection board to size where necessary and tightly butt joints for both horizontal and flashing work. Embed in uniform adhesive coat over waterproofing sheet at 2 gallons per 100 square feet.

3.03 FIELD QUALITY CONTROL

A. Installation of waterproofing system shall be inspected by the manufacturer’s authorized representative to ensure conformance with manufacturer’s installation requirements and this specification.

END OF SECTION 07131