ATT13-Spec_03_35_43_Polished_Concrete.pdf

SECTION 03 35 43

POLISHED CONCRETE FLOOR SYSTEM WITH COLOR

11/10

PART 1 GENERAL

1.1 SUMMARY

Section Includes: Products and procedures for lithium densifier and diamond polishing concrete floors using multi-step wet/dry mechanical process, and accessories indicated, specified, or required to complete polishing.

1.2 REFERENCES

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI B101.1 (2011) Floor Safety Standard

ANSI B101.3 (2012) Safety Standards Reduce Slip-and-Fall Accidents

ASTM INTERNATIONAL (ASTM)

ASTM E 1155 (1996; R 2008) Standard Test Method for Determining Floor Flatness and Floor Levelness Numbers

ASTM E 430 Standard Test Method for Measurement of Gloss of High-Gloss Surfaces by Abridged Goniophotometry

Terminology: As defined by the Concrete Polishing Association of America

(CPAA)

1.3 SUBMITTALS

SD-03 Product Data

Manufacturer's technical literature for each product indicated, specified, or required. Include manufacturer's technical data, application instructions, recommendations and Material Safety Data Sheet (MSDS).

Installer Qualifications

Data for company, principal personnel, experience, and training specified in PART 1 "Quality Assurance" Article below.

SD-06 Test Reports

Provide certified test reports confirming compliance with specified performance criteria in PART 3 "Field Quality Control" Articles below and dynamic coeficient of funtion test reports.

SD-10 Operation and Maintenance Data

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Provide manufacturer's instructions for maintenance of installed work, including methods and frequency recommended for maintaining optimum condition under anticipated use. These instructions should contain precautions against cleaning products and methods which may be detrimental to finishes and performance.

1.4 QUALITY ASSURANCE

1.4.1 Installer Qualifications

1. Experience: Company experienced in performing specified work similar in design, products, and extent to scope of this Project; with a record of successful in-service performance; and with sufficient production capability, facilities, and personnel to produce specified work. Installer should have successfully performed a minimum of 5 projects of at least 5000 square feet each.

2. Supervision: Maintain competent supervisor who is at Project during times specified work is in progress, and is currently certified as Craftsman or Master Craftsman by CPAA. Use an adequate number of skilled workmen who are thoroughly trained and experienced in the necessary craft.

3. Manufacturer Qualification: Approved by manufacturer to apply liquid applied products. Provide letter of certification from concrete finish manufacturer stating that installer is a certified applicator of special concrete finishes and is familiar with proper procedures and installation requirements required by the manufacturer.

1.4.2 Walkway Auditor

Certified by NFSI to test polished floors for static coefficient of friction according to NFSI 101-A.

1.4.3 Field Mock-up for Aesthetic Purposes

Before performing work of this Section, provide as many field mock-ups required to verify selections made under submittals and to demonstrate aesthetic effects of polishing.

1. Grind, hone, and polish a 5 ft. minimum square floor area include edges and joints.

2. Use same personnel, including supervisors, which will perform work.

3. Install products and materials according to specified requirements.

4. Work shall be representative of those to be expected for work.

5. Finish various components to show maximum variation that will exist in work.

6. Approval is for following aesthetic qualities:

a. Compliance with approved submittals.

b. Uniformity of exposed aggregate.

c. Uniformity of sheen.

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7. Obtain Contracting Officer or Architect approval before starting work on Project.

8. Protect approved field mock-ups from elements with weather resistant covering.

9. Maintain field mock-ups during construction in an undisturbed condition as a standard for judging completed work.

10. Do not demolish, alter, or remove field mock-ups until acceptable to Owner and/or Architect.

11. Approved mock-ups may become part of completed work, if undisturbed at time of substantial completion.

1.4.4 Coefficient of Funtion

Achieve following coefficient of friction by field quality control testing in accordance to the following standards:

1. ANSI B101.1 Static Coefficient of Friction - Achieve a minimum of .42 for level floor surfaces.

2. ANSI B101.3 Dynamic Coefficient of Friction - Achieve a minimum of .35 for level floor surfaces.

1.4.5 Pre-Installation of Concrete Conference

Prior to placing concrete for areas scheduled for polishing, conduct conference at Project.

1. Required Attendees:

a. Contracting Officer or Architect

b. General Contractor, including supervisor.

c. Concrete Producer / Finisher Subcontractor, including supervisor.

d. Concrete Polish System Subcontractor, including supervisor.

e. Technical representative of liquid applied product manufacturers.

f. Walkway auditor.

2. Minimum Agenda: Polisher shall demonstrate understanding of work required by reviewing and discussing procedures for, but not limited to, following:

a. Determine mock-up and representative areas of required work, discuss and evaluate for compliance with Contract Documents, including substrate conditions, surface preparations, sequence of procedures, and other preparatory work performed by other installers.

b. Review Contract Document requirements.

c. Review approved submittals.

d. Review procedures, including, but not limited to:

1) Details of each step of grinding, honing, and polishing operations.

2) Application of liquid applied products.

3) Protecting concrete floor surfaces until polishing work begins.

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4) Protecting polished concrete floors after polishing work is completed.

3. Reports: Record discussions, including decisions and agreements reached, and furnish copy of record to each party attending.

1.5 DELIVERY, STORAGE AND HANDLING

Deliver all material in original containers, bearing manufacturers labels indicating brand name and directions for storage, factory numbered and sealed until ready for installation.

Maintain records of product container numbers.

Store all materials in a dry, climate-controlled environment at a minimum of 55°F (13°C) and maximum of 85°F (29°C).

1.6 FIELD CONDITIONS

1.6.1 Damage and Stain Prevention

Take precautions to prevent damage and staining of concrete surfaces to be polished. If construction equipment must be used on these substrates, diaper all components that may drip fluids.

1. Prohibit vehicle parking over concrete surfaces to be polished.

2. Prohibit pipe cutting operations over concrete surfaces to be polished.

3. Prohibit storage of any items over concrete surfaces to be polished for not less than 28 days after concrete placement.

4. Prohibit ferrous metals storage over concrete surfaces to be polished.

5. Protect from petroleum, oil, hydraulic fluid, or other liquid dripping from equipment working over concrete surfaces to be polished.

6. Protect from acids and acidic detergents contacting concrete surfaces to be polished.

7. Protect from painting activities over concrete surfaces to be polished.

1.6.2 Environmental Limitations

Comply with manufacturer's written instructions for substrate temperature, ambient temperature, moisture, ventilation, and other conditions affecting liquid applied product application.

Where concrete is not within the specified tolerances, install manufacturer recommended repair and topping materials at the required thickness to achieve tolerances.

Concrete must be cured for a sufficient time period recommended by the System manufacturer (minimum 28 days) before the application can begin.

PART 2 PRODUCTS

2.1 LIQUID APPLIED PRODUCTS

Color: Black

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2.1.1 System Integrity

Provide a Polished Concrete System that is an engineered and integrated complete installation system requiring strict adherence to all specified installation processes, equipment, diamond abrasives, concrete preparation, joint treatment and chemicals to achieve the intended result. Do not substitute manufacturer's recommended products that will void the system warranty.

2.1.2 Lithium Densifier

Odorless, non-hazardous, silicate that penetrates concrete to react with free lime and calcium hydroxide to produce permanent chemical reaction that hardens and densifies concrete surface.

Emits no hazardous or offensive fumes and is V.O.C. content less than 50 gms/L.

2.2 ACCESSORIES

2.2.1 Patching Compound

Compound composed of 40 percent portland cement, 45 percent limestone, and 15 percent vinyl acetate copolymer, when mixed with dust salvaged from grinding process forms a paste that hardens when surface imperfections are filled.

2.2.2 Protective Cover

Non-woven, puncture and tear resistant, polypropylene fibers laminated with a multi-ply, textured membrane, not less than 18 mils in thickness.

2.2.3 Diamond Tooling

Abrasive tools that contain industrial grade diamonds within a bonded matrix (such as metallic, resinous, ceramic, etc) that are attached to rotating heads to refine the concrete substrate.

1. Bonded Abrasive: Abrasive medium that is held within a bonding that erodes away to expose new abrasive medium as it is used.

2. Metal Bond Tooling: Diamond tooling that contains industrial grade diamonds with a metallic bonded matrix that is attached to rotating heads to refine the concrete substrate. These tools are available in levels of soft, medium, and hard metallic matrices that are matched with contrasting concrete substrates (i.e. hard matrix/soft concrete, medium matrix/medium concrete, soft matrix/hard concrete) and are typically used in the grinding and early honing stages of the polishing process.

3. Resin Bond Tooling: Diamond tooling that contains industrial grade diamonds within a resinous bonded matrix (poly-phenolic, ester-phenolic, thermoplastic-phenolic) that is attached to rotating heads to refine the concrete substrate. Resin bond tooling does not have the soft/medium/hard characteristics of metal bond tooling and are typically used for the later honing and polishing stages of the polishing process.

4. Hybrid Tooling: Diamond tooling that combines metal bond and

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These types of tools are typically used as either transitional tooling from metal bond tools to resin bond tools or as a first cut tool on smooth concrete surfaces.

5. Transitional Tooling: Diamond tooling that is used to refine the scratch pattern of metal bond tooling prior to the application of resin bond tooling in an effort to extend the life of resin bond tooling and to create a better foundation for the polishing process.

6. Abrasive Pad: An abrasive pad, resembling a typical floor maintenance burnishing pad, that has the capability of refining the concrete surface on a microscopic level that may or may not contain industrial grade diamonds. These pads are typically used for the maintenance and/or restoration of previously installed polished concrete flooring.

2.3 POLISHING EQUIPMENT

Field Grinding and Polishing Equipment:

1. Variable speed, multiple head, counter-rotating, walk-behind machine with not less than 600 pounds of down pressure on grinding or diamond polishing pads.

2. If dry grinding, honing, or polishing, use dust extraction equipment with flow rate suitable for dust generated, with squeegee attachments.

Edge Grinding and Polishing Equipment: Hand-held or walk-behind machines which produces same results, without noticeable differences, as field grinding and polishing equipment.

Burnishing Equipment: High speed walk-behind or ride-on machines capable of generating 1000 to 2000 revolutions per minute and with sufficient head pressure of not less than 20 pounds to raise floor temperature by 20 degrees F.

Metal Bonded Pads: Grinding pads with embedded industrial grade diamonds of varying grits fabricated for mounting on equipment.

Resin Bonded Pads: Polishing pads with embedded industrial grade diamonds of varying grits fabricated for mounting on equipment.

Burnishing Pads: Maintenance pads for use with high speed burnishing equipment.

All grinding and polishing completed with grinder/polisher equipment connected to a HEPA Dust collector. HEPA filtration removes particulates in the 0.1 to 5 micron size.

PART 3 EXECUTION

3.1 EXAMINATION

Acceptance of Surfaces and Conditions:

1. Examine substrates to be polished for compliance with requirements and other conditions affecting performance.

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2. Document unsatisfactory conditions in writing. Proceed only when unsatisfactory conditions have been corrected in a manner complying with Contract Documents.

3. Starting work within a particular area will be construed as acceptance of surface conditions.

4. Verify that existing concrete has Floor Flatness and Floor Levelness ratings of at least 40, as measured by ASTM E 1155 -96.

5. Verify that existing concrete has cured a minimum of 28 days and meets finish and surface profile requirements in Division 03 Section "Cast-In-Place Concrete."

6. Conduct pre-installation conference, per Part 1 "Pre-Installation of Concrete Conference" Article above.

3.2 PREPARATION

3.2.1 Cleaning Existing Concrete Surfaces

Prepare and clean concrete surfaces. Provide sound concrete surfaces free of laitance, glaze, efflorescence, curing compounds, form-release agents, dust, dirt, grease, oil, paint splatter, and other contaminants incompatible with liquid applied products and polishing.

3.2.2 Treating Surface Imperfections

Repairs shall be completed after the first metal bond diamond grind and floor cleaning. Mix patching compound and grout material with dust created by grinding operations to match color of adjacent concrete surface. Fill surface imperfections including, but not limited to, holes, surface damage, small and micro cracks, air holes, pop-outs, and voids.

Work compound and treatment until color differences between concrete surface and filled surface imperfections are not reasonably noticeable when viewed from 10 feet away under lighting conditions that will be present after construction.

3.3 POLISHING CONCRETE FLOORS

3.3.1 Cut Level

Class B / Level 2 Cut - Fine Aggregate (Salt and Pepper) Finish: Remove not more than 1/16 inch of concrete surface by grinding and polishing resulting in majority of exposure displaying fine aggregate with no, or small amount of, medium aggregate at random locations.

3.3.2 Gloss Attainment ASTM E 430

Gloss readings are not to be obtained through the use of any microfilming products, sealers, coatings, enhancers or as the result of resin transfer from resin bond abrasives. Readings shall be taken not less than 10' (3

m) on center in field areas and within 1' (0.3 m) of floor area perimeters. In no case shall a reading be below 2% of specified minimum sheen:

a. Level B Sheen - Medium Gloss reading of 41 to 55. 800 grit diamond finish.

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3.3.3 Sequence to achieve LEVEL B-Medium Gloss

a. Using a .250" blade, install 3/8" deep decorative score lines in slab per floor pattern indicated on drawings.

b. Broom and vacuum the floor to remove all residual dust.

c. GRIND/POLISH #1: 60/80 Grit Metal Bonded Diamonds.

d. Install any required repair products as necessary; allow to dry completely before continuing any grinding operations.

e. GRIND/POLISH #2: #1 Transitional Diamonds, Ceramic Bonded.

f. Broom and vacuum the floor to remove all residual dust.

g. GRIND/POLISH #3: 200 Grit Resin Bonded Diamonds.

h. Broom and vacuum the floor to remove all residual dust.

i. GRIND/POLISH #4: 400 Resin Bonded Diamonds.

j. Broom and vacuum the floor completely to remove all residual dust.

k. Using an auto-scrubber the floor may be wet cleaned to insure a completely clean surface. Allow the surface to dry completely.

l. Apply lithium densifier per application instructions at a rate of 400 square feet per gallon (Actual rates may vary due to concrete porosity).

m. Allow lithium densifier to dry before continuing on to the next step.

n. GRIND/POLISH #5: 800 Resin Bonded Diamonds.

o. Broom and vacuum the floor to remove all residual dust.

p. MICROPOLISH/BURNISH #1: 800 Grit Diamond Impregnated Pad

q. Dry mop the floor clean to remove all debris.

r. Apply reactive micro-impregnating lithium polymer (stain and wear protective treatment) per application instructions at a rate of 2,500 square feet per gallon (Actual rates may vary due to concrete porosity).

s. Allow to dry a minimum of 15 minutes.

t. MICROPOLISH/BURNISH #2: 800 Grit Diamond Impregnated Pad.

u. Dry mop the floor clean to remove all debris.

v. Apply reactive micro-impregnating lithium polymer (stain and wear protective treatment) per application instructions at a rate of 3,000 square feet per gallon (Actual rates may vary due to concrete porosity).

w. Allow to dry a minimum of 15 minutes.

x. MICROPOLISH/BURNISH #3: 800 Grit Diamond Impregnated Pad.

3.3.3.1 Edges

a. Edges shall be polished to match floor area to within 1/8 inches of wall, floor drains, etc.; the polishing process will match the corresponding steps outlined above for the desired gloss level, and each edge polishing step shall be done immediately after the matching main polishing step.

b. Where desired, polished edge work of all areas shall be done with a 5 inches or 7 inches Hand Held or Walk Behind polishing tool.

c. Polishing may be performed before partition studs are erected or after partition studs are erected, but before gypsum board is installed. An approved floor protection must be provided by polisher for this option to be feasible, as well as coordination with other disciplines.

3.3.3.2 Joint Filler Application

a. Slab should be visibly dry and all floor scrubbing/washing activities should be suspended at least 48 hours prior to filler

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b. Joint Cleanout and preparation should be done utilizing dust-free, diamond blade equipped cleanout saws.

c. Fill joint in one pass, from bottom to top, slightly overfilling the joint.

d. After filler has fully cured, razor off excess to leave a flush filler profile. Timing of the razoring (30 min. to 1 hour typically) can affect flushness; test for shave time that will result in flush shave.

3.4 FIELD QUALITY CONTROL

3.4.1 Static Coefficient of Friction

Achieve and document a reading of not less than 0.5 for level floor surfaces, as determined by a certified NFSI Walkway Auditor using the NFSI 101-A quality control test.

3.4.2 Other Test Reports

Comply with the provisions of the following specification and standards, except as otherwise noted or specified, or as accepted or directed by the Owner and/or Architect. All test data shall be recorded and submitted upon completion of the job.

1. Section 03 30 00, Cast-In-Place Concrete

2. ASTM E 1155 -96, Standard Test Method for Determining Floor Flatness and Levelness using the F number system.

3. ASTM E 430 , Standard Test Method for Measurement of Gloss of High-Gloss Surfaces by Abridged Goniophotometry.

4. ASTM G23-81 , Standard Test Method for Ultraviolet Light and Water Spray Resistance

5. ACI 302 1 R -04, Guide for Concrete Floor and Slab Construction

a. Minimize burn marks.

3.5 CLOSEOUT ACTIVITIES

3.5.1 Maintenance Training

CPAA Master Craftsman shall train Owner's designated personnel in proper procedures for maintaining polished concrete floor.

3.6 PROTECTION

3.6.1 Covering

After completion of polishing, protect polished floors from subsequent construction activities with protective covering.

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2.3 POLISHING EQUIPMENT