070244 Spec 09612.pdf

SECTION 09612

EPOXY MORTAR FLOORING SYSTEM FOR AIRCRAFT MAINTENANCE FACILITIES

08/04

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 C 307 (2003) Tensile Strength of Chemical-Resistant

Mortar, Grouts, and Monolithic Surfacings

ASTM C 531 (2000) Linear Shrinkage and Coefficient of

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

ASTM C 579 (2001) Compressive Strength of Chemical-

Resistant Mortars, Grouts, Monolithic Surfacings, and Polymer Concretes

ASTM C 679 (2003) Tack-Free Time of Elastomeric Sealants

ASTM C 884 (1998) Thermal Compatibility between Concrete and Epoxy-Resin Overlay

ASTM D 1308 (2002e1) Effect of Household Chemicals on

Clear and Pigmented Organic Finishes

ASTM D 2240 (2004) Rubber Property - Durometer Hardness

ASTM D 2621 (1987; R 2000) Infrared Identification of

Vehicle Solids from Solvent-Reducible Paints

ASTM D 2697 (2003) Volume Nonvolatile Matter in Clear or

Pigmented Coatings

ASTM D 3335 (1985a; R 1999) Low Concentrations of Lead, Cadmium, and Cobalt in Paint by Atomic Absorption Spectroscopy

ASTM D 3718 (1985a; R 1999) Low Concentrations of

Chromium in Paint by Atomic Absorption Spectroscopy

ASTM D 3925 (2002) Sampling Liquid Paints and Related

Pigmented Coatings

ASTM D 412 (1998a; R 2002e1) Vulcanized Rubber and Thermoplastic Elastomers - Tension

ASTM D 4541 (2002) Pull-Off Strength of Coatings Using

Portable Adhesion Testers

ASTM D 6237 (2003) Painting Inspectors (Concrete and

Masonry Substrates)

ASTM D 638 (2003) Tensile Properties of Plastics

ASTM E 11 (2004) Wire Cloth and Sieves for Testing

Purposes

ASTM F 1869 (2004) 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

THE SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC-TU 2 (1997) Design, Installation, and Maintenance of Coating Systems for Concrete Used in Secondary Containment

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FED-STD-595 (Rev B; Am 1) Colors, Volume 1

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

29 CFR 1910.1000 Air Contaminants

29 CFR 1910.134 Respiratory Protection

29 CFR 1926.59 Hazard Communication

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation. The following shall be submitted in accordance with Section 01330 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

SD-08 Manufacturer's Instructions

Water-Based Alkaline Degreaser; G

SD-11 Closeout Submittals

Inspection Logbook; G

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

1.3.2 Certificates

1.3.2.1 Epoxy floor 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

1.3.2.2 Flooring System Applicator Qualifications

Minimum requirements for the installation contractor are as follows:

Installation contractor shall have 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. Contractor shall 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 totalling 200,000 square feet within the past two years. In addition to the above requirements, installation contractor shall 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/or 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. Sealant manufacturer shall list location of shops, 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. Flooring manufacturer shall list location of shops, 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, each area shall be reworked 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 (NFGS-09965), 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 Article entitled "ADHESION TESTING." To satisfy the warranty, adhesion testing shall produce cohesive failures within the concrete, concrete removal over 95 percent of each pull-off coupon, and/or adhesion no less than 400 psi. Each area failing to meet adhesion requirements shall require two additional adhesion tests to confirm results. Within the warranty period, remove to sound material and rework all areas unable to meet adhesion requirements. There shall be zero percent sealant failures within one year. Within the warranty period, remove and rework all sealant material with chemically attacked surfaces and/or lifting from joint walls. Topcoat cracking over sealant is excluded from warranty.

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 Material Safety Data Sheets (MSDS) 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/or 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 MSDSs 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 MSDSs 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 - 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 D 4541, ASTM D 6237, SSPC-TU 2, and ICRI 03732, including replica standards ICRI-CSP 1 through ICRI-CSP 9, at the job site.

1.7 PATCH TEST DEMONSTRATION

Prior to the submitted flooring system's approval, apply the complete flooring system to a 10 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 Article entitled "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, and/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 #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 patch test perimeter. Coarse scarification and/or pneumatic scabbling can be required to remove patch tests failing to meet adhesion requirements.

PART 2 PRODUCTS

2.1 JOINT SEALANT

The joint sealant shall be formulated 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 quartz non-skid grit broadcast. The complete flooring system shall be formulated 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, the primer coat shall be formulated to exhibit the properties as listed in Table Ic.

2.2.2 Grout Coat

In addition to the epoxy mortar flooring system requirements, the grout coat shall be formulated to exhibit the properties as listed in Table Id.

2.2.3 Urethane Topcoat

In addition to the epoxy mortar flooring system requirements, the urethane topcoat shall be formulated to exhibit the properties as listed in Table Ie.

2.3 GRAY/BLACK QUARTZ NON-SKID GRIT

Dust-free (washed and dry), minimum 99 percent pure, having the following sieve analysis when tested using a 2.2 pound sample

(ASTM E 11):

Sieve No. 40 100% passing Sieve No. 50 15-30% retained Sieve No. 60 70-85% retained Sieve No. 70 0 -15% retained

2.4 PREAPPROVED MATERIALS

Table II is a list of vendors with "preapproved materials."

PART 3 EXECUTION

3.1 COATING SAMPLE COLLECTION

The Contracting Officer and QC Manager shall 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 D 3925. 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 Article entitled "ADHESION TESTING," return coating samples to the installation contractor for proper disposal.

3.2 TILE AND TILE ADHESIVE REMOVAL

Remove tile 100 percent, employing one or more of the following techniques:

chipping, scraping, sanding, scarification, high-pressure water, and various hand tools. Remove tile adhesive 100 percent, using solvents and power scrubbing. Remove residual contamination using hot potable water under a minimum of 4,000 psi. Resulting surfaces shall appear clean and display the gray color of concrete.

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 shall 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.

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 and/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 Article entitled "DEGREASING." Shot blasting coarse concrete and/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.

3.7 COVE STRIP INSTALLATION

Install a continuous cove strip at a nominal height of 4 inches up each CMU perimeter wall base. Install a solvent resistant cove strip using a solvent resistant adhesive.

3.8 KEY-IN TERMINATIONS

Place the "Key-In" termination as detailed in SSPC-TU 2 Figure 8 at transition surfaces, directly below doorways, and adjacent walls, floor drains, drain grates (interior side), and all other obstructions embedded into the floor slab. The Key-In termination shall contain one vertical wall at a depth from 3/8 to 5/8 inch and, leading down to the resulting vertical depth, a sloped surface from 1-1/2 to 2 inches. A hand held concrete saw can be used to cut the correct vertical depth followed by power tool grinding to create a sloped surface. Remove concrete dust by vacuuming.

3.9 CRACK REPAIRS

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

3.9.1 Install Bondbreaker

Install bondbreaker, either solvent resistant bondbreaker tape or a 1/8 to 1/4 inch #20-#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.

3.9.2 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 Article entitled

"DEGREASING."

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 shall appear level, contain uniform thickness, and be free of surface imperfections including trowel marks.

3.11.5 Primer Application to CMU Walls

When the epoxy mortar has sufficiently cured, prime approximately 4 inches up base of CMU walls to cove strip and 2 inches adjacent the wall's base using the specified primer.

3.11.6 Epoxy Mortar Application to CMU Walls

Apply epoxy mortar directly into wet primer at 3/16 to 1/4 inch. Use a cove trowel to create a rounded transition between floor surfaces and perimeter wall bases. When sufficiently cured, sand the base and 4 inches up perimeter walls. Resulting finish shall contain a rounded transition of uniform thickness between flooring surfaces and CMU walls. When sufficiently cured, sand mortar surfaces. Resulting surface shall be free of surface imperfections including trowel marks.

3.11.7 Grout Coat Application

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.

3.11.8 Grout Coat Sanding

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

3.11.9 Saw Cutting and Sealing Joints

Use the "Conventional Sealed Joint" as detailed in Figure 1 of SSPC-TU 2 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.

3.11.9.1 Saw Cut Contraction Joints

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

3.11.9.2 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.

3.11.9.3 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.

3.11.9.4 Joint Sealant Application

Apply sealant directly into joints using a bulk-caulking gun. At room temperature, the resulting sealant application shall 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 quartz 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.

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 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 Article entitled "ADHESION TESTING."

3.11.10.5 Walkway Stripes

Place 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 shall cure and display performance equal to manufacturer's product literature. Remove and reapply improperly cured material.

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 D 6237 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. 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 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 D 4541) 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, a employ a best effort attempt to avoid fracturing and/or 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, and/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.

TABLE I

MATERIAL REQUIREMENTS

Table Ia - Sealant

Test Minimum Requirement (maximum where indicated)

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

Percent Volume Solids 100 %

Chemical Resistance to JP-8+100 48 hours immersion:)

Fuel @ 70ºF 2.0% (max) weight increase, (ASTM D 1308) (see note 1) 5.0% (max) volume increase, 2.0% (max) weight loss

Chemical Resistance to Motor 48 hours immersion:

Oils @ 70º F 2.0% (max) weight increase (ASTM D 1308) (see note 1) 5.0% (max) volume increase 2.0% (max) weight loss

Chemical Resistance to Skydrols 48 hours immersion:

@ 70ºF 2.0% (max) weight increase (ASTM D 1308) (see note 1) 5.0% (max) volume increase 2.0% (max) weight loss

Hardness (ASTM D 2240: Shore A) 20

Tensile Strength (ASTM D 412) 150 psi (or ASTM D 638)

Percent Elongation (ASTM D 412) 500% (or ASTM D 638)

Tack Free @ 65ºF 12 hours maximum

(ASTM C 679)

Adhesion to Sand Filled Epoxy 140 psi Polyamine

Adhesion to Urethane Topcoats 140 psi (paintable sealant)

NOTES:

(1) A 2 by 1/2 by 1/2 inch section of cured sealant shall be immersed and tested: three samples minimum.

Table Ib - Epoxy Mortar Flooring System

(maximum where indicated)

Compression Strength )ASTM C 579) 7,500 psi

Tensile Strength (ASTM C 307) 1,300 psi

Adhesion to Concrete (ASTM D 4541) 400 psi or (see note 1) 100 % failure in concrete

Heat Resistance, continuous exposure 140ºF

Heat Resistance, intermittent exposure 200ºF

Coefficient of Thermal Expansion 5.0 - 33.0 x 10<SPS>-6</SPS>in/in <SPS>0

</SPS>F

0 - 210ºF (ASTM C 531)

Thermal Compatibility between Concrete "pass"

(ASTM C 884)

Chemical Resistance to JP-8+100 Fuel 48 hours immersion:

@ 70ºF(ASTM D 1308) 2.0% (max) weight increase (see note 2) 2.0% (max) volume increase 2.0% (max) weight loss

Chemical Resistance to Motor Oils 49 hours immersion:

@ 70ºF(ASTM D 1308) 2.0% (max) weight increase (see note 2) 2.0% (max) volume increase 2.0% (max) weight loss

Chemical Resistance to Skydrols 48 hours immersion:

@ 70ºF(ASTM D 1308) 2.0% (max) weight increase (see note 2) 2.0% (max) volume increase 2.0% (max) weight loss

Lead (ASTM D 3335) 0.06% (max)

Cadmium (ASTM D 3335) 0.06% (max)

Chromium (ASTM D 3718) 0.00%

NOTES:

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

(2) Immediately following immersion, in addition to the listed requirements, mortar system shall be evaluated for blisters, checks, discoloration, softening, and lifting. Mortar system shall be visually free of blisters, checks, and discoloration, and display both substrate and intercoat adhesion no less than 350 psi (ASTM D 4541).

Table Ic - Primer

(maximum where indicated)

Resin System (ASTM D 2621) Epoxy Polyamine (two-pack)

Percent Volume Solids (ASTM D 2697) 100%

Color Clear to Amber

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

Moisture Insensitivity Throughout No effect: Insensitive to Service (ASTM F 1869, ASTM D 4541) moisture vapor emission at rates (see note 2) no more than 4.5 pounds moisture/24 hours, 1000 square feet

Adhesion to Concrete Throughout 400 psi or Service (ASTM D 4541) 100% failure in concrete (see note 3)

NOTES:

(1) Immediately following immersion, primer shall be evaluated for blisters, checks, discoloration, softening, and substrate lifting. Primer shall be visually free of blisters, checks and moderate discoloration, and display wet adhesion no less than 350 psi (ASTM D 4541).

(2) During and following application, primer shall remain unaffected by Moisture Vapor Emmsion (MVE) at rates no more than 4.5 pounds moisture per 24 hours, 1000 square feet: primer shall 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 shall display 400 psi adhesion and/or remove no less than 40 mils of concrete over 95% off each pull-off coupon.

Table Id - Grout Coat

(maximum where indicated)

Resin System (ASTM D 2621) Epoxy Polyamine (two-pack)

Percent Volume Solids (ASTM D 2697) 100%

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

Hardness (ASTM D 2240: Shore D) 80

Adhesion to Epoxy Mortar (ASTM D 4541) 400 psi

Table Ie - Urethane Topcoat

(maximum where indicated)

Resin System (ASTM D 2621) Aliphatic Urethane (two-pack)

Percent Volume Solids (ASTM D 2697) 51%

Topcoat Color (FED-STD-595) 17925 (white) or 17875 (ultra-light gray)

Walkway Strip Color: Red/Orange, 22197 (red/orange) semi-gloss (FED-STD-595)

Application Thickness per Coat 2.5 - 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 140ºF

Heat Resistance, intermittent exposure 200ºF

Chemical Resistance to JP-8+100 Fuel 48 hours immersion:

@ 70ºF (ASTM D 1308) 1.0% (max) weight increase (see note 1) 1.0% (max) volume increase 1.0% (max) weight loss

Chemical Resistance to Motor Oils 48 hour immersion:

@ 70ºF (ASTM D 1308) 1.0% (max) weight increase (see note 1) 1.0% (max) volume increase 1.0% (max) weight loss

Chemical Resistance to Skydrols 48 hours immersion:

@ 70ºF (ASTM D 1308) 1.0% (max) weight increase (see note 1) 1.0% (max) volume increase 1.0% (max) weight loss

NOTES:

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

(ASTM D 4541).

TABLE II

PREAPPOROVED MATERIALS*

Vendors Materials

Stonhard Primer: Standard Primer

(856) 779-7500 Epoxy Mortar: Stonclad GS Grout Coat: Stonkote GS4 Topcoat: Stonseal (Equivalent to Tennant HTS and TCU) Sealant: Vulkem 245

Polyspec Primer: 300EX

(281) 397-0033 Epoxy Mortar: Tuffrez 200 Grout Coat: Tuffrez 203 Topcoat: Tuffrez (Equivalent to Tennant HTS and TCU) Sealant: T-2235SL

Tennant Primer: Eco-MPE

(800) 553-8033 Mortar Coat: Eco-PT 250 Grout Coat: Eco-PT Topcoat: VOC-HTS and TCU Sealant: N/A **

Crawford Labs Primer: Florock 4700

(800) 356-7625 Epoxy Mortar: Florock 4700 Grout Coat: Florock 4700 Topcoat: Florock (Equivalent to Tennant HTS and TCU) Sealant: N/A **

General Polymers Primer: #3578, Universal Primer

(800) 543-7694 Epoxy Coat: #3562, Mortar Binder Resin Grout Coat: #3744GP, Novo-Flo Topcoat: #4618, (Equivalent to Tennant HTS and TCU) Sealant: Cor-Seal PS

NOTES:

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

-- End of Section --