05 05 20.00 27.pdf

DD#2 Complex Amendment 2021-04-06 Portsmouth Naval Shipyard, Kittery, ME

SECTION 05 05 20.00 27

POST-INSTALLED CONCRETE ANCHORS

02/21

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.

AMERICAN CONCRETE INSTITUTE (ACI)

ACI 355.2 (2007) Qualification of Post-Installed Mechanical Anchors in Concrete and Commentary

ACI 355.4 (2011) Qualification of Post-Installed Adhesive Anchors in Concrete (ACI 355.4) and Commentary

ASTM INTERNATIONAL (ASTM)

ASTM A36/A36M (2019) Standard Specification for Carbon Structural Steel

ASTM A153/A153M (2016a) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware

ASTM A193/A193M (2020) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications

ASTM A615/A615M (2020) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

ASTM E488/E488M (2015) Standard Test Methods for Strength of Anchors in Concrete and Masonry Elements

INTERNATIONAL CODE COUNCIL (ICC)

ICC IBC (2018) International Building Code

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2014) Safety and Health Requirements Manual

1.2 APPLICABILITY

This guide specification covers the requirements for all anchors that are post-installed into hardened concrete, concrete masonry, or brick. This

SECTION 05 05 20.00 27 Page 1 guide specification does not cover through bolts, powder or pneumatic actuated nails, or cast in anchors. Refer to Section 05 50 13 MISCELLANEOUS METAL FABRICATIONS for requirements of through bolts, powder or pneumatic actuated nails, or cast in anchors.

1.3 DEFINITIONS

1.3.1 Anchor

"Anchor" includes steel elements post-installed into hardened concrete, concrete masonry, or brick and used to transmit applied loads.

1.3.2 Periodic Special Inspections

"Periodic Special Inspection" as used herein means that, as a minimum, the Post-Installed Anchor Special Inspector must perform inspections in accordance with this specification.

1.3.3 Continuous Special Inspections

"Continuous Special Inspection" as used herein means that the Post-Installed Anchor Special Inspector observes the drilling and cleaning of holes, the injection of adhesive into the holes, and the insertion of anchors into the holes. When applicable for the type of installation, or as indicated in the project drawings, "Continuous Special Inspection" also includes observation of measures to secure the anchor during the adhesive curing period.

1.4 SUBMITTALS

Government approval is required for submittals with a "G" or "S" classification. Submittals not having a "G" or "S" classification are for information only. When used, a code following the "G" classification identifies the office that will review the submittal for the Government.

Submit the following in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:

SD-01 Preconstruction Submittals

Installer Qualifications; G AE

Post-Installed Anchor Special Inspector Qualifications; G

SD-03 Product Data

Mechanical Anchors in Concrete; G AE

Adhesive Anchor System in Concrete; G AE

Non-Shrink, Non-Metallic Grout; G AE

SD-06 Test Reports

Post-Installed Anchor Special Inspections Report; G AE

SD-07 Certificates

Post-Installed Anchor Certification; G

SECTION 05 05 20.00 27 Page 2

SD-08 Manufacturer's Instructions

Manufacturer's Printed Installation Instructions; G

Non-Shrink, Non-Metallic Grout; G

Manufacturer's Material Safety Data Sheets

1.5 QUALITY ASSURANCE

Perform all work in accordance with EM 385-1-1 and all manufacturer's instructions and recommendations. To protect personnel from overexposure to toxic materials, conform to the applicable manufacturer's Material Safety Data Sheets (MSDS) or local regulation. Submit the MSDS for epoxies and other potentially hazardous materials.

1.5.1 Qualifications

The submittals must identify individuals who will be working on this contract and their relevant experience and training. Do not make changes in approved personnel without prior approval of the Contracting Officer.

1.5.1.1 Installer Qualifications

Each worker engaged in the installation of post-installed anchors must have satisfactorily completed an applicable certification program or equivalent instruction program through the manufacturer or manufacturer's representative for all anchoring products they will install. A manufacturer's representative must train all installers per the installation instructions as listed in the ICC-ES Evaluation Report for the anchor being installed. Training must consist of a review and performance test of the complete installation process, including but not limited to:

(1) Hole drilling procedure

(2) Hole preparation & cleaning technique

(3) Adhesive injection technique & dispenser training / maintenance

(4) Anchor/threaded rod preparation and installation

(5) Rebar dowel preparation and installation

(6) Proof loading/torquing

Submit certification for each worker showing that they have completed the above training within three years prior to onsite work. Certification must include organization or manufacturer's name, instructor's name and qualifications, trainee's name, list of instruction received, date of instruction, and confirmation of successful performance tests.

1.5.1.2 Post-Installed Anchor Special Inspector Qualifications

The Contractor must retain the services of a third party Special Inspector independent of the installing contractor and manufacturer. The individual(s) who perform special inspections for post-installed anchors must meet all Installer Qualification requirements and have a minimum of 3 years of experience as a Special Inspector on previous projects involving

SECTION 05 05 20.00 27 Page 3 similar scope of work. Submit resumes, pertinent information, past experience, and training.

1.6 DELIVERY, STORAGE, AND HANDLING

1.6.1 Packing, Shipping, Handling, and Unloading

Deliver products to job site in manufacturer's or distributor's original packaging undamaged, complete with installation instructions. Inspect materials delivered to site for damage. Unload and store with minimal handling.

1.6.2 Storage

Protect, store, and handle materials in accordance with manufacturer's recommendations to prevent damage or deterioration. Do not allow chemical materials to freeze. Remove materials that have not be stored in accordance with the manufacturer's recommendations, including expired materials, from the job site.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Post-Installed Anchors

Provide anchors of the type, effective embedment, and diameter indicated on contract drawings. Minimum spacing and concrete edge distances must be as shown on contract drawings. Design values listed must be as tested according to ASTM E488/E488M for the substrate type, substrate moisture condition, concrete aggregate type (normal weight or lightweight concrete), and concrete/masonry strength. Minimum allowable strength tension and shear values must be as indicated on contract drawings. If more than one type of anchor is to be used on a project, clearly indicate on the submittal where each type of anchor will be used.

2.1.1.1 Post-Installed Anchor Certification

Submit product information with recommended design values and physical characteristics for each type anchor shown on the drawings.

Provide certified test reports showing compliance with specified performance characteristics and physical properties. Anchors must have one of the following certifications:

(1) ICC-ES Evaluation Report indicating conformance with current applicable ICC ES Acceptance Criteria

(2) Third party Evaluation Report in conformance with ACI 355.2 or ACI 355.4 , as applicable. Third party must be accredited under ISO/IEC 17025 by a recognized accreditation body conforming to the requirements of ISO/IEC 17011 in accordance with ACI 355.4 ."

2.1.1.2 Manufacturer's Printed Installation Instructions

Submit manufacturer's instructions for each anchor type shown on the drawings.

SECTION 05 05 20.00 27 Page 4

2.1.1.3 Mechanical Anchors in Concrete

Anchors must have been tested and qualified for performance in cracked and uncracked concrete in accordance with ACI 355.2 .

Anchors must be galvanized in accordance with ASTM A153/A153M or stainless steel in accordance with ASTM A193/A193M unless otherwise indicated.

2.1.1.4 Adhesive Anchor System in Concrete

Use an adhesive to bond steel anchors to concrete. The adhesive must be a moisture insensitive, structural adhesive. Anchors must have been tested and qualified for performance in cracked and uncracked concrete, horizontal and overhead applications, and long term creep in accordance with ACI 355.4 .

Threaded rod anchors must meet the requirements of ASTM A36/A36M.

Threaded rods must be galvanized in accordance with ASTM A153/A153M or stainless steel in accordance with ASTM A193/A193M unless otherwise indicated. Reinforcing bars must meet the requirements of ASTM A615/A615M Grade 60.

Adhesive anchors must have the below characteristic bond strengths for uncracked and cracked concrete in 2500 psi concrete with maximum short term temperatures of 130 degrees F and maximum long term temperatures of 110 degrees F:

ANCHOR Tau,uncr (characteristic bond strength, uncracked concrete)

Tau,cr (characteristic bond strength, cracked concrete)

(psi) (psi)

3/4" diameter threaded rod 2220 1290

#8 reinforcing bar 1560 840

2.2 EQUIPMENT

Assemble at the site of the work, sufficient equipment that is dependable, appropriate and adequate to accomplish the work specified. Maintain the equipment in good working condition.

PART 3 EXECUTION

3.1 ANCHORING AND REINFORCING

Install anchors in accordance with the spacing and edge clearances indicated on the drawings. Anchor capacity is also highly dependent on proper installation. Follow all manufacturer and Evaluation Report installation instructions.

3.1.1 Drilling and Installing Mechanical Anchors

Drill holes for anchors using drilling equipment and bits suitable for the intended purpose, in accordance with Manufacturer's published installation instructions. Diameter of holes must be as recommended by the anchor

SECTION 05 05 20.00 27 Page 5 manufacturer. Unless otherwise shown on the Drawings, all holes must be drilled perpendicular to the concrete surface. Deviations more than 6 degrees from perpendicular are not acceptable. Unless otherwise specified, do not drill holes in concrete or masonry until concrete, mortar, or grout has achieved full design strength. Mechanical anchors must not be installed in concrete that is less than 7 days old.

Clean holes, install anchors and set anchors in place in accordance with the manufacturer's recommendations. Protect threads and anchor from damage during anchor installation. Ensure proper embedment and placement in accordance with contract documents and all other work. Aim wedges away from any concrete edges that are less than 9 inches from centerline of hole.

Tighten nuts against smooth washers to the manufacturer's recommended torque, using a calibrated torque wrench. Following attainment of 10 percent of the specified torque, 100 percent of the specified torque must be reached within 7 or less complete turns of the nut. If the specified torque is not achieved within the required number of turns, the anchor must be removed and replaced unless otherwise directed by the Engineer of Record.

3.1.2 Drilling and Installing Adhesive Anchors

Drill holes for anchors using drilling equipment and bits suitable for the intended purpose, in accordance with Manufacturer's Printed Installation Instructions and Evaluation Report installation instructions. Diameter of holes must be as recommended by the anchor manufacturer. Unless otherwise shown on the drawings, all holes must be drilled perpendicular to the concrete surface. Deviations more than 10 degrees from perpendicular are not acceptable. Unless otherwise specified, do not drill holes in concrete or masonry until concrete, mortar, or grout has achieved full design strength. Adhesive anchors must not be installed in concrete that is less than 21 days old.

Clean holes, place grout, and install anchors in accordance with anchor manufacturer's recommendations. Remove excess adhesive after the anchor has been set in place. Remove spills on adjacent surfaces. Protect threads and anchor from damage during anchor installation. Ensure proper embedment and placement in accordance with contract documents and all other work. Do not disturb or load anchors before manufacturer specified cure time has elapsed.

Adhesives must be stored at temperatures prescribed by the manufacturer and must not be used beyond the expiration date.

3.1.3 Unused or Repairs to Drilled Holes

Any holes made for anchors that are not used must be filled with non-shrink, non metallic grout suitable for the orientation and size of hole and have a minimum compressive strength of 4000 psi. Repair must completely fill hole and be flush with existing concrete or masonry.

Place in accordance with manufacturer's recommended instructions. Final anchor positions must not be within1 inch of repair patches.

3.2 EMBEDDED ITEMS

Existing reinforcing bars or other embedded items in the structure may conflict with specified anchor locations. Existing reinforcing and

SECTION 05 05 20.00 27 Page 6 embedded items must not be damaged during installation of post-installed anchors .

The contractor must review the as-built drawings and must use Radar detection systems (such as Hilti Ferroscan), X-Ray, or other appropriate means to accurately locate the position of existing reinforcing bars and embedded items at the locations of the anchors in the field. Scanning method must provide enough accuracy and precision to locate the space between rebar. Structural integrity of existing concrete or masonry must not be impaired by investigating method.

Create a template at each anchor connection location prior to fabricating holes in connection plates. Template must be made by locating existing reinforcing with an approved reinforcement detection system.

3.3 TESTS AND INSPECTIONS

3.3.1 Mechanical Anchors

For mechanical anchors, periodic special inspections are required.

Inspections must be in accordance with ICC IBC and the Evaluation Report.

Mechanical Anchors must be inspected during installation, to verify anchor type, anchor dimensions, base material type, drill bit, hole dimensions, hole cleaning procedures, anchor spacing, edge distances, base material thickness, base material age, effective embedment, tightening torque, adherence to the manufacturer's printed installation instructions, and any additional items recommended in the Evaluation Report.

For mechanical anchors whose strength is dependent on a minimum installation torque, the installer under the supervision of the Special Inspector must torque test the anchors with a calibrated torque wrench.

Perform torque testing immediately on the first three anchors of each type and size, for each installer, and a minimum of 5 percent of randomly selected anchors. Anchor selection will be determined by the Contracting Officer.

For mechanical anchors whose strength is not dependent on a minimum installation torque, the Special Inspector must perform proof loading on the first three anchors of each type and size, for each installer and a minimum of 5 percent of randomly selected anchors. Anchor selection will be determined by the Contracting Officer. Perform confined tension proof load testing in accordance with ASTM E488/E488M . Use incremental loading for tensile test. Maintain proof load for a minimum of 10 seconds.

Consider anchors to have failed if displacement exceeds 0.1 inch D/10, where D is the nominal anchor diameter, or if any of the failure modes listed in ASTM E488/E488M occur.

Proof loads must be the minimum of the value shown on the Drawings, the values shown in the table below, or 50 percent of the tension capacity of the anchor:

SECTION 05 05 20.00 27 Page 7

ANCHOR EFFECTIVE EMBEDMENT CONFINED TENSION PROOF LOAD

(inches) (pounds)

Concrete Expansion Anchor, 1/2" diameter

2.5" to 3" in Concrete 4500

3.3.2 Adhesive Anchors

For adhesive anchors, periodic special inspection are required as a minimum. Where adhesive anchors are used to resist sustained tension in horizontal or upwardly inclined orientations, or where the findings of the Evaluation Report for the adhesive anchor product require it, continuous special inspection is needed. Inspections must be in accordance with ICC IBC and the Evaluation Report.

Adhesive anchors must be inspected during installation, to verify anchor type, anchor dimensions, base material type, base material age, drill bit, hole dimensions, hole cleaning procedures, anchor spacing, edge distances, base material thickness, effective embedment, tightening torque, adhesive mixing, filling of the hole with adhesive, adherence to the manufacturer's printed installation instructions, and any additional items recommended in the Evaluation Report.

The Special Inspector must perform proof loading on the first three anchors of each type and size, for each installer, and a minimum of 5 percent of randomly selected anchors. Anchor selection will be determined by the Contracting Officer. Perform confined tension proof load testing in accordance with ASTM E488/E488M . Use incremental loading for tensile test. Maintain proof load for a minimum of 10 seconds. Consider anchors to have failed if displacement exceeds 0.1 inch D/10, where D is the nominal anchor diameter, or if any of the failure modes listed in ASTM E488/E488M occur.

Adhesive anchors and capsule anchors must not be torque tested.

Proof loads must be the minimum of the value shown on the Drawings, the values shown in the table below, or 50 percent of the tension capacity of the anchor:

ANCHOR EFFECTIVE EMBEDMENT CONFINED TENSION PROOF LOAD

(inches) (pounds)

Adhesive anchor, 3/4" diameter rod

3.5" to 6" 7120

Adhesive anchor, #8 reinforcing bar

4" to 8" 20670

3.3.3 Action Required from Failed Tests/Inspections

Immediately report failed anchor locations and test results to the Contracting Officer. Anchors that fail to meet proof/torque load or

SECTION 05 05 20.00 27 Page 8 installation requirements must be regarded as malfunctioning. Do not re-use holes unless specifically allowed by manufacturer's published instructions and approved by the Post-Installed Anchor Special Inspector.

If any of the tested anchors fail to achieve the specified torque or proof load within the limits of the contract documents, test a minimum of two adjacent anchors for each anchor that fails.

Continuously special inspect and proof load/torque test any replacement anchors.

Fill unused anchor holes and patch failed anchor locations in accordance with this specification. Prior to performing the repair, the Contractor must submit to the Contracting Officer for approval, the proposed fill and patch materials.

Additional tests, repairs, delays, or modification of work to accommodate failed tests will be at no cost to the Government.

3.3.4 Post-Installed Anchor Special Inspections Report

Report the results of all inspections daily. Submit report as an electronic PDF file to the Contracting Officer for review by the Engineer of Record. The report must include the following:

(1) Exact locations of the inspected and tested work

(2) Inspector's name

(3) Date of inspection

(4) Summary of work completed during the inspection period

(5) Test results

(6) Statement by the Special Inspector that clearly identifies the tested anchors as being acceptable or rejected.

(7) Statement by the Special Inspector confirming that the materials and installation procedures conform with the approved contract documents and the manufacturer's published installation instructions.

3.4 DUST CONTROL

Control dust resulting from demolition to prevent the spread of dust and avoid creation of a nuisance in the surrounding area. Do not use water when it will result in, or create, hazardous or objectionable conditions such as ice, flooding, or pollution.

-- End of Section --

SECTION 05 05 20.00 27 Page 9