report08-1215.pdf

CLARK & MONTGOMERY COUNTY I‐64 REST AREAS

STRUCTURAL EVALUATION OF WALKS

FILE No. 625‐C0FD‐RA01‐00

BK # 08085.01

INVESTIGATION AND REPORT

DECEMBER, 2008

STRUCTURAL ENGIN REE S PSC

BROWN + KUBICAN

121 Prosperous Place Suite 10 Lexington, KY 40509

Phone: 859-543-0933 Fax: 859-543-0733

S. Craig Brown, PE Dan Kubican, PE

December 15, 2008

Mr. Bernard Engelman, Project Architect Division of Engineering and Contract Administration Bush Building, 1st Floor 403 Wapping Street Frankfort, Kentucky 40601

Re: Clark & Montgomery County I‐64 Rest Areas Structural Evaluation of Walks Engineering File No. 625‐C0FD‐RA01‐00

BK #08085.01

Dear Mr. Engelman;

Brown + Kubican, PSC Structural Engineers is pleased to present this report for review and comment.

This project consists of a structural review of apparent settlement cracks and severe spalling and degradation of the exterior perimeter walks immediately surrounding the main rest area facilities at both the Clark and Montgomery County rest areas.

Our submittal consists of a structural condition survey of the perimeter walks and exterior walls at the restroom buildings, a discussion of proposed repair techniques and product data, and an opinion of probable cost. While our scope was to focus on the perimeter walks and steps, we did discover some deteriorated conditions in adjacent wall and roof structures. We included these conditions in the report to notify the User of the conditions and provide the Commonwealth the opportunity to address these issues at this time.

We are enthusiastic about the importance of this project and look forward to its further development and fruition. If you have any questions or require any additional information, please don’t hesitate to call.

Sincerely, Principal‐in‐Charge

STRUCTURAL ENGIN REE S PSC

BROWN + KUBICAN

121 Prosperous Place Suite 10 Lexington, KY 40509

Phone: 859-543-0933 Fax: 859-543-0733

S. Craig Brown, PE

Clark & Montgomery County I‐64 Rest Areas Structural Evaluation of Walks

File No. 625‐C0FD‐RA01‐00

BK # 08085.01

TABLE OF CONTENTS

Condition Survey

Repair Methodology

Proposed Product Literature

Opinion of Probable Cost

INTRODUCTION

This study was initiated to investigate the deterioration of the perimeter slab on grade and perimeter retaining wall at the restroom buildings and begin recommendations for the repair of said deterioration.

Our condition survey was limited to observations from the exterior walkway, interior lobby space and rear maintenance room. Our investigation was visual in nature; material sampling and testing were not performed. Photographs were taken and are included within the body of this report. Original construction documents were made available and reviewed after our field observation. An analysis to determine the approximate foundation bearing pressure was made; however, a complete investigation and analysis (calculations) of the building structure for gravity and lateral loads was not performed.

Brown & Kubican, PSC makes no claim as to the structural adequacy or compliance with the Kentucky Building Code for any item not specifically discussed in the report.

The restroom buildings at the Clark and Montgomery rest areas appear to be identical in design and construction. The buildings are round in plan and are constructed predominantly of reinforced precast concrete. The roof structure is constructed of a folded plate approximately 4” thick which is segmented into 16 separate pieces with joints at each ridge. The plate roof is supported by precast concrete columns at the perimeter and a load‐bearing concrete masonry core. The roof segments cantilever past both the interior core and exterior support columns to form a covered walk. The exterior walls are constructed of precast concrete panels and glass curtainwall. The wall panels are isolated from both the roof and the columns by the surrounding glass walls. The walls were originally supported at the top by a steel channel which spanned horizontally between the columns and was hidden within the glass;

however, this support was supposedly removed during the window replacement several years ago. The perimeter precast columns and wall panels are supported by a continuous strip footing with integral spread footings below the columns. The slab on grade is cast around the wall panels and columns and bears on the perimeter retaining wall at the exterior edge of the covered walk.

Both the Clark and Montgomery County facilities exhibit very similar types of deterioration and past repairs. Both also appear to have been constructed on fill material mounded near the parking area to construct a building pad which is level directly around the building, but slopes immediately down to natural grade at the rear.

Clark County Rest Area Montgomery County Rest Area

OBSERVATIONS AND RECOMMENDATIONS‐Clark County A1. The sidewalk along the parking lot leading up to the restroom building has multiple cracks, spalls, and is unlevel due to settlement over a length of approximately 80 feet. Several sections of this wall appear to have been previously replaced.

This section of walk should be removed, the subgrade consolidated and filled, and a new slab on grade placed at original elevation.

A2. The access ramp leading to the restroom appears to have too steep of slope and does not have intermediate landings as would be required for current ADA guidelines. The walk has also differentially settled approximately 1 ½” at its connection to the building covered walk and at its midpoint. The settlement has been transitioned with wedges of cementitious mortar overlaid across the joints.

To reconstruct to meet current guidelines, a switchback ramp with perimeter retaining walls would likely be required due to the site confinements.

A3. The access stair leading to the restroom is constructed of 3 risers of concrete slab on grade. The treads are spalled up to 1/2” deep and have previously been patched with cementitious material.

The spalled surface could be bush‐hammered, cleaned, coated with bonding agent, and patched with structural repair mortar. However, as this is the main entrance to provide slip resistance and prevent trip hazards we recommend simply replacing these steps.

A4. The perimeter retaining wall has isolated areas of exposed corroded reinforcing steel and spalling. The deterioration does not affect the structural adequacy of the wall at this time;

however, the rate of deterioration typically accelerates with age.

If the building will likely remain in service for 10 years or longer, we would recommend that the spalled surface should be bush‐hammered, cleaned, coated with bonding agent, and patched with structural repair mortar. The concrete around the exposed reinforcing could be cut out to expose the steel. The steel should be cleaned and coated, and the concrete patched with a structural repair mortar. If the facility will likely be replaced, we recommend simply monitoring the condition.

A5. The covered walk at the southwest side is deteriorated at approximately 8 places with spalls 8” wide by ½ to 1 1/2” deep by 24 inches long with exposed, corroded reinforcing steel. Some of the spalls have previously been patched with cementitious material which is again spalling away.

The spalls are a trip hazard.

The perimeter of the spall area should be sawcut to ½” minimum depth around the perimeter of the spall and the area within the cut bush‐hammered to minimum ½” depth to remove all soft and unsound concrete and to fully expose the corroded reinforcing. The steel and concrete surface should be cleaned, coated with a bonding agent, and then patched with a structural repair mortar.

A6. Both the exterior and interior slab on grade are typically cracked in a circular pattern surrounding the exterior precast columns. Cracks vary in width up to 1/4” in width and appear to be more open at the top surface that against the subgrade. The cracks typically intersect the exterior wall in line with the juncture between the precast wall panel and glass curtainwall (approximately 24” from the column). The slab on grade is noticeably depressed at the building column relative to the mean slab on grade level. The crack orientation and depression are indicative of settlement of the building column foundation.

As shown on the original construction documents, the slab on grade was cast around the precast elements and through and over the foundation below the glass curtainwall. The footings are minimal in size – only 12” wide below the precast wall panels and glass curtainwall and 1’‐10” by 1’‐6” below the building columns. We have performed an analysis to determine the approximate foundation bearing stress. Assuming the spread footing only supports the column load (typical method of foundation design, but conservative in reality) the bearing stress under dead load and code mandated live load is approximately 3,700 psf. Utilizing the yield line fracture in the floor slab to show the distributed area actually supporting the column load, the approximate true bearing stress is likely closer to 1,700 psf. That said, the footing should be considered too small by modern engineering standards as most geotechnical engineers recommend earth supported foundations to have a minimum footprint of 18” width for footings and 24” square for spread footings to prevent punching shear through the soil. We expect that both the consistency of the engineered fill and small foundation size contribute to the settlement.

strip

Although the foundations are settling, we do not believe there is any danger of structural uld

Foundation settlement is typically stabilized by the installation of permanent steel underpinning piers d

A7. During the window replacement project several years ago, the steel channels at the top of each ry, or collapse because of it. Depending on the capability of the underlying soil, the condition co worsen over time. Settlement could lead to fracturing of the glass curtainwall.

“push” piers which pushed down to bedrock or capable soil using the weight of the structure to resist the driving force. Depending on the expected remaining service life of the building, they may be considered stabilize the foundation and help prevent future maintenance. Piers typically do not return the building to its original position. Unfortunately, by installing the the foundation would be founded on both stiff supports and the supposed softer fill material.

We recommend that if underpinning is chosen, that 1) a geotechnical analysis first be performe to determine capabilities of the underlying soil and potential depth of pier embedment and 2) piers be located at each of the perimeter building columns and midpoint of each wall panel between columns to prevent differential bearing conditions and settlement. The geotechnical report would assist in providing tighter bids as the approximate pier length could be better established.

precast wall panel were removed to install the new window mullions. These channels were the engineered lateral support to the precast wall panels, integrally connected to the tops of the panels and the precast concrete columns to resist lateral wind, and potentially seismic, forces Without the channels, the sole support for the wall systems is the 8” deep embedment into the slab on grade. Should the slab be removed temporarily, deteriorate, or need to withstand substantial wind or seismic loading the wall panel could topple causing severe damage, inju death. In addition, by removing the top support the wall panels are forced to cantilever instead of being simply supported each end ‐ effectively increasing the flexural stress by 4 times.

It appears that several of the solid wall panels at the rear of the building (enclosing the maintenance room) have exhibited lateral movement previously due to the removal of the support channel. A bridge plate with through bolts and plate washers has been added to realign the panels and tie them together.

We recommend that a structural lateral support be designed and installed between each of the sixteen perimeter columns, except at the main entry where the entire bay is filled with window wall. Such support is necessary for structural adequacy and safety, though it will be difficult to reinstall in an architecturally pleasing manner without the removal and reconstruction of the windows. We have performed preliminary calculations and found that an L3x3 is strong enough to brace the wall for wind loads. In order to install the new structure conduit to the pay phone and the map box will need to be relocated slightly.

OBSERVATIONS AND RECOMMENDATIONS‐Montgomery County

B1. The perimeter retaining wall has two large areas of mature concrete deterioration, spalling, delamination and exposed corroded reinforcing steel. The deterioration is quite severe and warrants structural repair.

The perimeter of the spalled and delaminated areas should be sawcut to ½” minimum depth around the perimeter of the spall and the area within the cut bush‐hammered to minimum ½” depth to remove all soft and unsound concrete and to fully expose the corroded reinforcing.

The steel and concrete surface should be cleaned, coated with a bonding agent, and then patched with a structural repair mortar.

B2. The majority of the covered walk is severely spalled and delaminated around the perimeter.

The slab has many previous repairs of partial replacement or cementitious patching material.

Many of these repairs have subsequently spalled.

We recommend that the entire perimeter slab on grade be removed and replaced. The slab will need to be sawcut immediate to each of the window walls in order to remove them. The slab should be chipped away from the precast wall panels so that a continuous expansion joint and sealant may be applied between new and existing. Due to the removal of the top wall support, see below, the wall is unstable especially after the slab removal and therefore must be permanently supported prior to slab removal.

B3. Both the exterior and interior slab on grade are typically cracked in a circular pattern surrounding the exterior precast columns. Cracks vary in width up to 1/4” in width and appear to be more open at the top surface that against the subgrade. The cracks typically intersect the exterior wall in line with the juncture between the precast wall panel and glass curtainwall (approximately 24” from the column). The slab on grade is noticeably lower at the building column relative to the mean slab on grade level. The crack orientation and depression are indicative of settlement of the building column foundation.

See description and recommendations made above for the Clark County facility.

B4. During the window replacement project several years ago, the steel channels at the top of each precast wall panel were removed to install the new window mullions. These channels were the engineered lateral support to the precast wall panels, integrally connected to the tops of the panels and the precast concrete columns to resist lateral wind, and potentially seismic, forces.

Without the channels, the sole support for the wall systems is the 8” deep embedment into the slab on grade.

See description and recommendations made above for the Clark County facility.

B5. The exterior corners of several roof panels are severely spalled and deteriorated with exposed corroded reinforcing at the valley.

The perimeter of the spalled area should be sawcut to ½” minimum depth around the perimeter and the area within the cut bush‐hammered to minimum ½” depth to remove all soft and unsound concrete and to fully expose the corroded reinforcing. The steel and concrete surface should be cleaned, coated with a bonding agent, and then patched with a structural repair mortar. Depending on the depth of deterioration, it may be necessary to form the patch, extend the repair mortar with pea gravel and cast the patch in place. Due to the consistency and materials in structural repair mortar, it will not be possible to provide an exposed aggregate finish similar to the existing without using a more standard concrete material and thereby sacrifice the durability, bonding capacity, and many years of its service life.

B6. The interior concrete masonry bearing wall at the building core has several cracks where the precast concrete roof panels bear on the wall as observed from the maintenance room. These may be caused by lateral sliding of the roof panels or thermal movement.

We recommend monitoring these cracks for signs of increased severity.

REPAIR METHODOLOGY

Repairs recommended are of two types. (1) Remove and replace the damaged item or component. (2) Repair and restore the damaged item or component to resume its as‐built function. The recommendations were selected based on our opinion of the most cost effective remedy in consideration with the cost of future maintenance and safety of use.

Some of the type of construction described in this report is specialized; requiring tools, equipment and techniques not commonly used in the construction industry. Advertisement for bids should seek contractors with experience in concrete restoration materials and procedures. Familiarity with said techniques and materials can be obtained through past project experience or training and certification by the material’s manufacturer. We recommend that the construction documents be formatted to encourage experience and product familiarity, and that a requirement for submittal and review of contractor qualifications be incorporated.

Material testing and inspection of the Contractor’s work should be provided for through an independent inspection agency. Similar to any new construction, material sampling for concrete and inspection of welds should be provided for.

This Report relies on manufactured and packaged concrete patches and admixtures to establish performance and quality. It is anticipated that the concrete specification for the construction phase will set forth performance requirements and require the Contractor to submit concrete mix designs.

Chemical treatments recommended were judged in our opinion to be cost effective protection of the Structures. Products are to be stored, applied, installed and otherwise used in accordance with the Manufacturer’s recommendations. Products named or designated by manufacturer are done so to indicate clearly the quality and performance expected for a particular application. Other manufacturer’s products having equal quality and performance would be acceptable, using a submittal‐approval system.

We have included material data sheets following this report for the Owner’s consideration.

Push Piers Foundation settlement is typically stabilized by the installation of permanent steel underpinning “push” piers which pushed down to bedrock or capable soil using the weight of the structure to resist the driving force. Piers are a form of stabilization – to help prevent future movement. They typically do not return the building to its original position and occasionally need to be rejacked after additional settlement takes place. To install the piers, the concrete slab on grade could be sawcut and partially removed outside each of the settling columns. The foundation would be exposed and then sawcut to remove the footing to the vertical face of the column or wall above. A push pier would then be bracketed to the foundation face and driven to refusal. The small excavation would then be filled with crushed stone and the slab replaced.

Walk and Slab Replacement Several sections of slab on grade, sidewalk, or stair slab on grade have deteriorated or settled to such a point that it is not economical or feasible to repair and fully remove the trip hazard / slick surface. In such instances we are recommending complete removal and replacement of the affected slab to stop the deterioration, remove the trip hazard, etc.

Concrete Spalls All concrete repairs called for in this section are to follow certain basic steps to achieve effective results.

Prepare damaged concrete areas for patches by removing concrete beyond the damaged material into sound material, outlined by a saw cut at least ½” deep. The ½” deep vertical edge will prevent weak feathered edging around the perimeter of the patch. Once the damaged material is excavated into sound concrete, dust and bruised concrete must be removed either by wire brushing and air or pressure washing. A clean sound concrete surface is necessary to successfully patch concrete. Exposed reinforcing steel will be blast cleaned and then coated with an anti‐corrosion bonding agent (Sika Armatec 110 EpoCem). Finally, return the surface to original level with structural repair mortar (SikaTop

123) troweled into place.

Precast Concrete Repairs The repair of the precast concrete roof plank will be conducted similar to the standard concrete spall with the exception that the patch need to be temporarily formed and then cast in place. The finish of the patch will not match the exposed aggregate of the original construction.

C on st ru ct io n

Description Sika Armatec 110 EpoCem is a 3-component, solvent-free, moisture-tolerant, epoxy-modified, cementitious product specifically formulated as a bonding agent and an anti-corrosion coating.

Where to Use n As an anti-corrosion coating for reinforcing steel in concrete restoration.

n As added protection to reinforcing steel in areas of thin concrete cover.

n As a bonding agent for repairs to concrete and steel.

n As a bonding agent for placing fresh, plastic concrete to existing hardened concrete.

Advantages n Excellent adhesion to concrete and steel.

n Acts as an effective barrier against penetration of water and chlorides.

n Long open time - up to 16 hours.

n Not a vapor barrier.

n Can be used exterior on-grade.

n Contains corrosion inhibitors.

n Excellent bonding bridge for cement or epoxy based repair mortars.

n High strength, unaffected by moisture when cured.

n Spray, brush or roller application.

n Non-flammable, solvent free.

Coverage Bonding agent: minimum (theoretical) on smooth, even substrate 80 sq. ft./gal. (=20 mils thickness).

Coverage will vary depending on substrate profile and porosity.

Reinforcement Protection: 40 sq. ft./gal. (=20 mils thickness) (2 coat application).

Packaging 3.5 gal. unit. (47.6 fl. oz. Comp. A + 122.1 fl. oz. Comp. B + 46.82 lb. Comp. C) Comp. A + B in carton, Comp. C in multi-wall bag.

1.65 gal. unit. (22.7 fl. oz. A + 57.6 fl. oz. B + 4 bags @ 5.5 lb.) Factory-proportioned units in a pail.

Sika Armatec® 110 EpoCem®

Bonding Agent and Reinforcement Protection

Product Data Sheet Edition 8.2003 Identification no. 182 Sika Armatec 110 EpoCem

Typical Data (Material and curing conditions @ 73°F and 50% R.H.)

Shelf Life 1 year in original, unopened packaging.

Storage Store dry at 40°-95°F (4°-35°C). Condition material to 65°-75°F (18°-24°C) before using. If components A and B are frozen, discard. Protect Component C from humidity.

Color Concrete gray

Density (Mixed) 125 lb./cu. ft. (2.0 kg.)

Pot Life Approximately 90 minutes

Compressive Strength (ASTM C-109) 3 days 4500 psi (31.0 MPa) 7 days 6500 psi (44.8 MPa) 28 days 8500 psi (58.6 MPa)

Flexural Strength (ASTM C-348) 28 days 1250 psi (8.6 MPa) Splitting Tensile Strength (ASTM C-496) 28 days 600 psi (4.1 MPa) Important Data for Sika Armatec 110 as a Corrosion Protective Coating

Water Water Permeability at 10 bar (145 psi) 8.92 x 10-15 ft./sec.

Control 7.32 x 10-10 ft./sec.

Water vapor diffusion coefficient µ H

O 110

Carbon Dioxide Carbon dioxide diffusion coefficient µ CO 14000

TEST DATA: Time-to-Corrosion Study

- Sika Armatec 110 more than tripled the time to corrosion

- Reduced corrosion rate by over 40%

Important Data for Sika Armatec 110 as a Bonding Agent Bond Strength (ASTM C882) 14 days moist cure, plastic concrete to hardened concrete:

Wet on Wet 2800 psi (19.3 MPa) 24 hr. Open Time 2600 psi (17.9 MPa)

Bond of Steel Reinforcement to Concrete (Pullout Test):

Sika Armatec 110 Coated 625 psi ( 4.3 MPa) Epoxy Coated 508 psi ( 3.5 MPa) Plain Reinforcement 573 psi (3.95 MPa) st ru ct io n

KEEP CONTAINER TIGHTLY CLOSED KEEP OUT OF REACH OF CHILDREN

NOT FOR INTERNAL CONSUMPTION FOR INDUSTRIAL USE ONLY

CONSULT MATERIAL SAFETY DATA SHEET FOR MORE INFORMATION

Sika warrants this product for one year from date of installation to be free from manufacturing defects and to meet the technical properties on the current technical data sheet if used as directed within shelf life. User determines suitability of product for intended use and assumes all risks. Buyer’s sole remedy shall be limited to the purchase price or replacement of product exclusive of labor or cost of labor.

NO OTHER WARRANTIES EXPRESS OR IMPLIED SHALL APPLY INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. SIKA SHALL NOT BE LIABLE UNDER ANY LEGAL THEOR Y FOR

SPECIAL OR CONSEQUENTIAL DAMAGES.

Visit our website at www.sikausa.com 1-800-933-SIKA NATIONWIDE Regional Information and Sales Centers. For the location of your nearest Sika sales office, contact your regional center.

Sika Corporation Sika Canada Inc. Sika Mexicana S.A. de C.V.

201 Polito Avenue 601 Delmar Avenue Carretera Libre Celaya Km. 8.5 Lyndhurst, NJ 07071 Pointe Claire Corregidora, Queretaro Phone: 800-933-7452 Quebec H9R 4A9 C.P. 76920 A.P. 136 Fax: 201-933-6225 Phone: 514-697-2610 Phone: 52 42 25 0122

Fax: 514-694-2792 Fax: 52 42 25 0537

Sika and Armatec are registered trademarks. Made in USA. Printed in USA.

How to Use Surface Preparation Cementitious substrates: Should be cleaned and prepared to achieve a laitance and contaminant-free surface prepared in accordance with the requirements specified by the overlay or repair material by blast cleaning or equivalent mechanical means. Substrate must be saturated surface dry (SSD) with no standing water.

Steel: Should be cleaned and prepared thoroughly by blast cleaning.

Mixing Shake contents of both Component ‘A’ and Component ‘B’. Empty entire contents of both Component ‘A’ and Component ‘B’ into a clean, dry mixing pail. Mix thoroughly for 30 seconds with a Sika paddle on a low speed (400-600 rpm) drill. Slowly add the entire contents of Component ‘C’ while continuing to mix for 3 minutes until blend is uniform and free of lumps. Mix only that quantity that can be applied within its pot life.

Application As a bonding agent - Apply by stiff-bristle brush or broom. Spray apply with Goldblatt Pattern Pistol or equal equipment. For best results, work the bonding slurry well into the substrate to ensure complete coverage of all surface irregularities. Apply the freshly mixed patching mortar or concrete wet on wet, or up to the maximum recommended open time, onto the bonding slurry.

Maximum recommended open time between application of Armatec 110 and patching mortar or concrete:

80°-95°F (26°-35°C) 6 hours 65°-79°F (18°-26°C) 12 hours 50°-64°F (10°-17°C) 16 hours 40°-49°F (4°-9°C) wet-on-wet

For corrosion protection only - Apply by stiff-bristle brush or spray at 80 sq. ft./gal. (20 mils). Take special care to properly coat the underside of the totally exposed steel. Allow coating to dry 2-3 hours @ 73°F, then apply a second coat at the same coverage. Allow to dry again before the repair mortar or concrete is applied. Pour or place repair within 7 days.

Limitations n Substrate and ambient temperature: Minimum 40°F (5°C) n Maximum 95°F (35°C) n Minimum thickness: As a bonding agent 20 mils.

n For reinforcement protection 40 mils n (2 coats, 20 mils each).

n Not recommended for use with expansive grouts.

n Use of semi-dry mortars onto Sika Armatec 110 EpoCem must be applied "wet on wet".

n When used in overhead applications with hand placed patching mortars, use "wet on wet" for maximum mortar build thickness.

n Substrate profile as specified by the overlay or repair material is still required.

n As with all cement based materials, avoid contact with aluminum to prevent adverse chemical reaction and possible product failure. Insulate potential areas of contact by coating aluminum bars, rails, posts etc. with an appropriate epoxy such as Sikadur Hi-Mod 32.

Caution Part A & B: IRRITANT; SENSITIZER - Can cause skin sensitization after prolonged or repeated contact.

Skin and eye irritant. High concentrations of vapor may cause respiratory irritation. Avoid skin contact. Use only with adequate ventilation. Use of safety goggles and chemical resistant gloves is recommended.

Part C: IRRITANT; SUSPECT CARCINOGEN - Contains crystalline silica, quartz (sand); cement. Skin and eye irritant. Dust may cause respiratory tract irritation. Avoid breathing dust. Use only with adequate ventilation. May cause delayed lung injury (silicosis). IARC list crystalline silica as having sufficient evidence of carcinogenicity to laboratory animals and limited evidence of carcinogenicity in humans. NTP also lists crystalline silica as a suspect carcinogen. Use of safety gloves is recommended. In case of high dust concentrations or exceedance of PELs, use an appropriate NIOSH approved respirator.

First Aid In case of eye contact, wash immediately with soap and water for 15 minutes; immediately consult a physician. In case of skin contact, wash with soap and water; consult a physician for irritation. For respiratory problems, remove person to fresh air and institute artificial respiration if necessary; consult a physician. In case of ingestion, immediately consult a physician. Wash clothing before reuse.

Clean-Up In case of spills or leaks, wear suitable protective equipment, contain spill, collect with absorbent material, and transfer to a suitable container. Ventilate area. Avoid contact. Dispose of in accordance with current, applicable local, state, and federal regulations.

Co ns tru ct io n

Sika FerroGard® 903 Penetrating, corrosion inhibiting, impregnation coating for hardened concrete

Description Sika FerroGard 903 is a corrosion inhibiting impregnation coating for hardened concrete surfaces. It is designed to penetrate the surface and then to diffuse in vapor or liquid form to the steel reinforcing bars embedded in the concrete. Sika FerroGard 903 forms a protective layer on the steel surface which inhibits corrosion caused by the presence of chlorides as well as by carbonation of concrete.

How it Works Sika FerroGard 903 is a combination of amino alcohols, and organic and inorganic inhibitors that protects both the anodic and cathodic parts of the corrosion cell. This dual action effect dramatically delays the initiation of corrosion and greatly reduces the overall corrosion activity.

Sika FerroGard 903 protects the embedded steel by depositing a physical barrier in the form of a protective layer on the surface of the steel reinforcement. This barrier inhibits corrosion of the steel.

Where to Use Sika FerroGard 903 is recommended for all steel-reinforced, prestressed, precast, post tensioned or marine concrete. Use of Sika FerroGard 903:

n Steel-reinforced concrete, bridges and highways exposed to corrosive environments (deicing salts, weathering) n Building facades and balconies n Steel-reinforced concrete in or near a marine environment n Parking garages n Piers, piles, and concrete dock structures n As part of Sika’s system approach for buildings and civil engineering structures

Advantages Sika FerroGard 903 offers owners, specifiers, port authorities, DOTs, and engineers, a new technology in corrosion inhibition that can easily be applied to the surface of existing concrete to extend the service life of any reinforced concrete structure.

n Protects against the harmful effects of corrosion by penetrating the surface of even the most dense concrete and diffusing to the steel to inhibit corrosion.

n Enhances the durability of reinforced concrete.

n Does not require concrete removal.

n Environmentally sound.

n Does not contain calcium nitrite.

n Easily applied by either spray or roller to all existing reinforced concrete.

n Can be applied to reinforced concrete that already exhibits corrosion.

n Adds additional benefits when used prior to protective coatings in concrete restoration systems.

n Water based for easy handling and application.

n Not a vapor barrier; allows vapor diffusion.

n FerroGard has been proven effective in both laboratory (ASTM G109/Cracked Beams) and field analysis.

n ANSI/NSF Standard 61 potable water approved

Coverage For normal concrete, application is 200 ft.2/gal. each coat. A minimum of two coats is recommended.

For dense concrete, application may exceed 300 ft.2/gal. Therefore, more than two coats may be required to achieve the total application rate: 100 ft.2/gal.

Packaging 5 gallon pails with spout, 55 gallon drums.

Product Data Sheet Edition 6.15.2004 Identification no. 197-543 Sika FerroGard 903

Typical Data [at 73°F(23°C)]

Shelf life 18 month minimum in original, unopened container

Storage Conditions Store at 40°-95°F (4°-35°C). Protect from freezing. If frozen, discard.

Color Pale Yellow

Viscosity 15 cps

Flash Point None (water based)

Density 1.13 (9.4 lbs./gal.)

pH 11 (±1)

Application Rate 100 ft.2 /gal. total application rate

How to Use Surface preparation Before applying Sika FerroGard 903 be sure the surface is clean and sound.

Remove all dirt, dust, oil, grease, efflorescence or existing coatings from concrete surface by steam cleaning, waterblasting or slightly sandblasting.

Allow concrete surface to dry prior to application of Sika FerroGard 903. The dryer the surface the better the penetration and effectiveness.

tru ct io n

KEEP CONTAINER TIGHTLY CLOSED KEEP OUT OF REACH OF CHILDREN

NOT FOR INTERNAL CONSUMPTION FOR INDUSTRIAL USE ONLY

CONSULT MATERIAL SAFETY DATA SHEET FOR MORE INFORMATION

Sika warrants this product for one year from date of installation to be free from manufacturing defects and to meet the technical properties on the current technical data sheet if used as directed within shelf life. User determines suitability of product for intended use and assumes all risks. Buyer’s sole remedy shall be limited to the purchase price or replacement of product exclusive of labor or cost of labor.

NO OTHER WARRANTIES EXPRESS OR IMPLIED SHALL APPLY INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. SIKA SHALL NOT BE LIABLE UNDER ANY LEGAL THEORY FOR

SPECIAL OR CONSEQUENTIAL DAMAGES.

Visit our website at www.sikausa.com 1-800-933-SIKA NATIONWIDE Regional Information and Sales Centers. For the location of your nearest Sika sales office, contact your regional center.

Sika Corporation Sika Canada Inc. Sika Mexicana S.A. de C.V.

201 Polito Avenue 601 Delmar Avenue Carretera Libre Celaya Km. 8.5 Lyndhurst, NJ 07071 Pointe Claire Corregidora, Queretaro Phone: 800-933-7452 Quebec H9R 4A9 C.P. 76920 A.P. 136 Fax: 201-933-6225 Phone: 514-697-2610 Phone: 52 42 25 0122

Fax: 514-694-2792 Fax: 52 42 25 0537 Quality Certification Numbers: Lyndhurst: FM 69711 (ISO 9000), FM 70421 (QS 9000), Marion: FM 69715, Kansas City: FM 69107, Santa Fe Springs: FM 69408

Sika and FerroGard are registered trademarks. Made in USA. Printed in USA.

Application Sika FerroGard 903 is applied by roller, brush or spray on concrete surfaces. When spraying, use a conventional airless spray system or hand-pressure equipment. A minimum of two coats is always recommended. Dense substrates may require more coats. Waiting time between coats of Sika FerroGard 903 is at least 1 hour. Allow a minimum of one day to allow Sika FerroGard 903 to dry and penetrate.

When Sika FerroGard 903 is used prior to the application of a repair mortar, concrete overlay, protective coating, Sikafloor system or any other application, care must be taken to remove any residue remaining on the surface from the application of Sika FerroGard 903. Clean the substrate in such a manner (i.e. push the water in one direction away and off from the surface to be overcoated) to completely remove any residue.

Horizontal surfaces require pressure washing (2,000 psi minimum) to remove the residue. Vertical surfaces may be rinsed with water or pressure washed. The use of Sika Armatec 110 EpoCem as a bonding agent prior to the application of repair mortars or concrete overlays is suggested. Drying times depend on environmental conditions, absorbency of the substrate and maximum recommended moisture content for the subsequently applied system.

Limitations n Minimum ambient and substrate temperatures 35°F.

n Do not apply when temperature is expected to fall below 35°F within 12 hours.

n If the applied surfaces will be submerged after the application of Sika FerroGard 903, a waterproof-ing coating must be applied prior to submersion.

n Substrate should be as dry as possible prior to the application.

n Protect glass, wood, brick, galvanized steel, copper and exposed aluminum during the application.

n Maximum chloride content of concrete structures intended to be treated with Sika FerroGard 903 is 6 lbs./y3 (measured at the level of the reinforcing steel). For levels up to 10 lbs./y3, consult technical service.

Caution Irritant - Skin and eye irritant. Vapors may cause respiratory tract irritation. Use only with adequate ventilation. Use of safety goggles and chemical resistant gloves is recommended. Remove contami-nated clothing.

First Aid In case of skin contact, wash thoroughly with soap and water. For eye contact, flush immediately with plenty of water for at least 15 minutes; contact physician immediately. For respiratory problems, remove person to fresh air. Wash clothing before re-use.

Clean Up In case of spills or leaks, wear suitable protective equipment, contain spill, collect with absorbent material, and transfer to a suitable container. Ventilate area. Avoid contact. Dispose of in accordance with current, applicable local, state, and federal regulations.

Test Method/Institute:

1. Cracked Concrete Beam Test (adapted from ASTM G109).

2. Secondary Neutron Mass Spectroscopy (SNMS) / Institute for Radiochemistry, Karlsruhe (Germany), Prof. Dr. J. Goschnick.

3. X-ray Photon Spectroscopy (XPS) and Secondary Ion Mass Spectroscopy (SIMS) / Brundle and

Associates, San Jose, CA and University Heidelberg (Germany), Prof. M. Grunze.

4. Performance of Corrosion Inhibitors in Practice, Graeme Jones, C-Probe Technologies Ltd., 2000.

Key Criteria Performance Level Test Method/Institute Corrosion inhibition FerroGard corrosion inhibitors delay the onset of corrosion and reduce the rate of corrosion by 65% versus control specimen after 1 year.

Penetration Rate in hardened concrete

FerroGard 903 penetrates independently of orientation (horizontal, vertical, overhead) at a rate of 1/10 to 4/5 inches (2.5 to 20 mm)per day, depending on the density of the concrete.

Depth of Penetration FerroGard 903 penetrates up to 3 inches (76 mm) in 28 days. 2

Protective layer on steel FerroGard 903 forms a protective layer on the reinforcing steel of high integrity measured at as much as100 Å in thickness.

Displacement of chlorides from steel surface

FerroGard 903 forms a continuous film on the reinforcing steel and displaces chloride ions from the steel surface.

Corrosion Rate Field Monitoring Reduction of corrosion rates in excess of 65%. 4 st ru ct io n SikaTop® 123 PLUS Two-component, polymer-modified, cementitious, non-sag mortar plus FerroGard 901 penetrating corrosion inhibitor

Description SikaTop 123 PLUS is a two-component, polymer-modified, portland cement, fast-setting, non-sag mortar. It is a high performance repair mortar for vertical and overhead surfaces, and offers the additional benefit of FerroGard 901, a penetrating corrosion inhibitor.

Where to Use n On grade, above, and below grade on concrete and mortar.

n On vertical and overhead surfaces.

n As a structural repair material for parking structures, industrial plants, water/waste water treatment facilities, roads, walkways, bridges, tunnels, dams, ramps, etc.

n Approved for repairs over cathodic protection systems.

Advantages n High compressive and flexural strengths.

n High early strengths.

n Increased freeze/thaw durability and resistance to de-icing salts.

n Compatible with coefficient of thermal expansion of concrete - Passes ASTM C-884 (modified).

n Increased density - improved carbon dioxide resistance (carbonation) without adversely affecting water vapor transmission (not a vapor barrier).

n Enhanced with FerroGard 901, a penetrating corrosion inhibitor - reduces corrosion even in the adjacent concrete.

n Not flammable, non-toxic.

n Conforms to ECA/USPHS standards for surface contact with potable water.

n USDA approved.

n ANSI/NSF Standard 61 potable water approved.

Yield 0.39 cu. ft./unit.

Packaging Component ‘A’ - 1 gal. plastic jug; 4/carton. Component ‘B’ - 44 lb. multi-wall bag.

Product Data Sheet Edition 8.2003 Identification no. 188 SikaTop 123 Plus

Typical Data (Material and curing conditions @ 73°F (23°C) and 50% R.H.)

Shelf Life One year in original, unopened packaging.

Storage Conditions Store dry at 40°-95°F. Condition material to 65°-75°F. before using.

Protect Component ‘A’ from freezing. If frozen, discard.

Color Concrete gray when mixed.

Mixing Ratio Plant-proportioned kit.

Application Time Approximately 15 min. after adding Component ‘B’ to Component ‘A’. Application time is dependent on temperature and relative humidity.

Finishing Time 20 to 60 min after combining components: depends on temperature, relative humidity, and type of finish desired.

Density (wet Mix) 132 lbs./cu. ft. (2.2 kg./l)

Flexural Strength (ASTM C-293) 28 days 2,000 psi (13.8 MPa)

Splitting Tensile Strength (ASTM C-496) 28 days 900 psi (6.2 MPa)

Bond Strength* (ASTM C-882 modified) 28 days 2,200 psi (15.2 MPa)

Compressive Strength (ASTM C-109) 1 day 3,500 psi (24.1 MPa) 7 days 6,000 psi (41.4 MPa) 28 days 7,000 psi (48.3 MPa)

Permeability (AASHTO T-277) 28 days Approximately 500 Coulombs. Electrical resistivity (ohm-cm) 27,000

Freeze/Thaw Resistance (ASTM C-666) 300 cycles 98%

Corrosion Testing for FerroGard 901

Cracked Beam Corrosion Tests:

Reduced corrosion rates 63% versus control specimens. ASTM G109 modified after 400 days

* Mortar scrubbed into substrate.

Substrate Concrete, mortar, and masonry products.

st ru ct io n

KEEP CONTAINER TIGHTLY CLOSED KEEP OUT OF REACH OF CHILDREN

NOT FOR INTERNAL CONSUMPTION FOR INDUSTRIAL USE ONLY

CONSULT MATERIAL SAFETY DATA SHEET FOR MORE INFORMATION

Sika warrants this product for one year from date of installation to be free from manufacturing defects and to meet the technical properties on the current technical data sheet if used as directed within shelf life. User determines suitability of product for intended use and assumes all risks. Buyer’s sole remedy shall be limited to the purchase price or replacement of product exclusive of labor or cost of labor.

NO OTHER WARRANTIES EXPRESS OR IMPLIED SHALL APPLY INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. SIKA SHALL NOT BE LIABLE UNDER ANY LEGAL THEOR Y FOR

SPECIAL OR CONSEQUENTIAL DAMAGES.

Visit our website at www.sikausa.com 1-800-933-SIKA NATIONWIDE Regional Information and Sales Centers. For the location of your nearest Sika sales office, contact your regional center.

Sika Corporation Sika Canada Inc. Sika Mexicana S.A. de C.V.

201 Polito Avenue 601 Delmar Avenue Carretera Libre Celaya Km. 8.5 Lyndhurst, NJ 07071 Pointe Claire Corregidora, Queretaro Phone: 800-933-7452 Quebec H9R 4A9 C.P. 76920 A.P. 136 Fax: 201-933-6225 Phone: 514-697-2610 Phone: 52 42 25 0122

Fax: 514-694-2792 Fax: 52 42 25 0537

How to Use Surface Preparation Concrete/Mortar: Remove all deteriorated concrete, dirt, oil, grease, and all bond-inhibiting materials from surface. Be sure repair area is not less than 1/8 inch in depth. Preparation work should be done by high pressure water blast, scabbler, or other appropriate mechanical means to obtain an exposed aggregate surface with a minimum surface profile of ±1/16 in. (CSP-5) Saturate surface with clean water. Substrate should be saturated surface dry (SSD) with no standing water during application.

Reinforcing Steel: Steel reinforcement should be thoroughly prepared by mechanical cleaning to remove all traces of rust. Where corrosion has occurred due to the presence of chlorides, the steel should be high-pressure washed with clean water after mechanical cleaning. For priming of reinforcing steel use Sika Armatec 110 EpoCem (consult Technical Data Sheet).

Priming Concrete Substrate: Prime the prepared substrate with a brush or sprayed applied coat of Sika Armatec 110 EpoCem (consult Technical Data Sheet). Alternately, a scrub coat of Sika Top 123 can be applied prior to placement of the mortar. The repair mortar has to be applied into the wet scrub coat before it dries.

Mixing Pour Component ‘A’ into mixing container. Add Component ‘B’ while mixing continuously. Mix mechanically with a low-speed drill (400 - 600 rpm) and mixing paddle or mortar mixer. Mix to a uniform consistency, maximum 3 minutes. Manual mixing can be tolerated only for less than a full unit. Thorough mixing and proper proportioning of the two components is necessary.

Application & Finish SikaTop 123 PLUS must be scrubbed into the substrate, filling all pores and voids. Force material against edge of repair, working toward center. After filling repair, consolidate, then screed. Material may be applied in multiple lifts. The thickness of each lift, not to be less than 1/8 inch minimum or more than 1.5 inches maximum. Where multiple lifts are required score top surface of each lift to produce a roughened surface for next lift. Allow preceding lift to reach final set, 30 minutes minimum, before applying fresh material. Saturate surface of the lift with clean water. Scrub fresh mortar into preceding lift. Allow mortar or concrete to set to desired stiffness, then finish with wood or sponge float for a smooth surface.

Curing 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. Curing compounds adversely affect the adhesion of following lifts of mortar, leveling mortar or protective coatings. Moist curing should commence immediately after finishing. If necessary protect newly applied material from direct sunlight, wind, rain and frost.

*Pretesting of curing compound is recommended.

Limitations n Application thickness: Minimum 1/8 inch (3 mm). Maximum in one lift - 1.5 in. (38 mm).

n Minimum ambient and surface temperatures 45°F (7°C) and rising at time of application.

n Do not use solvent-based curing compound.

n Size, shape and depth of repair must be carefully considered and consistent with practices recommended by ACI. For additional information, contact Technical Service.

n For additional information on substrate preparation, refer to ICRI Guideline No. 03732 Coatings, and

Polymer Overlays".

n If aggressive means of substrate preparation is employed, substrate strength should be tested in accordance with ACI 503 Appendix A prior to the repair application.

n As with all cement based materials, avoid contact with aluminum to prevent adverse chemical reaction and possible product failure. Insulate potential areas of contact by coating aluminum bars, rails, posts etc. with an appropriate epoxy such as Sikadur Hi-Mod 32.

Caution Component ‘A’ - Irritant - May cause skin/eye/respiratory irritation. Avoid breathing vapors. Use with adequate ventilation. Avoid skin and eye contact. Safety goggles and rubber gloves are recommended.

Component ‘B’ - Irritant; suspect carcinogen - Contains portland cement and sand (crystalline silica). Skin and eye irritant. Avoid contact. Dust may cause respiratory tract irritation. Avoid breathing dust. Use only with adequate ventilation. May cause delayed lung injury (silicosis). IARC lists crystalline silica as having sufficient evidence of carcinogenicity in laboratory animals and limited evidence of carcinogenicity in humans. NTP also lists crystalline silica as a suspect carcinogen. Use of safety goggles and chemical resistant gloves is recommended. If PELs are exceeded, an appropriate, NIOSH approved respirator is required. Remove contaminated clothing.

First Aid In case of skin contact, wash thoroughly with soap and water. For eye contact, flush immediately with plenty of water for at least 15 minutes, and contact a physician. For respiratory problems, remove person to fresh air.

Clean Up In case of spillage, scoop or vacuum into appropriate container, and dispose of in accordance with current, applicable local, state and federal regulations. Keep container tightly closed and in an upright position to prevent spillage and leakage.

Mixed components: Uncured material can be removed with water. Cured material can only be removed mechanically.

tru ct io n

Sikaflex®-1c SL High performance, self-leveling, 1-part polyurethane sealant

n Pitch Pans

Product Data Sheet

Sikaflex-1CSL

Typical Data (Material and curing conditions 73°F (23°C) and 50% R.H.)