09 67 23.13 Standard Resinous Flooring.pdf

Replace Security Forces and Communications Facility WKVB109058

SECTION 09 67 23.13

STANDARD RESINOUS FLOORING

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 A990/A990M (2021) Standard Specification for Castings, Iron-Nickel-Chromium and Nickel Alloys, Specially Controlled for Pressure-Retaining Parts for Corrosive Service

ASTM C881/C881M (2020a) Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete

ASTM D445 (2019a) Standard Test Method for Kinematic Viscosity of Transparent and Opaque Liquids (and Calculation of Dynamic Viscosity)

ASTM D523 (2014; R 2018) Standard Test Method for Specular Gloss

ASTM D570 (1998; E 2010; R 2010) Standard Test Method for Water Absorption of Plastics

ASTM D638 (2014) Standard Test Method for Tensile Properties of Plastics

ASTM D696 (2016) Standard Test Method for Coefficient of Linear Thermal Expansion of Plastics Between -30 degrees C and 30 degrees C With a Vitreous Silica Dilatometer

ASTM D1475 (2013) Standard Test Method for Density of Liquid Coatings, Inks, and Related Products

ASTM D1544 (2004; R 2010) Standard Test Method for Color of Transparent Liquids (Gardner Color Scale)

ASTM D1652 (2011; E 2012) Standard Test Method for Epoxy Content of Epoxy Resins

ASTM D2240 (2015; E 2017) Standard Test Method for Rubber Property - Durometer Hardness

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ASTM D2471 (1999) Standard Test Method for Gel Time and Peak Exothermic Temperature of Reacting Thermosetting Resins

ASTM F1869 (2022) Standard Test Method for Measuring Moisture Vapor Emission Rate of Concrete Subfloor Using Anhydrous Calcium Chloride

1.2 ADMINISTRATIVE REQUIREMENTS

1.2.1 Pre-Installation Meetings

Pre-installation Conference: Conduct conference at Project site.

1.2.2 Product Data

Within 30 days of contract award, submit manufacturer's catalog data for the following items:

a. Epoxy-Resin Binder/Matrix

b. Cured Epoxy Binder

d. Surface Sealing Coat

1.2.3 Design Mix Data

Within 30 days of contract award, submit design mix data for the following items, including a complete list of ingredients and admixtures:

a. Epoxy-Resin Binder/Matrix

b. Cured Epoxy Binder

c. Surface Sealing Coat

Ensure applicable test reports verify the mix has been successfully tested and meets design requirements.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" or "S" classification. Submittals not having a "G" or "S" classification are for Contractor Quality Control approval. 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-02 Shop Drawings

Installation Drawings ; G

SD-03 Product Data

Manufacturer's Catalog Data ; G

SD-04 Samples

Hardboard Mounted Epoxy Flooring ; G

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Floor Topping ; G

SD-05 Design Data

Design Mix Data ; G

SD-07 Certificates

Listing of Product Installations

Referenced Standards Certificates

SD-11 Closeout Submittals

Warranty ; G

1.4 DELIVERY, STORAGE, AND HANDLING

Protect materials from weather, soil, and damage during delivery, storage, and construction. Deliver materials in original packages, containers, or bundles bearing brand name and name of material.

Maintain materials used in the installation of floor topping at a temperature between 65 and 85 degrees F .

1.5 QUALITY CONTROL

Prior to commencement of work, submit referenced standards certificates for the following, showing conformance with the referenced standards contained in this section:

a. Epoxy-Resin Binder/Matrix

b. Cured Epoxy Binder

d. Surface Sealing Coat

1.5.1 Qualifications

Submit a listing of product installations for heavy duty epoxy flooring including identification of at least 5 units, similar to those proposed for use, that have been in successful service for a minimum period of 5 years. Identify purchaser, address of installation, service organization, and date of installation.

Ensure floor system applicators are experienced in the application of troweled aggregate thin-set floor topping.

1.5.2 Sampling

Submit hardboard mounted epoxy flooring samples not less than 12 inch square for each required color.

Provide panels showing nominal thickness of finished toppings, color, and texture of finished surfaces. Finished floor toppings and the approved samples are to match in color and texture.

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1.6 WARRANTY

Submit a 2 year written warranty for all materials and installation work.

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

Submit installation drawings for heavy duty epoxy flooring systems clearly designating the areas of application and the installation plan. Include in the installation plan, methods to control sand and dust if sand blasting is required.

Submit fabrication drawings for heavy duty epoxy flooring Systems consisting of fabrication and assembly details to be performed in the factory.

2.2 MATERIALS

2.2.1 Mixes

2.2.1.1 Epoxy-Resin Binder/Matrix

Provide a clear two-component compatible system epoxy resin binder consisting of: (1) a liquid blend of a biphenyl-based epoxy resin and an aliphatic polyglyceride ether, and (2) a liquid blend of two modified amine curing agents, which individually cures the epoxy resin at room temperature to a glossy smooth film. Ensure the two components and the cured epoxy binder have the following physical properties:

PROPERTY TEST METHOD REQUIREMENT

COMPONENT A (EPOXY RESIN)

Viscosity (kinematic), at 77 degrees F, centipoises

ASTM D445 3000 to 5000

Weight per epoxide, grams ASTM D1652 205 to 225

Color (Gardner Color Scale), maximum

ASTM D1544 5

Weight per gallon, pounds ASTM D1475 9.46 - 9.56

COMPONENT B (CURING AGENT)

Viscosity (kinematic), at 77 degrees F, centistokes

ASTM D445 75 to 125

Weight per gallon, pounds ASTM D1475 7.50 to 7.60

Color (Gardner Color Scale), maximum

ASTM D1544 8

2.2.1.2 Cured Epoxy Binder

Provide a cured epoxy binder with the following properties.

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PROPERTY TEST METHOD REQUIREMENT

Tensile strength, psi* at test temperature:

77 degrees F

ASTM D638 4500 to 6500

Tensile elongation, percent* at test temperature: 77 degrees F

ASTM D638 20 to 40

Water absorption, percent 24 hours at 77 degrees F, maximum

ASTM D570 0.40

Hardness, Shore D ASTM D2240 74 to 82

Linear shrinkage, inch/inch maximum

ASTM C881/C881M 0.006

Shrinkage, glass bow, inch divergence, maximum

ASTM A990/A990M 0.016

Coefficient of linear thermal expansion, inch/inch/degree C, maximum

ASTM D696

0 degrees C to 40 degrees C

200 X 10-6

Gel time/peak exotherm at 77 degrees F, 100 gm mass in 4 ounce metal container

ASTM D2471 20 to 40 minutes at 300 degrees F, maximum

*1/8 inch thick castings

**1/8 by 1 by 3 inch castings, aged in forced draft oven

2.2.1.3 Surface Sealing Coat

Provide nonambering aliphatic or aromatic moisture-curing polyurethane surface sealer into which has been incorporated a flatting agent. Add flatting agent not more than 24 hours prior to actual application of the coating. Ensure cured coating with flatting agent yields 60-degree specular gloss of 10 to 20 when tested in accordance with ASTM D523.

PART 3 EXECUTION

3.1 PREPARATION

Prior to applying resinous flooring material, inspect substrate and immediately report any unsatisfactory conditions that exist and repair.

Verify that the concrete substrates are dry and the moisture-vapor emissions are within acceptable levels according to the manufacturer's written instructions.

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Anhydrous Calcium Chloride Test: ASTM F1869. Proceed with application of resinous flooring only after substrates have a maximum moisture-vapor-emission rate of 1.36 kg of water/ 92.9 sq. meters 3 lb of water/1000 sq ft. of slab area in 24 hours.

Situ Probe Test: ASTM F 2170 . Proceed with application only after substrates do not exceed a maximum potential equilibrium relative humidity of 80 percent.

3.1.1 Safety Precautions

Prior to application in confined spaces of toppings and coatings containing flammable or toxic properties, institute safety precautions recommended by the manufacturer of the product.

Erect "NO SMOKING" signs, and prohibit smoking or use of spark- or flame-producing devices within 50 feet of any mixing or placing operation involving flammable materials.

Provide the personnel required to handle, mix, or apply toppings containing toxic or flammable properties with such items of personal protective equipment and apparel for eye, skin, and respiratory protection as are recommended by the manufacturer of the product. Ensure all personnel are trained in the appropriate use and wearing of personal protection equipment.

3.1.2 Protection of Adjacent Surfaces

In addition to the protection of adjacent surfaces during installation, provide areas used to store and mix materials with a protective covering under the materials. After application of the sealer coats, protect finished flooring during the remainder of the construction period. In areas of expected minimum or moderate traffic, cover floors with 70 pound kraft paper, with strips taped together and edges secured to prevent roll-up. Place vegetable fiberboard, plywood, or other suitable material that does not mar the flooring over the paper to protect areas used as passages by workmen and areas subject to floor damage because of subsequent building operations. Upon completion of construction, remove the protection, clean flooring and, where necessary, repair, reseal, or both, at no additional cost to the Government.

3.1.3 Concrete Subfloor

3.1.3.1 New Concrete Floors

Do not commence installation of the floor topping until the concrete has cured a minimum of 28 calendar days. Verify that the concrete floor is straight, properly sloped, and free of laitance, glaze, efflorescence, curing compounds, form-release agents, dust, dirt, grease, oil, and other contaminants incompatible with resinous flooring.Mechanically prepare substrates with the use of Diamond grinding equipment to provide surface sound concrete surfaces free of laitance, glaze, efflorescence, curing compounds, form-release agents, dust, dirt, grease, oil, and other contaminants incompatible with resinous flooring. Or,Shot-blast surfaces with an apparatus that abrades the concrete surface, contains the dispensed shot within the apparatus, and recirculates the shot by vacuum pickup or Diamond Grind with a dust free system. Comply with ASTM C 811 requirements, unless manufacturer's written instructions are more stringent.Repair damaged and deteriorated concrete according to resinous

SECTION 09 67 23.13 Page 6 flooring manufacturer's written recommendations.Use patching and fill material to fill holes and depressions in substrates according to manufacturer's written instructions.Treat control joints and other nonmoving substrate cracks to prevent cracks from reflecting through resinous flooring according to manufacturer's written recommendations.

3.1.4 Mixing Of Materials

Select the job mix proportions on the trial batch proportions used to prepare the floor topping samples as submitted and approved.

Use mechanical equipment for mixing of materials in accordance with the manufacturer's instructions.

Use rotating paddle-type masonry mortar mixers for preblending the three sizes and color pigment, if any, of the walnut shell aggregate and addition of the mixed epoxy resin binder. Ensure mixing times are as recommended by the materials supplier(s), provided mixing times result in homogeneous mixtures. Limit quantity of material mixed at one time to that which can be applied and finished within the working life of the mixtures. Verify that the temperature of materials at the time of mixing are between 65 and 85 degrees F .

3.2 APPLICATION

3.2.1 Areas of Application

Anchor plates set with the top surface at or above the finished epoxy floor level do not require coverage with this flooring material. Extend flooring under equipment, except when the equipment base is indicated to be flush against the structural floor. Cover and/or mask surfaces not to receive the epoxy floor topping, such as equipment or cabinets installed prior to surface-preparation efforts and adjacent to the flooring installation.

3.2.2 Application of Prime Coat and Troweling

Combine the epoxy binder components A and B in the proportions specified by the manufacturer to form a clear compatible system immediately on mixing. Cure combined components to a clear film possessing a glossy, non-greasy surface at relative humidities less than 80 percent, having the following properties after curing 24 hours at 77 degrees F , followed by 24 hours at 125 degrees F :

Ensure that the prepared subfloor surface is dry and at a temperature of not less than 60 degrees F when application of the floor topping is initiated. Immediately before application of the prime/scratch coat on the prepared surface, remove dust or other loose particles by blowing with compressed air or vacuum cleaned. Use only an air compressor equipped with an efficient oil-water trap to prevent oil contamination or wetting of surface.

Apply a thin roller coat of the epoxy binder specified to the prepared subfloor as a prime coat. As an aid to placing, compacting, and finishing the floor topping, form a scratch coat by sprinkling a minimum quantity of the walnut shell aggregate on the prime coat surface immediately following the prime coat application. Prior to application of the prime/scratch coat, fill cracks in the concrete per manufacturer's instructions, and make provisions to keep control or expansion joints open.

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Place the floor topping prior to final gelling of the prime/scratch coat.

Immediately after the materials are mixed as specified, dump the mixture in the placement area and spread to prolong troweling life. Screed or rough trowel placed materials to the specified thickness and then compact by the use of a smooth roller prior to finish troweling to a nominal thickness of 3/16 inch plus or minus 1/16 inch . Ensure all finished surfaces are free of ridges, hollows (bird-baths), trowel marks, and smoothness varies no more than 1/8 inch when tested with an 8 foot straightedge. Make provisions to maintain the work areas in a relatively dust-free environment during curing of the topping.

3.2.3 Sealer Coat

After the floor topping has set firmly (approximately 6 to 16 hours depending on subfloor temperature) in a relatively dust-free environment, apply two thin coats of the sealer coat, by means of brush, roller, squeegee, or notched trowel to provide a pore-free, easy-to-clean surface. At the time of sealer application, ensure that the surface is dust-free. Depending on relative humidity, allow the applied sealer to cure to a tack-free condition in 2 to 4 hours. Do not apply second coat until after the initial coat has cured to a tack-free, hard film.

Maintain topping areas in a relatively dust-free environment during curing of the sealer coats.

3.3 FIELD QUALITY CONTROL

3.3.1 Repairing

Remove and replace damaged or unacceptable portions of completed work with new work to match adjacent surfaces at no additional cost to the Government.

3.4 ADJUSTING AND CLEANING

Clean surfaces of the new work, and adjacent surfaces soiled as a result of the work. Remove all equipment, surplus materials, and rubbish associated with the work from the site.

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SECTION 09 67 23.13 Page 8

1.6 WARRANTY

3.1.4 Mixing Of Materials

3.4 ADJUSTING AND CLEANING