09 67 23.13.pdf

VBDZ192001 Renovate Operations Building 2A 101418 STRATTON ANGB, SCOTIA, NY Amendment #1 5/12/2021

SECTION 09 67 23.13

STANDARD RESINOUS FLOORING

11/15

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 C307 (2003; R 2012) Tensile Strength of Chemical-Resistant Mortar, Grouts, and Monolithic Surfacings

ASTM C413 (2011; R 2012) Absorption of Chemical-Resistant Mortars, Grouts, and Monolithic Surfacings and Polymer Concretes

ASTM C579 (2001; R 2012) Compressive Strength of Chemical-Resistant Mortars, Grouts, Monolithic Surfacings, and Polymer Concretes

ASTM C580 (2002; R 2012) Flexural Strength and Modulus of Elasticity of Chemical-Resistant Mortars, Grouts, Monolithic Surfacings, and Polymer Concretes

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

ASTM D4060 (2014) Abrasion Resistance of Organic Coatings by the Taber Abraser

ASTM D4541 (2017) Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion Testers

ASTM D635 (2014) Standard Test Method for Rate of Burning and/or Extent and Time of Burning of Self-Supporting Plastics in a Horizontal Position

ASTM F2170 (2018) Standard Test Method for Determining Relative Humidity in Concrete Floor Slabs Using in situ Probes

INTERNATIONAL CONCRETE REPAIR INSTITUTE (ICRI)

ICRI 310.2R (2013) Selecting and Specifying Concrete Surface Preparation for Sealers, Coatings, Polymer Overlays, and Concrete Repair

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1.2 ADMINISTRATIVE REQUIREMENTS

1.2.1 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.

c. Aggregate.

d. Surface Sealing Coat.

1.2.2 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" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that reviews the submittal for the Government. Submittals with an "S" are for inclusion in the Sustainability Notebook, in conformance to Section 01 33 29.00 06 SUSTAINABILITY REPORTING. Submit the following in accordance with Section 01 33 00.00 06 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Installation Drawings; G

Fabrication Drawings; G

SD-03 Product Data

Manufacturer's Catalog Data; G

VOC Content; G, S

SD-04 Samples

Hardboard and Mounted Epoxy Flooring and Wall Coating System; G

Metal Trim Accessory; G

Floor Topping; G

SECTION 09 67 23.13 Page 2

SD-05 Design Data

Design Mix Data; G

SD-07 Certificates

Listing of Product Installations; G

Referenced Standards Certificates; G

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.

c. Aggregate.

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-inches 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.

SECTION 09 67 23.13 Page 3

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 SYSTEM

EF-1: Double Broadcast Decorative Epoxy Quartz with ultra clear epoxy topcoat and ultra clear aliphatic polyester urethane final finish.

a. System Components: Manufacturer's standard components which are compatible with each other as follows:

(1) Base Coat: Four-component, troweled mortar base consisting of epoxy resin, curing agent, and finely graded silica aggregate.

(2) Second Coat: Three-component, free flowing epoxy formulation consisting of resin, curing agent, pigment and fine aggregate.

(3) Aggregate Coat: Colored quartz broadcast aggregate.

(4) Final Coat: Two Component, high-performance, UV-resistant, clear epoxy sealer. Final coat shall be applied at a thickness to produce a standard texture.

(5) Waterproofing: Provide manufacturer's standard waterproofing membrane system installed per manufacturer's instruction.

Waterproofing membrane is required in shower areas.

b. Performance Requirements:

(1) Resinous flooring shall withstand chemical attack by agents provided in writing by Owner, in temperatures and concentrations stated therein.

(2) Physical/Chemical Characteristics:

(a) Compressive Strength: 12,400 psi after 7 days ( ASTM C579).

(b) Tensile Strength: 2,200 psi ( ASTM C307).

(c) Flexural Strength: 4,800 psi ( ASTM C580).

(d) Hardness: 85-90 ( ASTM D2240/Shore D Durometer).

(e) Bond Strength: >400 psi (100 percent concrete failure per

ASTM D4541).

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(f) Abrasion Resistance: 0.04 gm max weight loss ( ASTM D4060, Taber Abrader).

(g) Flammability: Self extinguishing ( ASTM D635) Extent of burning 0.25 inches max.

(h) Water Absorption: 0.1 percent ( ASTM C413).

(i) Heat Resistance Limitation: 140 degrees F/60 degrees C (For continuous exposure) 200 degrees F/93 degrees C (For intermittent spills).

(j) All products must be 100 percent solids with zero VOCs.

(k) Final finish coat must be ultra clear and UV stable.

2.3 ACCESSORY MATERIALS

a. Patching and Fill Material: Resinous product of resinous flooring manufacturer.

b. Joint Sealants: Formulated by resinous flooring manufacturer for type of service and joint condition indicated.

Color: As selected by Contracting Officer.

PART 3 EXECUTION

3.1 PREPARATION

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

Moisture testing of concrete shall be conducted according the manufacturer's recommendations. If test results are above acceptable limits, Contractor shall include manufacturer's recommended moisture vapor reducer treatment.

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 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, SECTION 09 67 23.13 Page 5 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 a 30-30-30 waterproof 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 floor topping until concrete has cured a minimum of 28 calendar days. Verify concrete floor is straight, properly sloped, and has type finish as required by flooring manufacturer. Ensure concrete is moist cured with burlap or polyethylene. Prior to applying the prime coat, clean concrete surface by an approved method.

3.1.4 Mixing Of Materials

Select 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 pre-blending the sizes and color pigment, if any, of the 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 temperature of materials at the time of mixing are between 65 and 85 degrees F.

3.2 EXAMINATION

a. Verification: Verify that all substrate and environmental conditions are in compliance with requirements discussed during Pre-Installation Conference.

b. Mandatory Testing of Floor Slabs:

(1) Prior to the installation of flooring, it is mandatory that all surfaces are tested for moisture content, pH, and alkalinity levels that would be detrimental to the adhesion of coating materials. For tests to be accurate, temperatures and humidity levels should be stabilized for a minimum of 72 hours. NOTE:

TESTING PERFORMED BY ANY METHOD IN UNCONDITIONED SPACES WILL NOT

YIELD CONSISTENT RESULTS.

(2) Employ a radio frequency moisture meter to determine that residual un-combined moisture content of concrete slab is less than five

(5) percent by weight. Conduct ASTM F2170 to record the Relative Humidity. Do not apply high performance floor coatings to floor

SECTION 09 67 23.13 Page 6 slabs that exceed 85 percent RH content per ASTM F2170 unless otherwise approved by the material manufacturer, or unless treated using manufacturer's approved moisture vapor barrier system, at Contractor's expense. Install moisture vapor barrier system per manufacturer's written instruction.

c. Testing Activities During Resinous Coating Application:

(1) Material Sampling: Owner's representative may at any time and any number of times during resinous coating application require an independent testing agency, hired by GC with Owner's approval, to collect material samples for testing for compliance with requirements.

(a) Material samples will be taken, identified, sealed, and certified in presence of installer.

(b) Testing agency will test samples for compliance with requirements at the cost to the Owner, using applicable referenced testing procedures in addition to testing procedures listed in manufacturer's product data.

(2) If test results show applied materials do not comply with specified requirements, installer shall correct all deficiencies of coating system in a method and manner acceptable to the manufacturer's recommendations.

3.3 PREPARATION

a. General: Prepare and clean substrates in accordance with manufacturer's written instructions for substrate indicated. Provide clean, dry, and neutral pH substrate for resinous floor/wall application.

b. Concrete Floors: Provide sound concrete surfaces free of laitance, glaze, efflorescence, curing compounds, form-release agents, dust, dirt, grease, oil, and other contaminants incompatible with resinous flooring. Floor slabs shall be prepared as follows:

(1) Mechanically remove all finishes, mastics, adhesives and other compounds down to sound substrate. Demolition shall be in accordance with manufacturer's recommendations and written procedures. (Note: If during the demolition a setting bed is found beneath the existing flooring materials, manufacturer will provide written recommendation whether to remove it or leave it in place. If removal is required, installer will provide a change order to replace the setting bed with manufacturer's recommended material to provide proper sloping for drainage and to ensure proper adhesion of the specified coating system.)

(2) Profile sound surfaces for proper adhesion. For thin-film coatings and floors under 1,000 sf or with limited access:

Diamond grind to expose concrete matrix and profile concrete floor surfaces to a classification of CSP2 ( ICRI 310.2R -2013).

(3) For all other floor systems: Shot blast all concrete floor surfaces to a classification of CSP5 ( ICRI 310.2R -2013).

(4) Visually inspect shot blasted or grinded surfaces to make sure

SECTION 09 67 23.13 Page 7 that profiled surfaces are free of contaminants. Areas that are stained or visually contaminated shall be treated with a 15 percent by volume solution of aqueous trisodium phosphate (TSP) or other de-greasing agent as recommended by the coatings manufacturer. Rinse and dry all floor surfaces scheduled to receive high performance floor system finish prior to commencement of resinous flooring application.

(5) Remove and legally dispose of all debris and contaminants produced by the demolition and surface preparation process. Steel media resulting from the shot blasted floor slab surface shall be removed from cracks, slab edges, construction joints, and corners by magnets, magnetic broom, air blast, vacuum, or stiff bristle broom.

3.4 APPLICATION

3.4.1 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.

3.4.2 Application of Base 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 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 prior to 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, and make provisions to keep control or expansion joints open.

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

SECTION 09 67 23.13 Page 8 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.

3.4.3 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 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.

3.5 CURING

a. Cure resinous flooring components according to manufacturer's written instructions. Prevent contamination during curing processes.

(1) Temperatures shall be maintained at 70 degree F - 80 degree F if at all possible.

(2) Water leaks must be prevented as they will compromise epoxy components ability to set properly - water drips may compromise or stain finishes.

(3) Steam or any airborne contamination will adversely affect curing.

3.6 FIELD QUALITY CONTROL

3.6.1 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.

3.7 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.

3.7.1 Cleaning

a. Work area shall be left clean with all trash, equipment, and leftovers removed.

b. Floor and walls may be cleaned prior to final inspection, providing complete curing has taken place. Refer to Product Data Sheets for curing information for each product. Generally, non-chlorinated detergents should be used for the first month after curing is complete.

c. For optimum coating performance and cleanability, manufacturer recommends the use of liquid soaps to prevent caking on epoxy surfaces caused by bar soaps.

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3.7.2 Protection

Protection from damage and wear during the construction process is recommended. Comply with manufacturer's recommendations for protective materials and their method of application. Remove temporary protection prior to final inspection. Protection from welding, impact from heavy tools and other abuse is anticipated, the Contractor doing the work shall take extra care in protecting the floor with impact resistance and if necessary, flame resistant coverings. Removal of any temporary or protective material is not the responsibility of the Installer.

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