Amendment A00003 Spec 03 01 35-Revised 04MAR21.pdf

THIRD HIGH RESERVOIR MAINTENANCE AND IMRPOVEMENTS

SECTION 03 01 35

CONCRETE REPAIRS

01/13

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this section to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN CONCRETE INSTITUTE INTERNATIONAL (ACI)

ACI 503.1-503.4 (1992, R 2003) Four Epoxy Specifications

ASTM INTERNATIONAL (ASTM)

ASTM C109/C109M (2011b) Standard Test Method for Compressive Strength of Hydraulic Cement Mortars (Using 2-in. or (50-mm) Cube Specimens)

ASTM C33/C33M (2011a) Standard Specification for Concrete Aggregates

ASTM C881/C881M (2010) Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete

ASTM C882/C882M (2012) Bond Strength of Epoxy-Resin Systems Used with Concrete by Slant Shear

ASTM D1623 (2009) Tensile and Tensile Adhesion Properties of Rigid Cellular Plastics

ASTM D638 (2010) Standard Test Method for Tensile Properties of Plastics

NSF INTERNATIONAL (NSF)

NSF/ANSI 61 (2017) Drinking Water System Components - Health Effects

1.2 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 will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Summary of the Work; G, AE

Applicator Qualifications; G, AE

SECTION 03 01 35 Page 1

Alternative Materials and/or Methods of Work; G, AE

SD-02 Shop Drawings

Shop Drawings; G, AE

SD-03 Product Data

Technical Data Sheets; G, AE

SD-07 Certificates

Material Certifications; G, AE

1.3 THE REQUIREMENT

The Contractor shall furnish all materials, labor, equipment, tools, etc., required for the repair, renovation, and replacement of concrete and joints in concrete as indicated on the Drawings, specified herein, and determined by field survey.

The Contractor, in conjunction with the Engineer and the Government, shall determine the extent of cracked or deteriorated concrete and joints in concrete to be rehabilitated and/or repaired. Areas to be repaired shall be identified and established during a joint field survey conducted by the Contractor, the Government, and Engineer. Field survey shall be conducted after reservoir is removed from service and soil over burden is totally removed from over the reservoir. A summary of the work to be performed based on this survey shall be submitted to the Engineer for review, and such summary shall be approved by the Engineer prior to commencement of the Work.

Concrete repairs include the following:

a. Injection of waterproof injection grout into joints and cracks in the reservoir as deemed necessary by field survey and as shown on Contract Drawings and specified herein.

b. Installation of waterproof membrane patch over expansion joints as deemed necessary by field survey and as shown on Contract Drawings and specified herein.

c. Repair of spalled areas with surface spall repair approach as deemed necessary by field survey, and specified herein.

d. Repair of spalled areas with spall repair material requiring formwork as deemed necessary by field survey and specified herein.

e. Repair of structural cracks with epoxy crack repair binder for cracks in the reservoir as deemed necessary by field survey and specified herein.

Extent of repair work shall be determined by joint field survey of structure conducted after reservoir is taken out of service. Contractors shall base bid on estimated quantities of each type of concrete or joint repair as defined on the Contract Drawings and on the Price Schedule and as specified herein. Any necessary concrete repair will be assessed after contract award with quantities and pricing determined at that time.

SECTION 03 01 35 Page 2 e2waenag Cross-Out Soil over burden will not be removed as part of field survey e2waenag Cross-Out

Submit Shop Drawings detailing any planned deviation from the proposed construction sequence and/or method of repair.

The Contractor, based on their experience in their profession, may submit to the Engineer for approval, alternative materials and/or methods of work to assure the durability and watertight integrity of the repair work performed.

1.3.1 Qualifications

The Contractor shall furnish the name of all subcontractors/applicators which he proposes to use for this work, including necessary evidence and/or experience records to ascertain their qualifications in the application of epoxy, urethane, and polymer-modified mortars and grouts.

Approved applicator qualifications shall include:

a. A minimum of 5 years experience in applying epoxy, urethane, and polymer-modified and cement-based compounds similar to those specified in this Section.

b. A letter from the manufacturer of the specified materials, on the manufacturer's letterhead, signed by an officer of the company, stating that the subcontractor/applicator has been trained in the proper techniques for applying the product, including surface preparation and mixing, placing, curing, and caring for the manufacturer's products. This letter shall further state the subcontractor/applicator is on the manufacturer's approved list of contractors.

1.4 ADDITIONAL GUARANTEE

The Contractor shall guarantee all repair work performed under this Contract against defects in workmanship resulting in leakage and/or failure of concrete bond for a period of two years from the date of the Certificate of Substantial Completion.

PART 2 PRODUCTS

2.1 MATERIALS

Provide material certifications and technical data sheets on all grouts, mortars, epoxy resins, aggregates and repair products specified in this Section. All concrete repair materials and other products used for work within the reservoir shall conform to NSF/ANSI 61 for contact with potable water supplies.

2.1.1 Water

The water used for mixing concrete repair products shall be clear, potable, and free of deleterious substances.

2.1.2 Aggregate

All aggregate shall conform to ASTM C33/C33M. The aggregate supplier shall submit to the Engineer documentation that the proposed aggregates comply with ASTM C-33 and the requirements listed below:

a. Pea Gravel - Pea gravel shall meet the gradation and material requirements of Standard Size #8 as defined by ASTM C33/C33M. Pea

SECTION 03 01 35 Page 3 gravel shall be clean and free from deleterious matter and shall contain no limestone.

2.1.3 Epoxy Bonding Agent

An epoxy bonding agent shall be used when applying fresh concrete to previously placed concrete. Epoxy bonding agent shall conform to ASTM C881/C881M Type I, II, IV or V; Grade 2 for epoxy resin adhesives, depending on the application. The class of epoxy bonding agent shall be suitable for all ambient and substrate temperatures.

2.1.4 Anti-Corrosion Rebar Coating

All reinforcing steel cut or exposed during demolition and/or repair operations shall be protected with an anti-corrosive coating. The anti-corrosive coating shall be a three-component, epoxy-modified cementitious material specially formulated as a bonding agent and anti-corrosion coating. Product shall have a minimum bond strength of 2,800 psi in accordance with ASTM C882/C882M.

2.1.5 Epoxy Crack Repair Binder

Epoxy crack repair binder shall be a two-component, 100% solids, high-modulus, low viscosity epoxy adhesive designed for structural repair. Product shall conform to ASTM C881/C881M with a minimum tensile strength of 7,900 psi as per ASTM D638.

2.1.6 Epoxy Resin Binder

Epoxy resin binder shall conform to the requirements of ASTM C881/C881M, Type III, Grade 3, Class B and C for epoxy resin binder.

2.1.7 Waterproof Injection Grout

Waterproof crack repair material shall be a one-component, water-activated polyurethane hydrophilic injection grout capable of 700% expansion.

Polyurethane grout shall form a tough flexible foam seal that is impenetrable to water. Material shall have a minimum tensile strength of 300 psi in accordance with ASTM D1623.

2.1.8 Spall Repair Patching Material

All spall repairs not requiring formwork shall be repaired using a two-component, polymer-modified non-shrink cementitious mortar and shall have a minimum 28-day compressive strength of 7,000 psi as per ASTM C109/C109M. All spall repairs requiring formwork shall be repaired using a two-component, polymer-modified cementitious mortar/pea gravel mixture and shall have a minimum 28-day compressive strength of 7,000 psi as per ASTM C109/C109M. All spall repair materials shall conform to EPA/USPHS standards for surface contact with potable water supplies.

Products shall have a minimum bond strength of 2,500 psi at 28 days per

ASTM C882/C882M.

2.1.9 Waterproof Membrane Patch

Waterproof membrane patch shall be a flexible, NSF/ANSI 61 compliant, sealing strip secured to the concrete substrate with an epoxy adhesive.

Sealing system shall be installed per manufacturer's recommendations.

Minimum width of waterproof membrane patch shall be twelve (12) inches

SECTION 03 01 35 Page 4 unless shown otherwise on Contract Drawings.

2.1.10 Storage of Materials

The Contractor shall provide an area for repair material storage free from exposure to moisture in any form, before, during, and after delivery to the site. Manufactured materials shall be delivered in unbroken containers labeled with the manufacturer's name and product type. All mortar products shall be stored on raised platforms. Materials susceptible to damage by freezing shall be stored in a dry, heated, insulated area. Any material that has hardened, partially set, become caked and/or has been contaminated or deteriorated shall be rejected. All aggregates shall be stored in clean bins, scows or platforms.

PART 3 EXECUTION

3.1 GENERAL REQUIREMENTS

No repair work shall be undertaken when ambient temperatures are below manufacturer's safe recommendations. No admixtures, except those required by the manufacturer, shall be used in the repairs specified herein. All products shall be applied in strict accordance with manufacturer's recommendations. The Contractor shall furnish and install safe scaffolding and ladders for the Engineer's prework inspection, the repair work activities, and the Engineer's final inspection.

Sandblast or waterblast (3000-4000 psi waterjet) deteriorated areas to remove all loose concrete, existing coatings, unsound material, debris, and laitance. All surfaces shall be clean, free of dirt, grease, loose particles, and deleterious substances and shall be prepared according to manufacturer's requirements. This surface preparation shall be applied to all of the entire interior surface area of the walls and slab of the reservoir, including areas where repair will not be required. Surface preparation of entire extent of interior surface of walls and bottom shall include removal and disposal of all lime sediment deposits and biofilm.

Contractor shall isolate and collect all water used in cleaning and surface preparation and dispose of water offsite to avoid draining water into distribution system from Reservoir. Surface cleaning and preparation on interior of Reservoir shall not occur until joint material containing asbestos in floor joints of structure is removed and properly disposed of.

3.2 EPOXY BONDING AGENT

Existing concrete surfaces shall be roughened prior to application of bonding agent. Concrete surface shall be clean and sound, free of all foreign particles and laitance. Repair material shall be placed while bonding agent is still tacky. If bonding agent cures prior to placement of repair material, bonding agent shall be reapplied.

Repairing concrete with epoxy mortars shall conform to all the requirements of ACI 503.1-503.4 "Standard Specification for Repairing Concrete with Epoxy Mortars" (latest edition), except as modified herein.

3.3 ANTI-CORROSION REBAR COATING

Reinforcing steel cut or exposed during demolition and/or repair operations shall be sandblasted and cleaned prior to coating with an anti-corrosive coating. Anti-corrosive coating shall be applied as soon

SECTION 03 01 35 Page 5 as the reinforcement is exposed and cleaned. Coating shall thoroughly cover all exposed parts of the steel and shall be applied according to manufacturer's recommendations.

3.4 EPOXY CRACK REPAIR BINDER

Where indicated on the Drawings or determined via joint condition assessment, all existing structural cracks 1/4" or smaller shall be repaired by pressure injecting an epoxy crack repair binder into the prepared crack. Seal crack surface and install injection ports per manufacturer's recommendations. Holes drilled for injection ports shall not cut rebar. If rebar is encountered during drilling, the hole shall be abandoned and relocated, and the abandoned hole shall be patched immediately with epoxy resin binder flush with the surface of the existing concrete. Once the surface sealing material has cured, inject crack with epoxy crack repair binder using standard pressure injection equipment as directed by the manufacturer.

3.5 EPOXY RESIN BINDER

Epoxy resin binder shall be used to seal all existing rebar cut and burned off during demolition operations. Exposed rebar shall be burned back 1/2" minimum into existing concrete and the resulting void filled with epoxy resin binder.

3.6 WATERPROOF INJECTION GROUT

All existing, leaking cracks 1/4" or smaller shall be repaired by pressure injecting a waterproof injection grout into the prepared crack. Seal crack surface and install injection ports per manufacturer's recommendations. Holes drilled for injection ports shall not cut rebar.

If rebar is encountered during drilling, the hole shall be abandoned and relocated, and the abandoned hole shall be patched immediately with epoxy resin binder flush with the surface of the existing concrete. Once the surface sealing material has cured, inject crack with waterproof injection grout using standard pressure injection equipment as directed by the manufacturer.

3.7 SPALL REPAIR PATCHING MATERIAL

All voids or spalled areas to be repaired shall be chipped back to sound concrete a minimum 1/8" deep, cleaned and repaired with spall repair patching material according to manufacturer's recommendations. All patching shall provide a final finished surface which is flat, level and even with the existing concrete surface. Repair mortar shall not be feathered to meet existing concrete surface. A sawcut groove shall be scored around the perimeter of all areas to receive repair material a minimum depth of 1/8" to ensure feathering of the material does not occur. Final patching on horizontal surfaces shall receive a broom finish consistent with the finish on the existing structure.

3.8 WATERPROOF MEMBRANE PATCH

Thoroughly clean the concrete substrate and apply waterproof membrane patch according to manufacturer's recommendations.

3.9 CURING

All repair products shall be cured in strict accordance with manufacturer

SECTION 03 01 35 Page 6 recommendations.

3.10 WORK IN CONFINED SPACES

The Contractor shall provide and maintain safe working conditions for all employees and subcontractors. Fresh air shall be supplied continuously to confined spaces through the combined use of existing openings, forced-draft fans and temporary ducts to the outside, or by direct air supply to individual workers. Fumes shall be exhausted to the outside from the lowest level of the confined space. Electrical fan motors shall be explosion-proof if in contact with fumes. No smoking or open fires shall be permitted in or near areas where volatile fumes may accumulate.

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