Amendment_6_specs.pdf

MAIN TABLE OF CONTENTS

Green Brook Flood Risk Management Project

Segment R2 Extension, Segment T Raising and

East Main Street Storm Sewer Improvements

Borough of Bound Brook, New Jersey

SECTION TITLE

00 10 00 BID SCHEDULE INSTRUCTIONS, CONDITIONS, AND

NOTICE TO BIDDERS

00 60 00 REPRESENTATIONS AND CERTIFICATIONS

00 70 00 CONTRACT CLAUSES

00 80 00 SPECIAL CONTRACT REQUIREMENTS

DIVISION 00 – LIST OF DOCUMENTS

00 90 00 WAGE RATES

APPENDICES:

00 90 01 APPENDIX A – GUIDELINES FOR WORKING WITHIN OR IN

VICINITY OF NJ TRANSIT’S RIGHT-OF-WAY

00 90 02 APPENDIX B –CONSOLIDATED RAIL CORPORATION

SPECIFIC REQUIREMENTS FOR WORK ON ITS RIGHT-OF-

WAY CE-6

SPECIFICATIONS FOR PIPELINE OCCUPANCY CE - 8

SPECIFICATIONS FOR CONSTRUCTION OF RAILROAD

ROADBED CE – 75

MINIMUM ROADWAY CLEARANCES

00 90 03 APPENDIX C – NJ TRANSIT RAIL OPERATIONS

SPECIFICATIONS FOR STONE BALLAST

00 90 04 APPENDIX D – FULL DEPTH RUBBER GRADE CROSSING

00 90 05 APPENDIX E – STREAM ENCROACHMENT PERMIT

AND FRESHWATER WETLANDS PERMIT SEGMENT R-2

00 90 06 APPENDIX F – STREAM ENCROACHMENT PERMIT

AND FRESHWATER WETLANDS PERMIT SEGMENT T

00 90 07 APPENDIX G – NJ NEW JERSEY TRANSIT

SEGMENT T OCCUPANCY PERMIT NOVEMBER 2001

00 90 08 APPENDIX H – NEW JERSEY PERMIT EXTENSION ACT

SEPTEMBER 2012

00 90 09 APPENDIX I – BALD EAGLE GUIDELINES

DIVISION 01 - GENERAL REQUIREMENTS

01 12 00.00 18 DESIGN AND RECORD DRAWING REQUIREMENTS

01 32 01.00 18 PROJECT SCHEDULE

01 33 00.00 18 SUBMITTAL PROCEDURES

01 35 26 GOVERNMENTAL SAFETY REQUIREMENTS

01 35 45.00 10 CHEMICAL DATA QUALITY CONTROL

01 45 02.00 18 QUALITY CONTROL SYSTEM (QCS)

01 45 04.00 18 CONTRACTOR QUALITY CONTROL

01 45 20.00 18 TESTING FOR MECHANICAL AND ELECTRICAL SYSTEMS

01 50 20.00 18 STREAM DIVERSION AND DEWATERING

01 57 19.00 18 ARCHAEOLOGICAL EXCAVATION

01 57 20.00 10 ENVIRONMENTAL PROTECTION FOR CIVIL WORKS

01 57 23.00 10 STORM WATER POLLUTION PREVENTION MEASURES

(EROSION AND SEDIMENTATION CONTROL)

01 74 19 CONSTRUCTION AND DEMOLITION WASTE

MANAGEMENT

01 78 00.00 18 CLOSEOUT SUBMITTALS

01 78 23.00 18 OPERATION AND MAINTENANCE DATA

DIVISION 03 - CONCRETE

03 01 30.71 CONCRETE REHABILITATION

03 01 30.72 STRENGTHENING OF CONCRETE WITH FRP

(Fiber Reinforced Polymer) REINFORCEMENT

03 11 14.00 10 FORMWORK FOR CONCRETE

03 15 14.00 10 EXPANSION, CONTRACTION AND CONSTRUCTION

JOINTS IN CONCRETE FOR CIVIL WORKS

03 20 02 STEEL BARS AND WELDED WIRE FABRIC FOR

CONCRETE REINFORCEMENT FOR CIVIL WORKS

03 31 01.00 10 CAST-IN-PLACE STRUCTURAL CONCRETE FOR CIVIL

WORKS

03 50 00 PREFABRICATED MODULAR WALLS

DIVISION 05 - METALS

05 05 23.00 14 WELDING, STRUCTURAL

05 12 00 STRUCTURAL STEEL

05 48 10 SLUICE GATE

05 49 10 FLAP GATE

05 50 03.00 10 METALWORK FABRICATION, MACHINE WORK,

MISCELLANEOUS PROVISIONS

05 50 04.00 10 METALS: MISCELLANEOUS, STANDARD ARTICLES,

SHOP FABRICATED ITEMS FOR CIVIL WORKS

STRUCTURES

DIVISION 06 – WOOD PLASTICS AND COMPOSITES

06 10 00 ROUGH CARPENTRY

DIVISION 09 – FINISHES

09 06 90 COLOR SCHEDULE

09 90 00 PAINTS AND COATINGS

09 97 02.01 12 PAINTING: COAL TAR EPOXY SYSTEM

DIVISION 23 – HEATING VENTILATING AND AIR CONDITIONING

23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND

EXHAUST SYSTEMS

DIVISION 26 - ELECTRICAL

26 00 00.00 20 BASIC ELECTRICAL MATERIALS AND METHODS

26 05 00.00 40 COMMON WORK RESULTS FOR ELECTRICAL

26 05 19.00 10 INSULATED WIRE AND CABLE

26 08 00 APPARATUS INSPECTION AND TESTING

DIVISION 31 - EARTHWORK

31 00 00 EARTHWORK

31 05 22 GEOTEXTILES USED AS FILTERS

31 10 00 CLEARING FOR CIVIL WORKS

31 23 10.00 20 EXCAVATION, TRENCHING, AND BACKFILLING FOR

UTILITIES SYSTEMS

31 23 10.01 20 EXCAVATION, FILL AND BACKFILL FOR STRUCTURES

31 32 11 SOIL SURFACE EROSION CONTROL

31 41 16 METAL SHEET PILING

31 63 36 TEMPORARY SOLDIER PILE WALL SYSTEM

DIVISION 32 - EXTERIOR IMPROVEMENTS

32 01 16.17 COLD MILLING OF BITUMINOUS PAVEMENTS

32 11 26 BITUMINOUS BASE COURSE

32 11 27 BITUMINOUS-STABILIZED BASE COURSE, SUBBASE, OR

SUBGRADE

32 12 10 BITUMINOUS TACK AND PRIME COATS

32 12 16 HOT-MIX ASPHALT (HMA) FOR ROADS

32 17 24.00.10 PAVEMENT MARKINGS

32 92 19 SEEDING

32 93 00 EXTERIOR PLANTS

DIVISION 33 - UTILITIES

33 40 01 STORM DRAINAGE

33 71 02.00 20 UNDERGROUND ELECTRICAL DISTRIBUTION

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

35 20 14 STOP LOGS

35 20 16.59 CLOSURE GATES

35 31 19 STONE PROTECTION

35 41 00 SEGMENT R2 LEVEE CONSTRUCTION

35 41 00.01 SEGMENT T EXISTING LEVEE RAISING

SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 1 OF 1 PAGES

Green Brook FCP

R2 Extension, T Raising & E. Main Street Storm Sewer Improvements

03 01 30.71 SD.05 Design Data

1.4.1.1Job mix formula

SD.06 Test Reports

2.1.2aggregate

2.1.1.1Epoxy resin binder

2.1.1.2Epoxy grout

SD.07 Certificates

2.1.1.1Epoxy resin binder

2.1.1.2Epoxy grout

SD.08 Manufacturer’s Instructions

2.1.1Epoxy

03 01 30.72 SD.02 Shop Drawings

GLimits of FRP Reinforcing

G RODetails of epoxy injection crack

SD.06 Test Reports

Environmental durability

ICC Evaluation Report

SUBMITTAL REGISTER

CONTRACT NO.

TITLE AND LOCATION CONTRACTOR

CONTRACTOR:

SCHEDULE DATES

CONTRACTOR

ACTION

APPROVING AUTHORITY

A C T I V I T Y

N O

T R A N S M I T T A L

N O

S P E C

S E C T

DESCRIPTION

ITEM SUBMITTED

P A R A G R A P H

C L A S S I F I C A T I O N

G O V T

O R

A E

R E V W

R SUBMIT

APPROVAL

NEEDED

BY

MATERIAL

NEEDED

BY

A C T I O N

C O D E

DATE

OF

ACTION

DATE FWD

TO APPR

AUTH/

DATE RCD

FROM

CONTR

DATE FWD

TO OTHER

REVIEWER

DATE RCD

FROM OTH

REVIEWER

A C T I O N

C O D E

DATE

OF

ACTION

MAILED

TO

CONTR/

DATE RCD

FRM APPR

AUTH REMARKS

(a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q) (r)

R2 Extension, T Raising & E. Main Street Storm Sewe r Improvements SEGR2T

SECTION 03 01 30.71

CONCRETE REHABILITATION

04/06

PART 1 GENERAL

1.1 REFERENCES

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

ASTM INTERNATIONAL (ASTM)

ASTM C144 (2011) Standard Specification for Aggregate for Masonry Mortar

ASTM C31/C31M (2012) Standard Practice for Making and Curing Concrete Test Specimens in the Field

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

ASTM C39/C39M (2012) Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

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

1.2 DEFINITIONS

1.2.1 Epoxy Resin Binder

A two-component epoxy bonding system in low and med ium viscosities used by itself as a primer or for producing epoxy concrete or mortars when mixed with aggregate.

1.2.2 Epoxy Concrete

A combination of epoxy resin binder and fine and co arse aggregate used in the repair of spalling along joints or cracks, smal l surface spalls or "popouts."

1.2.3 Epoxy Mortar

A combination of epoxy resin binder and fine aggreg ate used in the surface repair of non-structural cracks and filling of saw kerfs.

1.2.4 Non-Pressure Epoxy Grout

A combination of epoxy resin binder, a mineral fill er and a thixotropic agent used in cementing dowels in place and the rep air of non-structural cracks.

SECTION 03 01 30.71 Page 1

1.2.5 Pressure Grouting Epoxy

A low viscosity epoxy resin system pumped under pre ssure into structural cracks in walls or pavements.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for inf ormation only. When used, a designation following the "G" designation i dentifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section 01 33 00.00 18 SUBMITTAL PROCEDURES:

SD-05 Design Data

Job mix formula

SD-06 Test Reports

Sieve analysis test for aggregate

Epoxy resin binder tests

Epoxy grout tests

SD-07 Certificates

Epoxy resin binder

Epoxy grout

SD-08 Manufacturer's Instructions

Epoxy repair material

Submit for mixing and applying.

1.4 QUALITY ASSURANCE

1.4.1 Design Data

1.4.1.1 Job Mix Formula

Submit, at least 15 days before work commences, a j ob-mix formula for each use of epoxy mortar. Test reports shall accompany the mix design.

Identify the proposed source of the materials and s tate the proportions of aggregates and epoxy resin. When determining job m ix, use samples of materials to be used on the job.

a. Trial batches: Perform a minimum of three tria l batchings in a certified testing laboratory. Try different aggreg ate-resin proportions to obtain satisfactory placing and fini shing characteristics but keep the proportion by weight o f aggregate to epoxy resin binder at least five to one. When mixing, ad d the fine aggregates first, and then the coarse aggregates. The final trial batch should be sufficiently wet so that some fines will "bleed" to the surface during finishing operations.

b. Supporting criteria: Include in the submittal the following data for

SECTION 03 01 30.71 Page 2 each trial batch:

(1) Proportions by weight

(2) Unit weights and specific gravities of constit uents

(3) Batch weights

(4) Compressive strengths of 3 by 6 inch cylinders, made in accordance with ASTM C31/C31M, air cured for 7 days and tested in accordance with ASTM C39/C39M. Compressive strength shall be a minimum of 4,000 psi.

(5) Curing time

1.4.2 Test Reports

1.4.2.1 Epoxy Resin Binder

Include the following:

a. Viscosity

b. Consistency

c. Gel time

d. Absorption

e. Shrinkage

f. Thermal compatibility

1.4.2.2 Epoxy Resin Grout

Include the following:

a. Epoxy number

b. Consistency

c. Compressive single shear strength

d. Pot life

1.5 DELIVERY, STORAGE, AND HANDLING

Inspect materials delivered to site for damage, unl oad and store with a minimum of handling. Deliver epoxy resin component s and aggregate materials in original sealed containers and store i n dry covered areas at temperatures below 90 degrees F . Remove from job site unused mixed materials which have reached end of working or pot life.

1.6 WEATHER LIMITATIONS

Halt work when weather conditions detrimentally aff ect the quality of patching or bonding concrete. Apply epoxy resin ma terials only when the contact surfaces are completely dry and if the atmo spheric and surface temperature ranges are suitable for the specified e poxy material. Follow

SECTION 03 01 30.71 Page 3 manufacturer's instructions for weather conditions and temperature ranges.

1.7 TRAFFIC CONTROL

Do not permit vehicular or heavy equipment traffic on the pavement in the work area during the curing period. At the end of the curing period, light local traffic may be permitted on the pavement if a pproved by the Contracting Officer.

1.8 EQUIPMENT

Use a container recommended by the epoxy manufactur er as the mixing vessel.

Use a power drive (air or spark-proof) propeller ty pe blade for mixing except that hand mixing may be used for small batch es. Use equipment specified by epoxy manufacturer for field mixing of aggregates and epoxy resin.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Epoxy

2.1.1.1 Epoxy Resin Binder for Concrete and Mortar

ASTM C881/C881M, Type III, Grade 1 or 2, Class B or C without mine ral filler.

2.1.1.2 Non-Pressure Epoxy Grout

ASTM C881/C881M Type IV, Grade 2 or 3, Class B or C with or withou t mineral filler.

2.1.2 Aggregate

For material passing No. 200 sieve provide a non-pl astic material composed of a minimum of 75 percent limestone dust, talc or silica inert filler.

Provide dry aggregate.

a. For epoxy concrete: ASTM C33/C33M, maximum size 1/2 inch .

b. For epoxy mortar: ASTM C144, No. 8 sieve.

PART 3 EXECUTION

3.1 PREPARATION

3.1.1 Epoxy Concrete

3.1.1.1 Patch Areas

Remove loose concrete from the spalled areas indica ted. Inspect the cavity for remaining defective concrete by tapping with a hammer or steel rod and listening for dull or hollow sounds. In areas wher e tapping does not produce a solid tone, remove additional concrete un til testing produces a solid tone. Make the entire cavity at least one inch deep. Sawcut edges of cavity to avoid feather edging. Prepare surface of cavity by sandblasting, grinding, or water blasting. Remove dust, dirt, and loosely bonded material resulting from cleaning. Ensure ca vity surfaces are dry.

SECTION 03 01 30.71 Page 4

3.2 MIXING MATERIALS

Make batches small enough to ensure placement befor e binder sets. Mix materials in accordance with manufacturer's recomme ndations.

3.3 PLACEMENT

3.3.1 Epoxy Concrete

Prime dry cavity surfaces with epoxy resin using a stiff bristle brush.

Make coating approximately 20 mils thick. Place epoxy concrete while primer is still tacky and in layers not exceeding o ne inch thick. Use vibratory floats, plates, or hand tampers to consol idate the concrete.

Level each layer and screed the final surface to ma tch the adjoining surfaces. Remove excess epoxy concrete on adjacent surfaces before the concrete hardens. Do not feather epoxy concrete ou t onto adjacent surfaces.

3.3.2 Epoxy Mortar

Prime surfaces with epoxy resin binder. Scrub prim e coat into surface with a stiff bristle brush. Make coating approximately 20 mils thick. Place epoxy mortar while primer is still tacky. Apply at a thickness recommended by the manufacturer. Work mortar into place and co nsolidate thoroughly so that contact surfaces are wetted by the mortar. Fi nish surface of mortar to the required texture. Do not feather edge epoxy mortar onto adjacent surfaces.

3.4 CURING

Cure epoxy materials in accordance with manufacture r's recommendations.

3.5 FIELD QUALITY CONTROL

3.5.1 Sampling

As soon as epoxy resin and aggregate materials are available for sampling, obtain by random selection a sample of each batch. Clearly identify samples by designated name, specification number, b atch number, project contract number, intended use and quantity involved .

3.5.2 Testing

At the discretion of the Contracting Officer, sampl es provided may be tested by the Government for verification.

3.5.3 Inspection

Check each repaired area for cracks, spalls, popout s and loss of bond between repaired area and surrounding concrete. Ch eck each repaired area for voids by tapping with a hammer or steel rod and listening for dull or hollow sounds. Immediately repair defects.

-- End of Section --

SECTION 03 01 30.71 Page 5

SECTION 03 01 30.72

Strengthening of Concrete with FRP (Fiber Reinforce d Polymer) Reinforcement 04/06

PART 1 GENERAL

1.1 REFERENCES

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

ASTM INTERNATIONAL (ASTM)

ASTM D 2563 (1994; R 2002e1) Classifying Visual Defects in Glass-Reinforced Plastic Laminate Parts

ASTM D 3039/D 3039M (2002e1) Tensile Properties of Polymer Matrix Composite Materials

ASTM D 638 (2003) Tensile Properties of Plastics

ASTM D 648 (2004) Deflection Temperature of Plastics Under Flexural Load in the Edgewise Position

ASTM D 790 (2003) Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for inf ormation only. When used, a designation following the "G" designation i dentifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section 01 33 00.00 18 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings G, RO

Limits of FRP Reinforcing G

Details of epoxy injection crack repair and epoxy resin patching.

G

Complete system details including, but not limited to, FRP Reinforcement, primer, resin, and protective coatin g.

SD-03 Product Data G, RO

Submit product data indicating product standards, p hysical and chemical characteristics, environmental durability, technical specifications, limitations, installation instructi ons, and general recommendations regarding each material.

SD-06 Test Reports

SECTION 03 01 30.72 Page 1

Environmental durability

Submit independent test report verifying the envir onmental durability of the proposed system to be used on thi s project. Such reports shall include as a minimum:

1. 10,000 hr. resistance to salt water

2. 10,000 hr. resistance to high temperature (38C) and high humidity (100%)

3. 10,000 hr. resistance to alkali solution (pH 9.5 )

4. 3,000 hr. resistance to dry heat (60C)

5. resistance to 20 freeze/thaw cycles

6. resistance to UV/condensation @ 100 cycles

7. resistance to diesel fuel (4 hr. exposure)

ICC Evaluation Report

Submit an approved ICC Evaluation Report in the n ame of the proposed FRP system to be used on this project.

Submit for record test results of the Pull-off te st to determine FRP adhesion to concrete substrate.

SD-07 Certificates

Submit for record, a qualification statement by the Contractor listing their completed FRP Reinforcement projects, including size, location, owner, engineer/architect and conta ct numbers.

SD-09 Manufacturer's Field Reports

Submit for record Daily Construction Logs kept by the Contractor. These logs shall include the following information:

Weather and temperature at application times; Amoun t of product used and square footage/linear footage of substrate covered; Batch numbers of all products used; Names of all crew mem bers; Any bond-strength tests, noting location, quantity and who performed these tests.

Submit for record a complete description of the F RP Reinforcing system materials, surface preparation, application procedures, application rates, and cure times.

Submit for record copies of purchase order and pa ckaging slips showing quantities and dates of primer and resin pu rchased.

Submit for record Material Safety Data Sheets (MS DS) of each product, used on site.

1.3 QUALITY ASSURANCE

1. Manufacturer shall have a nationally recognized program of contractor training, certification and technical support.

2. The Manufacturer shall have minimum five years e xperience in FRP Reinforcement confirmed by actual field tests of mi nimum 50 successful installations.

SECTION 03 01 30.72 Page 2

3. The Manufacturer shall be able to supply testing data to demonstrate system properties and durability of the actual FRP Reinforcement to be used.

1.3.1 Quality Control procedures

Quality Control procedures performed by the Contrac tor shall include, but not be limited to the following:

1. The Contractor shall be trained by the Manufactu rer and shall have completed a program of instruction in the use of FR P Reinforcement.

2. The Contractor shall have a minimum of two years experience in FRP Reinforcement confirmed by actual field tests of at least 5 successful installations.

3. The Contractor shall inspect all materials prior to application to assure that they meet specifications and have arriv ed to the job-site undamaged.

4. The FRP Reinforcement shall be completely inspec ted by the contractor during and immediately following application of the composite materials.

Conformance with the design drawings, proper alignm ent of fibers and quality workmanship shall be assured. Entrapped air shall be released or rolled out before the epoxy sets. Defects shall be noted in the Daily Construction Log.

5. After FRP Reinforcement has cured, the contracto r shall inspect the all work to check for voids and or debonding. Repairs s hall be made as per Par.

3.7 Repair of Defects, and noted in the Daily Const ruction Log.

1.4 Reference Standards

Comply with the following reference standards, exce pt where more stringent requirements are indicated on the Drawings or speci fied herein:

1. American Concrete Institute (ACI)

a. ACI 440.2R-08, Guide for the Design and Construc tion of Externally Bonded FRP Systems for Strengthening Concrete Struc tures

b. ACI 440R-07, Report on Fiber-Reinforced Polymer (FRP) Reinforcement for Concrete Structures

c. ACI 440 R-96, State-of-the-Art Report on Fiber R einforced Plastic (FRP) Reinforcement for Concrete Structures.

d. ACI 503 R, Pull-off test to determine FRP adhesi on to concrete substrate.

2. International Concrete Repair Institute (ICRI)

a. ICRI Guideline No. 03742, Guide for the Selectio n of Strengthening Systems for Concrete Structures Sika CarboDur ® Composite Strengthening Systems

b. ICRI Guideline No. 03739, Guide to Using In-Situ Tensile Pull-Off Tests to Evaluate Bond of Concrete Surface Materials

3. Sika CarboDur Composite Strengthening Systems – Engineering Guidelines for Design and Application.

SECTION 03 01 30.72 Page 3

1.5 Job-Site Conditions

A. Do not apply FRP Reinforcement materials if rain ing, snowing, or dew condensation is expected or existing concrete surfa ce is wet or if the ambient or surface temperature are below 40° F (4°C ).

B. The ambient temperature and temperature of the e poxy components shall be between 50° F (10°C) and 80° F (27°C) at the time o f mixing. See appropriate technical data sheets for more specific instructions.

C. Precautions should be taken to avoid damage to a ny surface near the work zone due to mixing and handling of the specified ma terial.

D. The Contractor is solely responsible for fume co ntrol and shall take necessary precautions against injury to Installer p ersonnel or adjacent building occupants during application of primer and resin, etc. Contractor personnel shall use protective equipment and area s hall be well vented to the outside. As a minimum, Installer must take the following precautions:

1. Contractor to locate and protect building air in take during application.

2. Contractor to follow all state, federal, and loc al safety regulations.

3. Contractor to follow all Manufacturers’ safety r equirements as indicated on appropriate MSDS sheets.

1.6 Delivery, Storage, and Handling

A. Deliver primer, saturant and protective coating in original, unopened containers with the Manufacturer’s name, labels, pr oduct identification, and batch numbers.

B. FRP Reinforcement shall be stored in a cool dry area away from direct sunlight, flame, moisture, or other hazards.

C. Store primer, saturant and protective coating un der conditions as recommended by the Manufacturer in a cool dry place out of direct sunlight.

Products that have exceeded their shelf life shall not be used.

D. Contractor is required to confirm that all mater ials used in accordance with this Section conform to local, state, and fede ral environmental and worker’s safety laws and regulations.

E. During operations Contractor shall maintain barr icades

F. The Contractor shall properly dispose of empty c ontainers in accordance with local regulations.

PART 2 PRODUCTS

2.1 FRP Reinforcement Fabric and/or Laminate

A. FRP Reinforcement fabric shall be high strength, high modulus, fiber fabric that may be unidirectional or woven (in vari ous fiber architectures) to suit specific repair needs.

1. FRP Reinforcement fabric shall be of the type, s ize, layer and location as indicated on the Drawings.

2. FRP Reinforcement fabric shall meet the followin g minimum requirements:

SECTION 03 01 30.72 Page 4

PROPERTY REQUIREMENT ASTM TEST METHOD

Laminate Tensile Strength, 3,000 LB/Laye r ASTM D 3039/D 3039M n primary fiber direction, 1 layer, per inch width

Laminate Tensile Modulus, 3.4x10ˆ6 psi ASTM D 3039/D 3039M In primary fiber direction

Laminate Elongation at break 3.0% ASTM D 3039/D 3039M

Dry Fabric Weight, Minimum, 27 oz./yd2 per square yard

Percent Laminate Tensile Strength Retained after:

7 days, 100% humidity,100°F (38°C) 90% 3,000 hrs exposure to alkali 90% 3,000 hrs exposure to salt water 90% 3,000 hrs exposure at 140°F (60°C) 90%

Visual Defects ASTM D 2563/D 3039M

* Prior to testing, laminate samples shall be cured at least 7 days at 70°F then post-cured at 140°F for 48 hours

1. Products must be submitted to the Contracting Of ficers Representative for approval a minimum of two weeks prior to the bi d date.

B. FRP Precured Strip shall be high strength, high modulus, unidirectional carbon fiber reinforced polymer (CFRP).

1. FFRP Precured Strip shall be of the type, size, layer and location as indicated on the Drawings.

2. FRP Precured Strip, shall meet the following min imum requirements

PROPERTY REQUIREMENT ASTM TEST METHOD

Laminate Tensile Strength, 406,000 psi ASTM D 3039/D 3039M in primary fiber direction, Laminate Tensile Modulus, 23.2x10ˆ6 ps i ASTM D 3039/D 3039M In primary fiber direction

Laminate Elongation at break 1.69% ASTM D 3039/D 3039M

Laminate Thickmess 0.147 im.

Fiber Volume, Minimum, 68% ASTM D 2563

1. Products must be submitted to the Contracting Officers Representative for approval a minimum of two weeks prior to the bid date.

SECTION 03 01 30.72 Page 5

2.2 Concrete Surface Primer

A. Surface Primer shall be a two component, 100% so lids, moisture/tolerant, high modulus, high strength epoxy.

B. Surface Primer shall meet the following minimum requirements:

PROPERTY REQUIREMENT ASTM TEST METHOD

Tensile Strength 8,000 psi D638 ASTM D 638 Tensile Modulus 250,000 psi D638 ASTM D 638 Elongation at Break 3.0% D638 ASTM D 638 Flexural Strength 11,500 psi D790 ASTM D 790 Flexural Modulus 500,000 psi D790 ASTM D 790 Heat Deflection Temp. (HDT) 117 F D648 ASTM D 648

1. Products must be submitted to the Contracting Of ficers Representative for approval a minimum of two weeks prior to the bi d date.

2.3 Fabric Saturant

A. Saturant resin shall be two component, 100% soli ds, moisture tolerant, high strength, high modulus epoxy.

B. Saturants shall meet the following minimum requi rements:

PROPERTY REQUIREMENT ASTM TEST METHOD

Tensile Strength 8,000 psi D638 ASTM D 638 Tensile Modulus 250,000 psi D638 ASTM D 638 Elongation at Break 3.0% D638 ASTM D 638 Flexural Strength 11,500 psi D790 ASTM D 790 Flexural Modulus 500,000 psi D790 ASTM D 790 Heat Deflection Temp. (HDT) 120 F D648 ASTM D 648

1. Products must be submitted to the Contracting Of ficers Representative for approval a minimum of two weeks prior to the bi d date.

2.4 Epoxy Repair Mortar

A. Protective coating shall be polymer or acrylic b ased and shall be UV resistant.

B. Approved products are:

1. Products must be submitted to the Contracting Of ficers Representative for approval a minimum of two weeks prior to the bi d date.

2.5 Protective Coating

A. Protective coating shall be polymer or acrylic b ased and shall be UV resistant.

B. Approved products are:

1. Products must be submitted to the Contracting Of ficers Representative for approval a minimum of two weeks prior to the bi d date.

SECTION 03 01 30.72 Page 6

PART 3 EXECUTION

3.1 General

A. Inspect surfaces to receive the work and report immediately in writing to the Engineer as required in the General Conditio ns and deficiencies in the surface that render if unsuitable for proper ex ecution of this work

B. Protect vehicles, concrete, and other items surr ounding work area from dust or damage due to Work of this Section.

3.2 Surface Preparation

A. All concrete surfaces shall be dry and free of s urface moisture and frost, and tested by the Contractor to evaluate moi sture transmission in accordance with ASTM D4263 “Indicating Moisture in Concrete by the Plastic Sheet Method.“

B. All concrete surfaces shall be sound. Remove det eriorated concrete, dust, laitance, grease, paint, curing compounds, wa xes, impregnations, foreign particles, and other bond inhibiting materi als from the surface by blast cleaning or equivalent mechanical means.

C. All concrete surfaces shall be air blasted and v acuumed clean to a dust free condition.

D. Concrete surface irregularities less than one in ch shall be ground and smoothed and/or filled with an approved repair mort ar (e.g., Sikadur 30) with the addition of 1 part oven dried sand to make an epoxy mortar.

Surface irregularities shall be limited to less tha n 0.04 inches (1 mm).

Surface irregularities greater than one inch shall be repaired using an approved cementitious repair mortar (e.g. SikaTop 1 23).

E. External concrete corners shall be rounded to at least a 1/2” radius when perpendicular to fiber orientation and interna l corners shall be smoothed by trowelling epoxy mortar into the corner s.

F. The adhesive strength of the concrete shall be v erified after preparation by random pull-off testing (ACI 503R) a t the direction of the Engineer. Minimum tensile strength is 200 psi with concrete substrate failure, or as approved by the Engineer.

3.3 Mixing Primer and Saturant

A. Mix components in accordance with Manufacturer’s recommendations.

B. Diluting is not permitted. Pre-condition materia ls as indicated on technical data sheet.

C. Mix only that quantity which can be used within its pot life.

D. Do not batch delivered units into smaller quanti ties. Mix only full units.

3.4 Primer Application

A. Apply primer in accordance with Manufacturer’s r ecommendations.

B. Primer may be applied with a brush or roller. Ap ply second coat as

SECTION 03 01 30.72 Page 7 necessary after first coat has penetrated into conc rete.

C. Surface depressions shall be filled with epoxy f iller per manufacturers’ instructions.

D. Primer must be covered with fiber within 24 hour s of application, depending on temperature conditions. If 24-hour win dow is exceeded, the primed surfaces must be solvent wiped with a fast f lashing solvent (e.g.

MEK) or roughened with sandpaper to break the amine blush.

3.5 FRP Reinforcement Application

Method 1: Wet Lay-Up

A. Apply FRP Reinforcement in accordance with Manuf acturer’s recommendations.

B. When using saturator equipment, follow Manufactu rer’s procedures for proper machine set-up and calibration. Rollers shal l be calibrated to saturate the fabric with the proper resin-to-fabric ratio. The roller gap shall be checked daily by a qualified Sika CarboDur ® Composite Strengthening Systems technician for accuracy. The resin-to-fabric ratio shall also be verified by resin usage and documente d on the daily project logs.

C. Once the fabric is saturated, it may then either be spooled for easy handling, or cut to specified lengths and booked fo r handling. Care must be taken not to damage the fibers

D. The fabric may then be applied to the surface wi th no delay. Work from one end to the other, taking care to orient the fib ers as specified. Remove any air entrapped in the fabric with a ribbed rolle r or squeegee.

E. Sheets shall be lapped in the longitudinal direc tion 6 inches minimum or as indicated on the Drawings. Note: no lapping is r equired of the sheets parallel to the direction of fiber orientation.

Method 2: Dry Lay-Up

A. Apply FRP Reinforcement in accordance with Manuf acturer’s recommendations.

B. FRP Reinforcement sheets shall be cut beforehand into prescribed lengths. Sheets shall be lapped in the longitudinal direction 6 inches minimum or as indicated on the Drawings. Note: no l apping is required of the sheets parallel to the direction of fiber orien tation.

C. Follow Manufacturer’s recommendations regarding primer open times.

D. Apply a primary saturant coat uniformly by rolle r brush.

E. Apply FRP Reinforcement sheets fiber side down t o the concrete over the fresh saturant using a ribbed roller to remove any air bubbles.

F. FRP Reinforcement sheets shall be left alone for about 30 minutes allowing for the primary saturant to soak through t he fabric. Correct any dislocation on lifting.

G. Apply secondary saturant coat with roller over i nstalled sheets in order

SECTION 03 01 30.72 Page 8 to impregnate and replenish primary saturant.

H. If succeeding FRP Reinforcement sheets are speci fied on the Drawings repeat application procedures.

Method 3: Precured Strip Application

A. Apply FRP Precured Strip in accordance with Manu facturer’s recommendations.

B. Care shall be taken not to damage the fibers in handling and unpacking the Strips.

C. Strips may be either delivered to project site i n factory pre-cut lengths, or cut on site. Care must be taken not to fray or otherwise damage the fibers when field cutting. Follow Manufacturer’ s recommendations for field cutting of strips.

D. Strips shall be cleaned with a fast flashing sol vent (e.g. MEK) to remove any bond inhibiting materials. A clean white cotton rag shall be used for this purpose. Continue cleaning the Strip in this manner until no black residue shows on the rag. Cleaning shall be p erformed the same day the strips are to be used.

3.6 Curing

A. Protect finished installation of FRP Reinforceme nt from rain, sand, dust, etc. using protective sheeting or other barri ers. Do not allow protective sheeting to come in contact with finishe d application.

B. Curing of finished application shall be a minimu m of 24 hours and in order to achieve full strength curing shall be exte nded for a period of two weeks at an average ambient temperature of 68°F.

3.7 Repair of Defects

A. Upon completion of the curing process, the insta lled system shall be checked for areas where saturant has not penetrated or where saturant has not completely cured. Such areas shall be epoxy inj ected to re-establish bond subject to the approval of the Project Enginee r.

B. Repair procedures shall be performed in accordan ce with guidelines established by ACI 440.2R-08 (paragraph 7.2.3) and approved by the Project Engineer. All repairs shall be subject to the same application, curing and quality control specifications as the original work .

1. Small delaminations and voids less than 2 in2 ea ch are permissible as long as the delaminated area is less than 5% of the total laminate area and there are no more than 10 such delaminations per 10 ft2.

2. Medium sized delaminations and voids greater tha n 2 in2 but less than 25 in2 may be repaired by epoxy resin injection or ply replacement, depending on the size and number of delaminations and their l ocation. The repair procedure should be determined by the Project Engin eer.

3. Larger size delaminations and voids greater than 25 in2 should be repaired by selectively cutting away the affected s heet and applying an overlapping sheet patch of equivalent plies. The ov erlap should extend a minimum of 6 in. in all directions.

SECTION 03 01 30.72 Page 9

3.8 Protective Coating

A. Apply protective coating in accordance with Manu facturer’s recommendations.

3.9 Cleaning

A. Uncured saturants may be cleaned from tools with an approved solvent and properly disposed.

B. Cured saturants shall be removed by mechanical m eans and properly disposed.

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