03_01_30.71_-_R0003.pdf

DLA Warehouse Bldg #9670 15013 Joint Base Lewis-McChord, WA W912DW-17-B-0008

SECTION TABLE OF CONTENTS

DIVISION 03 - CONCRETE

SECTION 03 01 30.71

CONCRETE REHABILITATION AND POLISHING

04/06

PART 1 GENERAL

1.1 REFERENCES

1.2 DEFINITIONS

1.2.1 Epoxy Resin Binder

1.2.2 Epoxy Concrete

1.2.3 Epoxy Mortar

1.2.4 Non-Pressure Epoxy Grout

1.2.5 Pressure Grouting Epoxy

1.3 SUBMITTALS

1.4 QUALITY ASSURANCE

1.4.1 Design Data

1.4.1.1 Job Mix Formula

1.4.2 Test Reports

1.4.2.1 Epoxy Resin Binder

1.4.2.2 Epoxy Resin Grout

1.5 CONCRETE FLOOR POLISHING SYSTEM

1.5.1 General

1.5.2 Performance Requirements

1.5.3 Installer Certification

1.5.4 Finish and Appearance

1.5.4.1 Level of cut

1.5.4.2 Level of Sheen

1.6 DELIVERY, STORAGE, AND HANDLING

1.7 WEATHER LIMITATIONS

1.8 TRAFFIC CONTROL

1.9 EQUIPMENT

PART 2 PRODUCTS

2.1 REHABILITATION MATERIALS

2.1.1 Epoxy

2.1.1.1 Epoxy Resin Binder for Concrete and Mortar

2.1.1.2 Non-Pressure Epoxy Grout

2.1.2 Aggregate

2.2 GRINDING AND POLISHING EQUIPMENT

2.3 CONCRETE POLISHING MATERIALS

2.3.1 General

2.3.2 Concrete Densifier

2.3.3 Concrete Sealer

2.3.4 Grinding and Polishing

2.3.5 Cleaning and Preparation Agents

2.4 CONCRETE EXPANSION JOINT FILLER

PART 3 EXECUTION

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3.1 CONCRETE REHABILITATION

3.1.1 Preparation

3.1.1.1 Epoxy Concrete Patching

3.1.1.2 Spalls at Joints and Cracks

3.1.1.3 Joints and Cracks

3.1.1.4 Epoxy Mortar for Cracks and Saw Kerfs

3.1.1.5 Epoxy Grout for Cracks

3.1.2 MIXING MATERIALS

3.1.3 Placement

3.1.3.1 Epoxy Concrete

3.1.3.2 Epoxy Mortar

3.1.3.3 Cementing Dowels

3.1.4 Curing

3.1.5 Joint Repair Amounts

3.2 QUALITY CONTROL

3.2.1 Sampling

3.2.2 Testing

3.2.3 Inspection

3.3 CONCRETE POLISHING

3.3.1 GENERAL

3.3.2 Concrete Substrate Grinding And Polishing

3.3.3 Densifier And Sealer Application

3.3.4 Testing

3.4 CONCRETE EXPANSION JOINTS

3.5 PROTECTION, REPAIR, AND CLEANING

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SECTION 03 01 30.71 Page 2

SECTION 03 01 30.71

CONCRETE REHABILITATION AND POLISHING

04/06

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 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 (2013) Standard Specification for Concrete Aggregates

ASTM C39/C39M (2017) Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

ASTM C779/C779M (2012) Abrasion Resistance of Horizontal Concrete Surfaces

ASTM C881/C881M (2014) Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete

ASTM E430 (2011) Standard Test Methods for Measurement of Gloss of High-Gloss Surfaces by Abridged Goniophotometry

1.2 DEFINITIONS

1.2.1 Epoxy Resin Binder

A two-component epoxy bonding system in low and medium 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 coarse aggregate used in the repair of spalling along joints or cracks, small surface spalls or "popouts."

1.2.3 Epoxy Mortar

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

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1.2.4 Non-Pressure Epoxy Grout

A combination of epoxy resin binder, a mineral filler and a thixotropic agent used in cementing dowels in place and the repair of non-structural cracks.

1.2.5 Pressure Grouting Epoxy

A low viscosity epoxy resin system pumped under pressure 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 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-03 Product Data

Concrete Densifier

Concrete Sealer

Concrete Expansion Joint Filler; G

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

Installer Certification

SD-08 Manufacturer's Instructions

Epoxy repair material

Submit for mixing and applying.

SD-10 Operation and Maintenance Data

Cleaning and Maintenance Requirements; G

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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 job-mix formula for each use of epoxy concreteand epoxy mortar. Test reports shall accompany the mix design. Identify the proposed source of the materials and state the proportions of aggregates and epoxy resin. When determining job mix, use samples of materials to be used on the job.

a. Trial batches: Perform a minimum of three trial batchings in a certified testing laboratory. Try different aggregate-resin proportions to obtain satisfactory placing and finishing characteristics but keep the proportion by weight of aggregate to epoxy resin binder at least five to one. When mixing, add 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 each trial batch:

(1) Proportions by weight

(2) Unit weights and specific gravities of constituents

(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 10,000 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:

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a. Epoxy number

b. Consistency

c. Compressive single shear strength

d. Pot life

1.5 CONCRETE FLOOR POLISHING SYSTEM

1.5.1 General

After warehouse concrete floors have been rehabilitated, provide polished concrete floor system for interior concrete floors by dry grinding and polishing with various size grit metal-bonded and resin-bonded diamonds and application of concrete sealer.

1.5.2 Performance Requirements

Improve performance of floor by installation of polished concrete floor system as measured by ASTM C779/C779M and ASTM E430.

Finish and appearance quality standards in accordance with Concrete Polishing Association of America (CPAA):

Level 3 – Medium Aggregate: Exposing more of the overall girth of the aggregate within the substrate. The depth of grind will depend greatly on the placement and finishing procedures. Generally this level of grind can be achieved within 1/8 inch of the surface.

Level of sheen per ASTM E430 when the concrete surfaced is mechanically processed. Gloss readings are not to be obtained through the use of any microfilming products, sealers, coating, enhancers or the result of resin transfer from resin bond abrasives. Readings shall be taken not less than ten feet on center in field areas and within one foot of floor area perimeters. In no case shall a reading be below two percent of specified minimum sheen.

Level B Sheen (Semi-Gloss) as determined by gloss reading of 60-70.

1.5.3 Installer Certification

Use experienced installers who have successfully performed a minimum of five projects of at least 5,000 square feet each. Upon request provide listing of projects and contact references. Provide letter of certification from manufacturer stating that Installer is certified applicator of polished concrete finishing system specified and is familiar with proper procedures and installation requirements required by the manufacturer.

1.5.4 Finish and Appearance

Quality Standards in accordance with Concrete Polishing Association of America (CPAA).

1.5.4.1 Level of cut

Provide Level 3 - Medium Aggregate exposing the overall girth of the aggregate within the substrate. The depth of grind will depend greatly on

SECTION 03 01 30.71 Page 6 the placement and finishing procedures. Generally this level of grind can be achieved within 1/8 inch of the surface.

1.5.4.2 Level of Sheen

In accordance with ASTM E430 when the concrete surfaced is mechanically processed. Gloss readings are NOT to be obtained through the use of any microfilming products, sealers, coating, enhancers or the result of resin transfer from resin bond abrasives. Take test readings in accordance with Paragraph TESTING below. In no case shall a reading be below 2 percent of specified minimum sheen.

Provide Level B Sheen (Semi-Gloss) as determined by gloss reading of 60-70.

1.6 DELIVERY, STORAGE, AND HANDLING

Inspect materials delivered to site for damage, unload and store with a minimum of handling. Deliver epoxy resin components and aggregate materials in original sealed containers and store in 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.

1.7 WEATHER LIMITATIONS

Halt work when weather conditions detrimentally affect the quality of patching or bonding concrete. Apply epoxy resin materials only when the contact surfaces are completely dry and if the atmospheric and surface temperature ranges are suitable for the specified epoxy material. Follow manufacturer's instructions for weather conditions and temperature ranges.

1.8 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 approved by the Contracting Officer.

1.9 EQUIPMENT

Use a container recommended by the epoxy manufacturer as the mixing vessel.

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

PART 2 PRODUCTS

2.1 REHABILITATION MATERIALS

2.1.1 Epoxy

2.1.1.1 Epoxy Resin Binder for Concrete and Mortar

2.1.1.2 Non-Pressure Epoxy Grout

ASTM C881/C881M Type IV, Grade 2, Class B with or without mineral filler.

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2.1.2 Aggregate

For material passing No. 200 sieve provide a non-plastic 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. Conform to the following requirements:

Sieve Designation Percent Passing by Weight

1/2 in. 100

3/8 in. 93-100

No. 4 70-80

No. 8 50-65

No. 16 37-53

No. 30 20-37

No. 50 10-20

No. 100 5-10

No. 200 3-5

b. For epoxy mortar: ASTM C144, maximum size No. 40 sieve.

2.2 GRINDING AND POLISHING EQUIPMENT

A. Floor Grinder: Polishing shall be a dry diamond method, not wet, utilizing metal bonded diamond/resin bonded diamond multi orbital planetary action opposing rotational diamond headed machine with approximate grinding pressure of 675 pounds or more.

B. Vacuum System: Vacuum system shall be directly connected to floor grinder to reduce amount of dust exposure. HEPA filtration system is required.

2.3 CONCRETE POLISHING MATERIALS

2.3.1 General

1. Provide products which are recommended by manufacturers to be fully compatible with project substrate conditions and special concrete floor finish materials, means and methods.

2. Provide special concrete floor finish products from a single manufacturer unless otherwise approved.

3. All products used shall comply with Environmental Protection Agency (EPA) volatile organic compound (VOC) evaporation requirements.

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2.3.2 Concrete Densifier

Clear, odorless liquid form of a lithium silicate to permanently seal, densify, dustproof and harden concrete surfaces and provide abrasion resistance by penetrating into concrete pores and chemically reacting.

Products must conform and meet minimum performance characteristics as described herein.

2.3.3 Concrete Sealer

Clear, highly concentrated, quick drying penetrating water and oil repellent sealer specifically designed to deeply impregnate the surface pores and chemically bond with the concrete floor to increase durability.

2.3.4 Grinding and Polishing

Provide other related materials as recommend by manufacturer, not specifically described, but required for complete and proper system installation.

2.3.5 Cleaning and Preparation Agents

Products recommended by manufacturer for project conditions.

2.4 CONCRETE EXPANSION JOINT FILLER

Provide a one-component, self-levelling, urethane sealant manufactured for the purpose of filling concrete expansion joints in surfaces with vehicle traffic. Store and use product between 40 and 100 degrees F.

PART 3 EXECUTION

3.1 CONCRETE REHABILITATION

3.1.1 Preparation

3.1.1.1 Epoxy Concrete Patching

Remove loose concrete from any spalled areas. Inspect the cavity for remaining defective concrete by tapping with a hammer or steel rod and listening for dull or hollow sounds. In areas where tapping does not produce a solid tone, remove additional concrete until 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 cavity surfaces are dry.

3.1.1.2 Spalls at Joints and Cracks

For spalls to be repaired that are adjacent to joints and working cracks insert preformed joint filler to the working faces of the spall. Trim filler to fit shape of the working faces of joint or crack so epoxy material is prevented from bypassing filler. Where practicable, extend filler horizontally and vertically into joint or crack opening. Secure filler strip in place prior to and during placement of epoxy concrete.

Apply a bond breaker to working faces at keyed joints. Keep bond breaker off of concrete surface to be bonded. After the epoxy concrete has completely cured, saw out the top inch of the preformed joint filler and install liquid joint sealer.

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3.1.1.3 Joints and Cracks

Clean and seal joints and cracks in accordance with manufacturer's instructions.

3.1.1.4 Epoxy Mortar for Cracks and Saw Kerfs

Apply epoxy mortar to newly exposed loose and unsound materials. Prepare surfaces by sandblasting, scarifying or waterblasting. Remove dust, dirt, and loosely bonded material resulting from cleaning. Ensure surfaces are dry before application of epoxy mortar.

3.1.1.5 Epoxy Grout for Cracks

Clean each crack of dust, dirt, loose concrete and unsound material. Apply epoxy grout at a thickness recommended by the manufacturer. Work grout into place and consolidate thoroughly so that contact surfaces are wetted by the grout. Finish surface of grout to the required texture. Do not feather edge epoxy grout onto adjacent surfaces.

3.1.2 MIXING MATERIALS

Make batches small enough to ensure placement before binder sets. Mix materials in accordance with manufacturer's recommendations.

3.1.3 Placement

3.1.3.1 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 one inch thick. Use vibratory floats, plates, or hand tampers to consolidate the concrete.

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

3.1.3.2 Epoxy Mortar

Prime surfaces with epoxy resin binder. Scrub prime 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 consolidate thoroughly so that contact surfaces are wetted by the mortar. Finish surface of mortar to the required texture. Do not feather edge epoxy mortar onto adjacent surfaces.

3.1.3.3 Cementing Dowels

Immediately prior to placing the dowel, clean hole of dust and other deleterious material with a high pressure air hose. Fill hole halfway with grout. Insert dowel in hole by rotating it at least one complete turn while tapping it down. If necessary add more grout to fill hole.

3.1.4 Curing

Cure epoxy materials in accordance with manufacturer's recommendations.

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3.1.5 Joint Repair Amounts

For this work, use a figure of 150 linear feet total.

3.2 QUALITY CONTROL

3.2.1 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, batch number, project contract number, intended use and quantity involved.

3.2.2 Testing

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

3.2.3 Inspection

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

3.3 CONCRETE POLISHING

3.3.1 GENERAL

1. Install diamond polished concrete floor finishing system for a Level 3 (semi-polished)gloss finish per manufacturer’s recommendations and instructions. Use equipment, means and methods for proper installation.

2. Where walls, columns or substrate penetrations are installed adjacent to or through polished concrete floor finish areas, extend grinding and polishing process to within one inch maximum distance from perimeter of surface interrupting condition by means necessary for uniform appearance with field surface area finish.

3. Where existing substrates are not in compliance with specified tolerances provide repair, grinding, patching or other remedies recommended by special concrete floor finish manufacturer for project conditions and approved by the COR.

4. As part of the concrete floor grinding/polishing work, where differential settlement between slabs and between slabs and thresholds has occured, grind down transitions that are greater than 1/4 inch to 1/4 inch or less.

3.3.2 Concrete Substrate Grinding And Polishing

1. Use equipment, means and methods recommended by manufacturer.

2. Grind, polish and clean concrete floor surfaces using methods depending on substrate conditions to achieve project system performance and appearance criteria. A level 3 polish is achieved by going up to an 800-grit requiring a minimum of 6 abrasive passes. Final gloss reading shall be 50-60.

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3. Scrub and rinse floor and remove residual color, dust, and debris.

4. All grinding and polishing passes shall be made in the same direction until the entire given area has been covered.

3.3.3 Densifier And Sealer Application

1. Prior to application of product, substrate to be clean, dry and absorbent. Confirm surface absorbency with a light water spray. If surface does not wet uniformly, use appropriate surface preparation cleaner or mechanical process to remove remaining surface contaminants per manufacturer’s recommendations.

2. Calculate Target Coverage Rate: Variations in concrete quality, porosity, job conditions, temperature, and relative humidity will affect coverage rates and drying times. Test a representative section of the substrate surface to calculate the target coverage rate, but not less than 200 sqft per gallon.

3. Apply material at specified coverage rate by means recommend by manufacturer. Apply sufficient product to wet the surface without producing puddles. Use a clean, soft bristle push broom, microfiber pad, or other means recommended by manufacturer to spread the product and ensure uniform wetting, saturation, and penetration of surfaces.

4. If surfaces dry immediately or become sticky, increase rate of application and reapply product. Avoid excess material puddling.

5. Before product dries and cures, immediately clean surfaces not intended to receive application of material.

6. Allow treated surfaces to dry or cure for duration recommended by manufacturer for project conditions.

7. Remove any dried powder residue using stiff broom, power sweeper, automatic scrubbing machine, and/or cleaning agent recommended by manufacturer. Avoid pads or brushes which may damage the floor finish.

8. Once dry, burnish surface using a high-speed burnisher, or polishing pad for use on gloss finishes, to heat and fuse the material bond to increase durability and longevity. Surface temperatures immediately behind the burnisher must achieve 90.5 degrees Fahrenheit.

9. Repeat sealer and stain inhibiter material application and burnishing process between coats as necessary for specified gloss finish. Apply up to three coats maximum.

3.3.4 Testing

1. Test with a properly calibrated abridged goniophotometry device in accordance with ASTM E430.

2. Record results on floor plan diagram. Readings shall be taken not less than ten feet on center in field areas and within one foot of floor area perimeters.

3. Results shall comply with specified system performance and appearance criteria.

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4. Rework areas not in compliance until acceptable results are achieved or otherwise approved by Owner and/or COR.

3.4 CONCRETE EXPANSION JOINTS

After polishing concrete floors, prepare concrete expansion joints indicated on the floor plans by removing all previous grout fillers and damaged or unsound sections of felt. Thoroughly clean surfaces to receive filler of dirt, dust, oil, grease, or other contaminants before applying joint filler. Apply to dry surfaces only for best bonding.

Tape each side of joints to prevent excess spreading of filler material and to provide a cleaner appearance. If the joint is more than one deep, partially fill with closed-cell backer rod. Fill joint and clean excess uncured joint filler from surface with mineral spirits. Tool filler to reduce any differential settlement between slabs.

For this work, use a figure of 700 linear feet total. Priority shall be given to thresholds between bays and areas where forklifts travel across joints.

3.5 PROTECTION, REPAIR, AND CLEANING

A. Provide disposal of slurry, dust, and debris in compliance with applicable codes.

B. Remove debris and spatter from adjoining surfaces as necessary.

C. Repair damages to surface caused by cleaning operation and construction activities.

D. Restrict areas to traffic, cover and provide protection as specified and per manufacturer’s recommendations to prevent damage by other trades during project completion.

E. Protect from elements, sweep, clean, and maintain until project completion and Government’s acceptance of the work.

F. Provide manufacturer's written instructions and recommendations on proper cleaning and maintenance requirements for inclusion in the O&M Manual in accordance with Section 01 78 23 OPERATION AND MAINTENANCE DATA.

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