Loading...
HomeMy WebLinkAboutAPPROVED, Empress - Project Specifications (Permit Package) - 10-18-2021 (SIGNED) Page 1 of 12 CSM Engineering, LLC 208 SW Ocean Boulevard Stuart, Florida 34994 o: 772-220-4601 w: www.CSM-E.net Empress Condominium Association Permit Package – Transformer Room Emergency Repair Located At: Empress Condo 9600 S. Ocean Drive Stuart, FL 34996 Attn: Howard DaCosta e: Empresscondo@bellsouth.net o: 772-229-3003 Charles A. Darden Jr. Florida Registered Professional Engineer #76910 Page 2 of 12 TABLE OF CONTENTS Title Page 1 Table of Contents 2 Scope of Work 3-4 Scope of Work Attachments: Inspection Plan 5 Section 1 - Concrete Repair Specifications 6-8 Section 2 - Corrosion Inhibitor Specifications 9-10 Section 3 - ICRI Standards 11 & Attached Section 4 – Emergency Repair Drawings 12 & Attached Charles A. Darden Jr. Florida Registered Professional Engineer #76910 Page 3 of 12 SCOPE OF WORK CONTRACTOR shall provide all labor, supervision, parts, materials, testing, tools, equipment, utilities, permits, temporary facilities, sanitary facilities, swing stages, and scaffolding, required for completion of the below described WORK in accordance with the applicable drawings, specifications, codes and standards. The WORK to be performed by CONTRACTOR includes: 1) Mobilization: First floor transformer room 2) Protection of Existing Conditions (As required): a) Provide protection systems for existing site exterior components, including vegetation and private property of residents and visitors, which may be damaged as a result of CONTRACTOR’S performance of the WORK. Existing conditions of all site components that are in proximity to the WORK shall be surveyed and documented by CONTRACTOR prior to the commencement of work. 3) Concrete Repairs: a) Investigation and excavation of deteriorated concrete and reinforcing steel shown on the below listed attached Inspection Spreadsheets and Inspection Drawings, and as directed by ENGINEER. Estimated quantities shown on the attachments are subject to revision based on the results of such investigation and excavation. b) Surface preparation of excavated areas. c) Restoration of oxidized reinforcing steel. d) Installation of Sika Galvashield XP+ galvanic sacrificial anodes as directed by ENGINEER. e) Patching and/or placement of concrete in the prepared areas to match adjoining surfaces. 4) Waterproofing System (As required): a) Apply corrosion inhibitor over the repaired concrete deck and edge on walkways and balconies that are not enclosed within a weather tight system. b) In locations specified by ENGINEER, install Sika Sikalastic, STO Decocoat, or BASF MasterSeal (formally Sonoguard) waterproofing system consisting of primer, base coat and top coat (aggregate and backroll) in accordance with manufacturer’s specifications. 5) Stucco Repairs (As required): a) Prepare all damaged stucco surfaces and apply stucco finish to match existing adjacent stucco surfaces. 6) Painting (As required): a) Preparation and painting (prime coat plus one finish coat) in accordance with the manufacturer’s recommendations of all repair areas and surfaces disturbed by CONTRACTOR to match the existing adjacent finish. 7) Demobilization Page 4 of 12 ATTACHED INSPECTION DRAWINGS Emergency Repair Drawings (Section 4): S-1 Cover Sheet, Map, & Key S-2 – S-2.2 Notes S-3 First Floor Emergency Repair D-1 Typical Shoring Details D-2 Typical Dust Wall Details D-3 – D-4 Concrete Repair Details D-5 Typical Waterproofing Details D-6 – D-6.1 Waterproofing Specifications D-7 Concrete Bag Mix Specification D-8 Concrete Truck Mix Specification D-9 Caulking Specification D-10 Zinc Anode Specification D-11 Steel Protection Specification D-12 Railing Specification ATTACHED SPECIFICATIONS AND DRAWINGS The above WORK shall be performed in accordance with the following attached Specifications and Drawings: Section 1 – Concrete Repair Specifications Section 2 – Corrosion Inhibitor Specifications Section 3 – ICRI Standards Charles A. Darden Jr. Florida Registered Professional Engineer #76910 Page 5 of 12 ENGINEER OF RECORD INSPECTION PLAN GENERAL A. ENGINEER shall review any work underway, as appropriate. All structural repairs, including reinforced concrete repairs at each location require specific engineering inspections and approvals. Non-structural work, such as stucco, overlays, waterproofing, and all non-reinforced concrete placements do not require inspections and approvals at each phase of work but will be subject to ongoing engineering observations and approvals during the work. B. CONTRACTOR shall notify ENGINEER at least 2 business days prior to any required inspection. C. During the onsite inspections, ENGINEER shall review any work underway, regarding work locations, methods, shoring, forms, safety, property protection, concrete placements, proper curing of newly placed concrete, OWNER concerns, or any other items as appropriate. D. CONTRACTOR’s site superintendent shall maintain a set of inspection drawings and spreadsheets marked up to indicate the current work status. Theses shall be available for review by ENGINEER and OWNER upon request. E. ENGINEER shall submit a written report to the Building Department at the end of construction. CONCRETE RESTORATION A. ENGINEER shall identify and mark out all areas to be investigated and / or excavated by contractor prior any excavation being performed. B. EXCAVATION LIMITS: ENGINEER shall inspect and approve, as required, all limits of concrete removal and all steel reinforcement repairs. ENGINEER shall verify contractor measurements and approve or disapprove, as required, all contract chargeable quantities for all repairs. C. APPROVAL TO PLACE CONCRETE: ENGINEER shall inspect all areas prior to concrete placement and give approval, as required, for all concrete placements. ENGINEER shall inspect all prep work, including forms, shoring, safety, steel bar repairs, sheathing installation and any adjustments to excavation limits. D. PLACEMENT OF CONCRETE: All design mix truck placements of concrete require on site engineering and shall be inspected by ENGINEER during placements. Approval of design mix placement based on slump results, environmental conditions, etc. shall be at the discretion of ENGINEER. ENGINEER may also require inspections of bag goods concrete placements. E. FINAL: ENGINEER shall inspect and approve, as required, the completion of all repairs, including any correction or punch list items for each work area as appropriate. ASSOCIATED WORK A. ENGINEER shall approve all removal of existing rail and screen enclosures, exterior and interior glass systems and doors, shutter systems, tile and other floor coverings prior to any removal work being performed. B. ENGINEER, with OWNER’s approval, shall designate the disposition of all building components to be removed prior to its removal. C. CONTRACTOR shall document the condition and functionality of all building components to be removed and reinstalled and ENGINEER shall approve same prior to removal. D. ENGINEER shall inspect the reinstallation of existing building components to verify that it is in accordance with the manufacturer’s recommendations and that the condition and functionality have not been degraded. ENGINEERING APPROVALS A. ENGINEER shall approve all work completed. B. ENGINEER shall approve or disapprove, as required, specifications for all contractor-supplied materials at least 7 days prior to planned material use or placement. C. ENGINEER shall determine any disputes regarding reasonableness of repairs involving structural integrity. CONTRACTOR’S DUTIES 1. The CONTRACTOR is totally responsible for the permit application and all costs, including renewing the permit in a timely manner before expiration, and close-out final, without cost to the Owner. 2. Upon receipt of permit, the CONTRACTOR shall transmit a copy of the permit showing the permit number to the Owner and Engineer of Record for correspondence with the building department. 3. The CONTRACTOR is responsible to request and submit the inspection dates to the building department as needed. 4. The CONTRACTOR is responsible to protect building, driveways, landscaping, and personal property. 5. The CONTRACTOR is to responsible to submit a Project Schedule prior to mobilization. 6. The CONTRACTOR is responsible to submit a revised Project Schedule with each Pay Application. Pay Applications are to be sent electronically to the ENGINEER for approval prior to approval/signing of hardcopy. 7. The CONTRACTOR is responsible to submit supplier lien releases with each Pay Application. END OF SECTION Page 6 of 12 SECTION - 1 CONCRETE REPAIR SPECIFICATIONS PART 1 - GENERAL 1.1 DESCRIPTION OF THE WORK: A The scope of work to be performed under the terms of this contract includes furnishing of all materials, labor, services, utilities, permit fees, supervision, tools and equipment, required or incidental to the demolition, repair and replacement of the deteriorated concrete. The work will include, but is not limited to, the following elements: 1 Demolition, removal and disposal of deteriorated concrete and reinforcing steel as identified by ENGINEER. 2 Surface preparation and installation of repair materials of the deteriorated concrete and reinforcing as identified by ENGINEER. 1.2 SUBMITTALS A Contractor shall submit to ENGINEER for review and acceptance, concrete mix designs, manufacturer’s product information and manufacturer’s installation instructions for all materials specified. B Certification of non-reactivity of all aggregate. 1.3 SITE OBSERVATIONS A Surface preparation of all repair areas shall be observed and accepted by ENGINEER prior to placement of the repair materials. B Concrete surfaces shall be observed and accepted by ENGINEER prior to placement of balcony tile or other finish materials. C Engineer shall be notified a minimum of 24 hours prior to all observations. PART 2 - PRODUCTS 2.1 CONCRETE BAG MIX A MATERIALS 1 USE SIKACRETE 211 SCC Plus REPAIR MIX; STO Products are acceptable upon approval. 2 Water to be clean, clear, fresh water, with no additives. 2.2 ALTERNATE MATERIALS A Acceptance of alternate products and materials shall be considered at the sole discretion of ENGINEER. All repair materials shall be provided by a single manufacturer to the extent possible. PART 3 - EXECUTION 3.1 CONCRETE MIX A Follow instructions from manufacturer. This will be monitored by Engineer. 3.2 CONCRETE TESTING A CONTRACTOR shall perform and maintain records on the composition, quantity, and slump test results for each batch mixed. B CONTRACTOR shall prepare test cylinders and arrange for testing by a certified testing agency as requested by ENGINEER and approved by OWNER. If cylinders pass such tests, the OWNER shall reimburse contactor for cost of testing. 3.3 SHORING A Contractor shall provide jacking, shoring and bracing to accomplish the Work and for all existing structural elements to remain until all structural modifications have been completed and accepted for their intended use. Contractor shall submit shop drawings for jacking, shoring and bracing for approval by ENGINEER prior to commencing shoring work. B Shoring design shall prevent movement of adjacent slab areas from the existing conditions. 3.4 CONCRETE REPAIR A Concrete repairs shall be provided for those areas identified with spalling, deterioration, and unacceptable concrete. B Remove all concrete surface coverings (stucco, decorative coatings, etc) along with loose, spalled, and unsound concrete in the area of the deterioration. Removal shall be performed with small pointed tools rather than wide chisel edges to prevent micro cracking and continued spalling of the concrete which is to remain. C The area of concrete to be removed shall extend along the length of the reinforcing, beyond the limits of the reinforcing deterioration a minimum of 2" into sound concrete. D Concrete shall be removed completely around the reinforcing steel providing a minimum clearance of 3/4" between the reinforcing and the concrete to remain. E Provide a ½" minimum depth saw-cut, perpendicular or slightly undercut to the concrete surface at the limits of the repair to prevent feathering of the patch material. Do not cut any reinforcing, except as accepted by ENGINEER. F Application of repair concrete shall not be less than ½" in depth. G Prepare all concrete surfaces to receive the repair material, including the saw-cut, to achieve a minimum surface profile depth of 3", where possible, with a new fractured aggregate surface to adequately anchor the patch material. H Remove all rust and scaling of the reinforcing thoroughly by media blasting and/or mechanical wire brushing. Page 7 of 12 I Thoroughly clean the exposed concrete surface to receive the patch of all traces of dirt, grease, oil, dust, and other contaminants which may prevent proper bonding of the repair materials. J The prepared concrete surface shall be saturated surface dry (SSD), but free of standing water. Apply a bond coat of slurry, prepared with the repair concrete, with a stiff bristle brush covering all exposed steel and all concrete surface areas. K While scrub coat is still wet, place repair concrete mix design in accordance with ACI 301 in a continuous pour and in accordance with ICRI. 3.5 CURING. A Apply water mist to repaired area (i.e. form work, patches) or burlap or carpet remnants to surface. Misting involves any method to maintain the exposed patch or repair area, in a wet condition to prevent surface cracks and reduce moisture loss during cure. B All concrete shall cure a minimum of 28 days prior to application of any coatings or finishes. C An observation shall be conducted by ENGINEER prior to application of any coatings on the concrete. Any cracks in the repair areas shall be repaired in accordance with the requirements for crack repairs. Repair of cracks shall be at no additional cost to the Owner. 3.6 REPAIR MORTARS A Repair mortars may be used in lieu of ready mix concrete for partial depth repair areas of less than one (1) cubic foot of material and as accepted by ENGINEER. 1 The prepared concrete surface shall be saturated surface dry (SSD), but free of standing water. Apply a scrub coat of slurry prepared from the repair mortar to all surface areas, filling all pores and voids. 2 While scrub coat is still wet, apply acceptable polymer modified cementitious repair compound in maximum lifts of 3" and 1-1/2" for use on vertical and overhead surfaces, respectively. If forms are to be used, depths well in excess of these can be achieved in any one application. For large and/or deep repairs, mechanical anchors, studs, reinforcing dowels, etc., shall be provided where existing reinforcing does not provide mechanical anchorage. The top surface of each lift shall be scratched and reprimed with slurry prior to application of subsequent lifts. 3 The use of aggregate is not allowed except as otherwise recommended by the manufacturer. 4 The following repair mortars may be used: a Sika – Sika Full Depth 211 SCC Plus. STO products acceptable upon Engineer approval. Page 8 of 12 3.7 REINFORCING PREPARATION AND REPLACEMENT A All reinforcing with deterioration of more than 15% of the original bar diameter, as determined by ENGINEER, shall be replaced. B To permit lapping of the new reinforcing steel, the concrete shall be removed along the length of the reinforcing, a minimum of 12" beyond the deterioration into sound concrete to permit splicing of the reinforcing. C After the reinforcing has been prepared, lap the new reinforcing beside the entire length of the exposed reinforcing, secure in place with tie wires. D Following all other procedures for the concrete repair as indicated. E Where the removal of concrete to achieve the required lap length is not practical as determined by ENGINEER, bar development can be achieved by embedding the reinforcing into existing sound concrete a minimum of 9" with: 1 Sika – Sikadur 32 (Preferred) 2 BASF - Concresive 1090 Liquid F Reinforcing steel shall be ASTM A615 grade 60 minimum. G Prime reinforcing steel prior to concrete placement with: 1 Sika – Armatec 110 EpoChem (Preferred) 2 BASF - EMACO P-24 3 BASF – Zincrich Rebar Primer 3.8 CRACK REPAIR A Crack repairs will be performed for all areas identified by ENGINEER. B Remove all loose and unsound concrete within and adjacent to the crack. C For all topside horizontal cracks, vee-notch the surface of the crack with a mechanical router or hand chipping tool to a maximum width of ¼". Remove loose debris. Substrate may be dry or damp prior to product application. Where accessibility to the underside of the concrete slab is available, seal all visible cracks with an epoxy resin adhesive paste or Portland cement-based quick setting compound to act as a dam to hold the liquid epoxy resin adhesive until cured. D Prime prepared substrate with neat Sikadur 35, Hi-Mod LV epoxy resin mortar. Strike off and level, finishing with a trowel. E Seal cured epoxy resin mortar with epoxy resin adhesive binder to provide additional moisture and chemical protection. F Maximum application thickness of epoxy resin mortar on interior substrates not to exceed 1½" per lift. G Use pressure injection equipment to seal cracks on underside and vertical faces of concrete beams, columns and corbels with: 1 EUCO 452 M.V. Epoxy System or 2 Sikadur 35, Hi-Mod LV epoxy resin mortar or 3 Seal ports and cracks with Sikadur 31, Hi-Mod Gel, or Sikadur 33 or 4 Simpson Strong Tie ETI Epoxy Injection System 3.9 SURFACE APPLIED CORROSION INHIBITOR A Apply Sika Ferrogard 903 in accordance with SECTION 2 to 28 day cured, exposed concrete surfaces identified by ENGINEER. END OF SECTION 1 Page 9 of 12 SECTION - 2 CORROSION INHIBITOR TREATMENT SPECIFICATIONS PART 1 - GENERAL 1.1 SUMMARY A Section Includes: 1 Surface applied concrete steel reinforcement corrosion inhibitor: 2 Extended written warranty. 1.2 SUBMITTALS A Substitution requests must be submitted 14 day prior to bid date. B Product Data: Manufacturer’s specifications and technical data including the following: 1 Detailed specification of construction and fabrication. 2 Manufacturer’s installation instructions. 3 Certified test reports indicating compliance with performance requirements specified herein. C Quality Control Submittals: 1 Statement of qualifications. 2 Statement of compliance with Regulatory Requirements. 3 Manufacturer’s field reports. 1.3 QUALITY ASSURANCE A Manufacturer’s Qualification: Not less than 5 years experience in the actual production of specified products. B Installer’s Qualifications: Firm experienced in installation or application of systems similar in complexity to those required for this Project, plus the following: 1 Acceptable to or licensed by manufacturer. 2 Not less than 3 years experience with systems. 3 Successfully completed not less than 5 comparable scale projects using this system. C Product Qualifications: The corrosion inhibitor shall conform to the following characteristics: 1 Color: Slightly amber (fugitive dye may be added) 2 Density: 7.3 to 7.4 lbs/gallon 3 Nitrite content: less than 1% 4 Chloride content: less than 20 ppm 5 pH: 6.5 to 8 6 Material must reduce total corrosion of heavily corroding concrete rebar by an average of 90%, at an internal concrete relative humidity of 75% or greater. 7 Must reduce corrosion by 90% or greater using FHWA RD-98-153 test protocol on crack slab black bars subjected to 48 weeks of cyclic salt water ponding. 8 Must increase the resistance of chloride ions using AASHTO T277 “Rapid Determination of the Chloride Permeability of Concrete” by 90% minimum. 9 Note: A qualified independent laboratory must perform all corrosion and chloride data. D Regulatory Requirements: Products shall comply with State and local regulations regarding Volatile Organic Content (VOC). 1.4 DELIVERY STORAGE AND HANDLING A Packing and Shipping: Deliver products in original unopened packaging with legible manufacturer’s identification. B Storage and Protection: Comply with manufacturer’s recommendations. 1.5 PROJECT CONDITIONS A Environmental Requirements: 1 Maintain ambient temperature above 40 degrees F during and 24 hours after installation. 2 Do not proceed with application on materials if ice or frost is covering the substrate. 3 Do not proceed with application if ambient temperature of surface exceeds 100 degree F. 4 Do not proceed with the application of materials in rainy conditions or if heavy rain is anticipated with 4 hours after application. Page 10 of 12 1.6 SPECIAL WARRANTIES A The system manufacturer shall furnish the Owner a written single source performance warranty that the concrete reinforcement corrosion inhibitor will be free of defects related to workmanship or material deficiency for a ten (10) year period from the date of completion of the work provided under this section of the specification. The following performance standards shall be specifically covered under the warranty: Using a device which employs linear polarization with a guard ring (device should be certified under SHRP) the corrosion current of the treated concrete shall be less then 0.5 µA/cm2 for the life of the warranty period. B The Corrosion Inhibitor Manufacturer shall be responsible for providing labor and material to retreat areas of the structure that does not comply with the warranty requirements. PART 2 - PRODUCTS 2.1 MATERIALS A Inhibitor shall be ready-to-use, non-water-borne, surface applied product manufactured in an ISO 9002 certified facility, meeting or exceeding the physical and performance characteristics of the following approved product: 1 Sika Ferrogard 903 (Penetrating, corrosion inhibiting, impregnation coating for hardened concrete). PART 3 - EXECUTION 3.1 EXAMINATION A Verification of Conditions: Examine areas and conditions under which Work is to be performed and identify conditions detrimental to proper or timely completion. 1 Do not proceed until unsatisfactory conditions have been corrected. 3.2 PREPARATION A Protection: 1 Unless inhibitor does not affect adhesion of sealants, paints and patching materials all adjacent surfaces shall be protected as necessary in accordance with the manufacturer’s recommendations. 2 Follow the manufacturer’s recommendations regarding condition of concrete surfaces before, during and after application. B Surface Preparation: 1 All caulking, joint sealants, repairing, and patching of concrete surfaces shall be installed and cured before application of inhibitor. If specified by ENGINEER, apply corrosion inhibitor to routed cracks prior to application of sealant. Confirm with Inhibitor Manufacturer compatibility of materials. 2 Prior to application of corrosion inhibitor, concrete surfaces shall be dry and cleaned of all dust, dirt, debris, grease, oil, grout, mortar, and other foreign matter. Concrete patches and all existing surfaces shall be prepared as recommended by the corrosion inhibitor manufacturer and acceptable to ENGINEER. 3.3 FIELD QUALITY CONTROL A Test Applications: Before application of inhibitor will be accepted, a test panel will be applied to the concrete to verify performance under the warranty provisions. 3.4 APPLICATION A Product shall be applied as supplied by the manufacturer without dilution or alteration. B Corrosion inhibitor shall be applied in accordance with the use of either spray, brush, or roller as per manufacturer’s recommendations. Corrosion inhibitor shall be applied at a net coverage rate of 75-100 ft2/gallon, in two or three equal coats, with a minimum one hour dry time between coats. C Follow manufacturer’s recommendations concerning protection of glass, metal and other non-porous substrates. Contractor will be responsible to clean all surfaces that are contaminated by the corrosion inhibitor. D Follow manufacturer’s recommendation concerning protection of plants, grass and other vegetation. Contractor will be responsible for replacing all plants, grass or vegetation damaged by the corrosion inhibitor. 3.5 CLEANING A As Work Progresses: Clean spillage and overspray from adjacent surfaces using materials and methods as recommended by corrosion inhibitor manufacturer. B Remove protective coverings from adjacent surfaces when no longer needed. 3.6 COMPLETION A Work that does not conform to ENGINEER’s specifications shall be corrected and/or replaced as directed by the Owners Representative at the contractor’s expense without extension of time. END OF SECTION 2 Page 11 of 12 SECTION - 3 ICRI Standards See attached Product Data Sheets. GUIDELINES TECHNICAL Prepared by the International Concrete Repair Institute December 2008 Guideline No. 310.1R–2008 (formerly No. 03730) Copyright © 2008 International Concrete Repair Institute Guide for Surface Preparation for the Repair of Deteriorated Concrete Resulting from Reinforcing Steel Corrosion 310.1R–2008 GuIDe foR SuRfaCe PRePaRatIon foR the RePaIR of DeteRIoRateD ConCRete ReSultInG fRom ReInfoRCInG Steel CoRRoSIon About ICRI Guidelines The International Concrete Repair Institute (ICRI) was founded to improve the durability of concrete repair and enhance its value for structure owners. The identification, development, and promotion of the most promising methods and materials are primary vehicles for accelerating advances in repair technology. Working through a variety of forums, ICRI members have the opportunity to address these issues and to directly contribute to improving the practice of concrete repair. A principal component of this effort is to make carefully selected information on important repair subjects readily accessible to decision makers. During the past several decades, much has been reported in the literature on concrete repair methodsandmaterialsas they havebeendeveloped and refined. Nevertheless, it has been difficult to find critically reviewed information on the state of the art condensed into easy-to-use formats. To that end, ICRI guidelines are prepared by sanctioned task groups and approved by the ICRI Technical Activities Committee. Each guideline is designed to address a specific area of practice recognized as essential to the achievement of durable repairs. All ICRI guideline documents are subject to continual review by the membership and may be revised as approved by the Technical Activities Committee. Technical Activities Committee Kevin Michols, Chair Jim McDonald, Secretary Randy Beard Don Caple Bruce Collins William “Bud” Earley Don Ford Tim Gillespie Peter Golter Peter Lipphardt David Rodler Michael Tabassi David Whitmore Pat Winkler Producers of this Guideline Surface Preparation Committee Pat Winkler, Chair* Dan Anagnos Randy Beard Bruce Collins William “Bud” Earley Peter Emmons* Andrew Fulkerson Randy Glover Fred Goodwin* Kurt Gottinger Tyson Herman Dave Homerding Bob Johnson David Karins Ken Lozen* Jim McDonald Beth Newbold Jeffery Smith Sandra Sprouts Rick Toman Patrick Watson *Contributing editors Synopsis This guideline provides guidance on concrete removal and surface preparation procedures for the repair of deteriorated concrete caused by reinforcing steel corrosion. Removal geometry, configuration of the repair area, removal process, edge preparation, reinforcement repair, surface preparation and inspection necessary for durable repairs are discussed. Special considerations for concrete removal associated with column repair are included. Keywords anodic ring effect, bonding, bruising, corrosion, delamination, deterioration, reinforcing steel, structural repair, surface preparation. This document is intended as a voluntary guideline for the owner, design professional, and concrete repair contractor. It is not intended to relieve the professional engineer or designer of any responsibility for the specification of concrete repair methods, materials, or practices. While we believe the information contained herein represents the proper means to achieve quality results, the International Concrete Repair Institute must disclaim any liability or responsibility to those who may choose to rely on all or any part of this guideline. GuIDe foR SuRfaCe PRePaRatIon foR the RePaIR of DeteRIoRateD ConCRete ReSultInG fRom ReInfoRCInG Steel CoRRoSIon 310.1R–2008 Contents 1.0 Introduction ............................................................................................................................ 1 2.0 Definitions .............................................................................................................................. 1 3.0 Exposure of Reinforcing Steel ................................................................................................. 1 4.0 Anodic Ring (Halo) Effect........................................................................................................ 2 5.0 Removal Geometry ................................................................................................................. 2 6.0 Configuration of Repair Area .................................................................................................. 3 7.0 Concrete Removal/Surface Preparation ................................................................. 3 7.1 exposing and undercutting of Reinforcing Steel .................................................................. 3 7.2 Preparation of the Repair Perimeter ................................................................................... 4 7.3 Cleaning of the Concrete Surface and Reinforcing Steel ..................................................... 4 8.0 Inspection and Repair of Reinforcing Steel ............................................................................. 5 9.0 Final Surface Inspection ......................................................................................................... 5 10.0 Special Conditions at Columns ............................................................................................... 6 11.0 Summary ................................................................................................................................ 7 12.0 References .............................................................................................................. 7 12.1 Referenced Standards and Reports ................................................................................... 7 GuIDe foR SuRfaCe PRePaRatIon foR the RePaIR of DeteRIoRateD ConCRete ReSultInG fRom ReInfoRCInG Steel CoRRoSIon 310.1R–2008 - 1 1.0 Introduction This guideline provides owners, design profes- sionals, contractors, and other interested parties with a recommended practice for the removal of deteriorated concrete caused by the corrosion of reinforcing steel, including the preparation of the removal cavity to provide a clean sound surface to bond a repair material. This guideline outlines removal geometry, configuration, removal process, edge preparation, reinforcement repair, surface preparation, and inspection prior to placing a repair material. An engineer should evaluate the impact of concrete removal on structural capacity prior to performing concrete removal and repair. The repair methods involve saw cutting and concrete removal using impact tools, hydrodemolition, and other removal techniques. Special caution should be taken to locate and avoid cutting or damaging embedded reinforcing bars, prestressing strands, post- tensioning tendons, or electrical conduits. Cutting into these items can be life threatening and may significantly affect structural integrity. This guideline also contains a discussion of concrete removal and preparation for the repair of columns where the concrete is in compression. Special consideration must be given to the repair of concrete in compression as the load-carrying capacity of the element may be permanently compromised during the concrete removal and preparation process. While the procedures outlined herein have been used to successfully remove concrete and prepare the removal cavity on many projects, the requirements for each project will vary due to many different factors. Each project should be evaluated individually to ascertain the applicability of the procedures described herein. Refer to ACI 506R-05, “Guide to Shotcrete” for surface prepar- ation prior to shotcrete application. 2.0 Definitions Anodic ring effect: Corrosion process in which the steel reinforcement in the concrete surrounding a repaired area begins to corrode preferentially to the steel reinforcement in the newly repaired area (sometimes referred to as the halo effect). Bruised surface (micro-fracturing): Asurface layer weakened by interconnected microcracks in concrete substrates caused by the use of high- impact, mechanical methods for concrete removal, and surface preparation; fractured layer typically extends to a depth of 0.13 to 0.38 in. (3 to 10 mm) and, if not removed, frequently results in lower bond strengths as compared with surfaces prepared with nonimpact methods. Carbonation: The conversion of calcium ions in hardened cementitious materials to calcium carbonate by reaction with atmospheric carbon dioxide. Carbonation reduces the pH of the concrete and its ability to protect reinforcing steel and embedded metal items from corrosion. Chloride contamination: Contamination of concrete with chloride ions commonly used in deicing salts and accelerating admixtures such as calcium chloride and sodium chloride. Chloride contamination above the threshold for corrosion can result in corrosion of the reinforcing steel. Chloride threshold: The amount of chloride required to initiate steel corrosion in reinforced concrete under a given set of exposure conditions; commonly expressed in percent of chloride ion by mass of cement. Corrosion: Degradation of concrete or steel reinforcement caused by electrochemical or chemical attack. Microcrack: Acrack too small to be seen with the unaided eye. Tensile pulloff test: A test to determine the unit stress, applied in direct tension, required to separate a hardened repair material from the existing concrete substrate. The test may also be used to determine the maximum unit stress that the existing concrete substrate is capable of resisting under axial tensile loading and the near- surface tensile strength of a prepared surface (refer to ICRI Technical Guideline No. 210.3– 2004 [formerly No. 03739] and ASTM C1583). Substrate: The layer immediately under a layer of different material to which it is typically bonded; an existing concrete surface that receives an overlay, partial-depth repair, protective coating, or some other maintenance or repair procedure. 3.0 Exposure of Reinforcing Steel The practice of completely removing the concrete (undercutting) from around the corroded reinforcement, no matter what degree of corrosion is found, is keytoachievinglong-termperformance of surface repairs. In most cases, complete removal of the concrete from around the reinforcing steel is the best practice, where protection of the reinforcing steel within the 2 - 310.1R–2008 GuIDe foR SuRfaCe PRePaRatIon foR the RePaIR of DeteRIoRateD ConCRete ReSultInG fRom ReInfoRCInG Steel CoRRoSIon repair cavity is achieved by providing a uniform chemical environment around the reinforcing steel. If noncorroded reinforcing steel is exposed and the concrete is chloride contaminated, removal of the concrete around the reinforcing should occur or other corrosion-reducing means should be considered. Reinforcing steel partially embedded in chloride-contaminated concrete is susceptible to future accelerated corrosion. If, for structural reasons, the concrete cannot be completely removed from around the corroded reinforcing steel or if a corrosion inhibiting system is not used, the repair may be compromised due to continued corrosion. If there is a potential trade-off between durability and structural capacity, structural capacity should always take priority. When reinforcing steel is not fully exposed through the concrete removal and preparation process, alternative corrosion inhib- iting systems should be considered. These systems may include use of corrosion inhibitors, sacrificial anodes, or cathodic protection. 4.0 Anodic Ring (Halo) Effect The existing concrete surrounding a repair area in chloride-contaminated or low pH reinforced concrete is susceptible to accelerated corrosion. This is due to the electrical potential differential between the chloride contaminated or low pH existing concrete and the chloride-free or high pH repair material. This anodic ring effect can result in accelerated corrosion of the surrounding reinforcing steel leading to future concrete deterioration. To assess existing concrete conditions beyond the repair area, chloride content and pH of the concrete at the level of the reinforcing steel should be determined. Where the chloride content exceeds the threshold level for the initiation of corrosion or where the reinforcing steel is susceptible to corrosion as a result of carbonation, a corrosion inhibiting system should be considered to minimize future corrosion. Other measures may also be considered, such as the application of sealers and coatings, to slow the corrosion process. In severely chloride- contaminated or carbonated concrete, the complete removal and replacement of the contaminated concrete at and beyond the repair area may be necessary to provide a successful long-term repair. 5.0 Removal Geometry Examples of the removal geometry for several different types of reinforced concrete elements are shown in Fig. 5.1 through 5.6. Repairs may be located on horizontal, vertical, and/or overhead surfaces. The removal in Fig. 5.5 and 5.6 is for columns where the removal will not affect the structural capacity of the column. Removal of concrete within the reinforcing or to expose the reinforcing (concrete in compression) is a special condition and is discussed in Section 10. Fig. 5.1: Partial depth repair, slab or wall, section Fig. 5.2: Full depth repair, slab or wall, section GuIDe foR SuRfaCe PRePaRatIon foR the RePaIR of DeteRIoRateD ConCRete ReSultInG fRom ReInfoRCInG Steel CoRRoSIon 310.1R–2008 - 3 Fig. 5.3: Beam or rib repair, elevation Fig. 5.4: Beam or rib repair, section Fig. 5.5: Column repair, elevation Fig. 5.6: Column repair, section 6.0 Configuration of Repair Area Deteriorated and delaminated concrete should be located and marked prior to starting the removal process. Delaminated concrete can be located using sounding or other suitable techniques. The repair area should extend a minimum of 6 in. (152 mm) beyond the actual delaminated concrete. Note that during concrete removal, repair areas can grow in size beyond the areas identified due to incipient delaminations that are not readily identifiable by sounding. Repair configurations should be kept as simple as possible, preferably square or rectangular with square corners (Fig. 6.1). This may result in the removal of sound concrete. Reentrant corners should be minimized or avoided, as they are susceptible to cracking. Fig. 6.1: Areas of deterioration and recommended removal configurations 7.0 Concrete Removal/Surface Preparation 7.1 Exposing and Undercutting of Reinforcing Steel Remove concrete from the marked areas and undercut exposed reinforcing steel (Fig. 7.1) using impact breakers, hydrodemolition, or another suitable method. Undercutting will provide clearance under the reinforcing steel for cleaning and full bar circumference bonding to the repair material and the surrounding concrete. Bonding 4 - 310.1R–2008 GuIDe foR SuRfaCe PRePaRatIon foR the RePaIR of DeteRIoRateD ConCRete ReSultInG fRom ReInfoRCInG Steel CoRRoSIon the repair material to the full circumference of the reinforcing steel will secure the repair structurally. Provide a minimum of 0.75 in. (19 mm) clearance between exposed reinforcing steel and surrounding concrete or 0.25 in. (6 mm) larger than the coarse aggregate in the repair material, whichever is greater. Sound concrete may have to be removed to provide proper clearance around the reinforcing steel. If impact breakers are used for partial depth concrete removal, the breaker should not exceed 30 lb (12 kg). A 15 lb (7 kg) breaker is preferred Fig. 7.1: Remove concrete to undercut and expose reinforcing steel and provide uniform repair depth Fig. 7.2: Saw cut perimeter to provide vertical edge Fig. 7.3: Abrasive blasting to clean substrate and reinforcing to minimize damage to the substrate, reinforcing steel, and surrounding concrete. Concrete removal should extend along the reinforcing steel until there is no further delam- ination, cracking, or significant corrosion and the reinforcing steel is well bonded to the surrounding concrete. Care should be taken to avoid significant and sudden changes in the depth of concrete removal, as the repair material is more susceptible to cracking at these locations. If noncorroded reinforcing steel is exposed during the removal process, care should be taken to not damage the bond to the surrounding concrete. If the bond between the reinforcing steel and concrete is broken, undercutting of the reinforcing steel is required. Remove all deteriorated concrete and additional concrete as required to provide the proper configuration and/or the minimum required thickness of repair material as required by the manufacturer of the repair material and/or the project specifications. 7.2 Preparation of the Repair Perimeter The perimeter of the repair area should be saw cut 0.75 in. (19 mm) deep to provide a vertical edge (Fig. 7.2) for the repair material. This will avoid featheredging of the repair material. Depending on the repair material selected, the depth of the existing reinforcing and the manufacturer’s recommendations, a saw cut depth less than 0.75 in. (19 mm) deep may be sufficient. Care should be taken to avoid cutting the existing reinforcing steel. 7.3 Cleaning of the Concrete Surface and Reinforcing Steel The use of high-impact, mechanical methods to remove deteriorated concrete will result in a surface layer weakened by interconnected micro- cracks in the concrete substrate. The fractured (bruised) layer can extend to a depth of 0.125 to 0.375 in. (3 to 10 mm) into the resultant concrete substrate and may result in reduced bond strength. Remove the bruised layer and bond-inhibiting materials such as dirt, concrete slurry, and loosely bonded concrete by oil-free abrasive blasting (Fig. 7.3) or high-pressure water blasting. The GuIDe foR SuRfaCe PRePaRatIon foR the RePaIR of DeteRIoRateD ConCRete ReSultInG fRom ReInfoRCInG Steel CoRRoSIon 310.1R–2008 - 5 saw-cut edge of the repair area should also be blasted to roughen the polished vertical surface caused by the saw-cutting. All concrete, corrosion products, and scale should be removed from the reinforcing steel by oil-free abrasive blasting or high-pressure water blasting. Verify that the reinforcing steel and concrete surface are free from dirt, oil, cement fines (slurry), or any material that may interfere with the bond of the repair material. Inspect the repair cavity to verify that all delaminations and deterioration have been removed. If hydro- demolition is used, cement fines (slurry) must be completely removed from the repair surface. A tightly-bonded light rust build-up on the reinforcing surface is usually not detrimental to bond. If a protective coating is applied to the reinforcing steel, follow the coating manufacturer’s recom- mendations for steel surface preparation. 8.0 Inspection and Repair of Reinforcing Steel Loose reinforcement should be secured in its original position by tying to secure bars or by other appropriate methods to prevent movement during placement of repair material. If reinforcing steel has lost cross-sectional area, a structural engineer should be consulted. Repair reinforcing steel by either replacing the damaged/deteriorated steel or placing supple- mental reinforcing steel in the affected section (Fig. 8.1). Supplemental reinforcing steel may be lap-spliced or mechanically spliced to existing reinforcing steel. The supplemental reinforcing steel should extend (lap length) beyond the damaged/deteriorated area in accordance with ACI 318, “Building Code Requirements for Structural Concrete.” 9.0 Final Surface Inspection Immediately prior to placing the repair material, inspect the repair cavity to verify that all bond- inhibiting materials (dirt, concrete slurry, loosely bonded aggregates, or any material that may interfere with the bond of the repair material to the existing concrete) have been removed. If bond- inhibiting materials are present, the repair cavity should be recleaned as previously described. To verify the adequacy of the prepared concrete surface and completeness of bond- inhibiting material removal, a tensile pulloff test (ICRI Technical Guideline No. 210.3–2004 or ASTM C1583) should be considered to evaluate the bond strength capacity and tensile strength of the existing concrete substrate. This test may also be performed after the repair is complete. The pulloff strength requirement should be established by the engineer and included as a performance specification for the repair. Fig. 8.1: Repair of damaged/deteriorated reinforcing 6 - 310.1R–2008 GuIDe foR SuRfaCe PRePaRatIon foR the RePaIR of DeteRIoRateD ConCRete ReSultInG fRom ReInfoRCInG Steel CoRRoSIon 10.0 Special Condition at Columns Fig. 10.1: Column load path Fig. 10.2a: Column repair Fig. 10.3: Column load path following repair Fig. 10.2b: Column section GuIDe foR SuRfaCe PRePaRatIon foR the RePaIR of DeteRIoRateD ConCRete ReSultInG fRom ReInfoRCInG Steel CoRRoSIon 310.1R–2008 - 7 Undercutting of reinforcement is a best practice in tensile zones of concrete. In columns, the primary loading condition is compression. From a design perspective, the concrete section contained within the reinforcing cage is considered to carry the compressive loads (Fig. 10.1). The concrete outside of the reinforcement is considered as protective concrete cover for fire and corrosion protection of the reinforcement. Removing the concrete within the column reinforcing steel (Fig. 10.2) can greatly increase the compressive stress in the reinforcing steel and the remaining concrete. Upon concrete removal, compressive load paths redistribute around the repair (deteriorated) sections (Fig. 10.3). Depending on the size of the concrete removal area behind the column steel, buckling of the column vertical reinforcing bars can occur. In the majority of cases, shoring systems will not unload the compressive stress in the column section. When new repair material is placed in the prepared area, the new material cures and most materials undergo drying shrinkage, which results in the new material being put into a tensile stress state. The new material will not carry compressive loads until the original concrete compresses further, forcing the repair material into compression. If further compression is beyond the capacity of the existing concrete, failure of the column may occur. This key concept affects the concrete preparation process. In normal concrete repair (other than columns), removal of the concrete surrounding the corroding reinforcement (also known as undercutting) is a normal and necessary process to provide for a long-term durable repair. To remove concrete around vertical reinforcing steel in a column (removing concrete inside the reinforcing bar cage) can cause the remaining concrete and/or reinforcement in the column to become overstressed. From a structural point of view, this condition may not be desirable. If concrete is to be removed inside the reinforcement cage, a qualified structural engineer should determine the impact of the repair on potential reinforcement buckling and overall structural capacity of the column. Note that the discussion in this section is also applicable in concept to compression zone portions of other structural members such as beams, slabs, and walls (with or without compression reinforcement) where on-going compressive stress exists and where adequate shoring cannot be installed prior to repairs topreventdisplacementsandcorresponding stress redistributions during repairs. 11.0 Summary The repair of deteriorated concrete resulting from reinforcing steel corrosion is necessary to extend the service life of the structure. Performing concrete repairs using industry-best practices will ensure the success and longevity of the repair. Understanding the existing conditions and cause of corrosion will assist the engineer in specifying the type and extent of the repair required, and the type of corrosion mitigation systems and/or preventative measures that should be considered to protect the structure from future deterioration. 12.0 References 12.1 Referenced Standards and Reports The following standards and reports were the latest editions at the time this document was prepared. Because these documents are revised frequently, the reader is advised to contact the proper sponsoring group if it is desired to refer to the latest version. American Concrete Institute (ACI) ACI 506R, “Guide to Shotcrete” ACI E706 (RAP 8), “Installation of Embedded Galvanic Anodes” American Society for Testing and Materials (ASTM International) ASTM C1583, “Standard Test Method for Tensile Strength of Concrete Surfaces and the Bond Strength or Tensile Strength of Concrete Repair and Overlay Materials by Direct Tension (Pull- off Method)” International Concrete Repair Institute (ICRI) ICRI Concrete Repair Terminology ICRI Technical Guideline No. 130.1R–2008 (formerly No. 03735), “Guide for Methods of Measurement and Contract Types for Concrete Repair Work” ICRI Technical Guideline No. 210.3-2004 (formerly No. 03739), “Guide for Using In-Situ Tensile Pull-Off Tests to Evaluate Bond of Concrete Surface Materials” 8 - 310.1R–2008 GuIDe foR SuRfaCe PRePaRatIon foR the RePaIR of DeteRIoRateD ConCRete ReSultInG fRom ReInfoRCInG Steel CoRRoSIon ICRI Technical Guideline No. 310.3–2004 (formerly No. 03737), “Guide for the Preparation of Concrete Surfaces for Repair Using Hydro- demolition Methods” ICRI Technical Guideline No. 320.2R–2008 (formerly No. 03733), “Guide for Selecting and Specifying Materials for Repair of Concrete Surfaces” These publications may be obtained from these organizations: American Concrete Institute 38800 Country Club Drive Farmington Hills, MI 48331 www.concrete.org ASTM International 100 Barr Harbor Drive West Conshohocken, PA 19428 www.astm.org International Concrete Repair Institute 3166 S. River Road, Suite 132 Des Plaines, IL 60018 www.icri.org 3166 S. River Road, Suite 132 Des Plaines, IL 60018 Phone: 847-827-0830 Fax: 847-827-0832 Web site: www.icri.org E-mail: info@icri.org Page 12 of 12 SECTION - 4 Emergency Repair Drawings See attached Drawings & Specifications. ©CSM Engineering, LLC208 SW Ocean BoulevardStuart, Florida 34994772-220-4601www.CSM-E.netCERTIFICATE OF AUTHORIZATION: 29057EMPRESS CONDOMINIUMNEMPRESSKEY:1-2-3-41 - AMOUNT OF DAMAGE2 - LOCATION OF DAMAGE3 - TYPE OF DAMAGE4 - HEIGHT OF DAMAGE (COLUMN AND WALL ONLY)EXAMPLES:LOCATION MAPEMPRESS CONDOPROJECT LOCATIONSHEET DESCRIPTIONESTIMATED DAMAGE ©CSM Engineering, LLC208 SW Ocean BoulevardStuart, Florida 34994772-220-4601www.CSM-E.netCERTIFICATE OF AUTHORIZATION: 29057EMPRESS CONDOMINIUMSTRUCTURAL DESIGN CRITERIA:STRUCTURAL AND MISCELLANEOUS STEEL:CONSTRUCTION SAFETY:BUILDING EXISTING NOTES:DEMO & INSTALLATION:CONSTRUCTION SAFETY: ©CSM Engineering, LLC208 SW Ocean BoulevardStuart, Florida 34994772-220-4601www.CSM-E.netCERTIFICATE OF AUTHORIZATION: 29057EMPRESS CONDOMINIUMCONCRETE AND REINFORCING STEEL:SHOP DRAWINGS AND FORM WORK PLANS: ©CSM Engineering, LLC208 SW Ocean BoulevardStuart, Florida 34994772-220-4601www.CSM-E.netCERTIFICATE OF AUTHORIZATION: 29057EMPRESS CONDOMINIUM ©CSM Engineering, LLC208 SW Ocean BoulevardStuart, Florida 34994772-220-4601www.CSM-E.netCERTIFICATE OF AUTHORIZATION: 29057EMPRESS CONDOMINIUMFIRST FLOOR LAYOUTN FIRST FLOORTRANSFORMERROOMOVERHEAD CONCRETE DAMAGE PHOTOS ©CSM Engineering, LLC208 SW Ocean BoulevardStuart, Florida 34994772-220-4601www.CSM-E.netCERTIFICATE OF AUTHORIZATION: 29057EMPRESS CONDOMINIUM ©CSM Engineering, LLC208 SW Ocean BoulevardStuart, Florida 34994772-220-4601www.CSM-E.netCERTIFICATE OF AUTHORIZATION: 29057EMPRESS CONDOMINIUM ©CSM Engineering, LLC208 SW Ocean BoulevardStuart, Florida 34994772-220-4601www.CSM-E.netCERTIFICATE OF AUTHORIZATION: 29057EMPRESS CONDOMINIUM ©CSM Engineering, LLC208 SW Ocean BoulevardStuart, Florida 34994772-220-4601www.CSM-E.netCERTIFICATE OF AUTHORIZATION: 29057EMPRESS CONDOMINIUM ENLARGED SECTION DETAILWATERPROOFING SECTIONWATERPROOFING - PLAN VIEW©CSM Engineering, LLC208 SW Ocean BoulevardStuart, Florida 34994772-220-4601www.CSM-E.netCERTIFICATE OF AUTHORIZATION: 29057EMPRESS CONDOMINIUM ©CSM Engineering, LLC208 SW Ocean BoulevardStuart, Florida 34994772-220-4601www.CSM-E.netCERTIFICATE OF AUTHORIZATION: 29057EMPRESS CONDOMINIUM ©CSM Engineering, LLC208 SW Ocean BoulevardStuart, Florida 34994772-220-4601www.CSM-E.netCERTIFICATE OF AUTHORIZATION: 29057EMPRESS CONDOMINIUMOverlay SpecificationWaterproofing Sealer Specification ©CSM Engineering, LLC208 SW Ocean BoulevardStuart, Florida 34994772-220-4601www.CSM-E.netCERTIFICATE OF AUTHORIZATION: 29057EMPRESS CONDOMINIUM ©CSM Engineering, LLC208 SW Ocean BoulevardStuart, Florida 34994772-220-4601www.CSM-E.netCERTIFICATE OF AUTHORIZATION: 29057EMPRESS CONDOMINIUM ©CSM Engineering, LLC208 SW Ocean BoulevardStuart, Florida 34994772-220-4601www.CSM-E.netCERTIFICATE OF AUTHORIZATION: 29057EMPRESS CONDOMINIUM ©CSM Engineering, LLC208 SW Ocean BoulevardStuart, Florida 34994772-220-4601www.CSM-E.netCERTIFICATE OF AUTHORIZATION: 29057EMPRESS CONDOMINIUM ©CSM Engineering, LLC208 SW Ocean BoulevardStuart, Florida 34994772-220-4601www.CSM-E.netCERTIFICATE OF AUTHORIZATION: 29057EMPRESS CONDOMINIUM ©CSM Engineering, LLC208 SW Ocean BoulevardStuart, Florida 34994772-220-4601www.CSM-E.netCERTIFICATE OF AUTHORIZATION: 29057EMPRESS CONDOMINIUMANCHOR REPLACEMENT PLAN VIEWANCHOR WITH WASHERSANCHOR REPLACEMENT SECTION