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CSM ENGINEERING, LLC 208 SW OCEAN BOULEVARD STUART, FL13RIDA 34994 o: 772-220-4601 E N G I N E E R I N G w: W W W C S M-E.N ET CIVIL STRUCTURAL • MARINE GRAND ISLES CONDOMINIUM PERMIT PACKAGE z I - F N f e r s i. 111 Ill Located At: Grand Isles 3702 North AlA Fort Pierce, Florida 34949 Prepared For: Board of Directors Inspected On: July 2018 GEIV • ' . No 76 10 Q STATE. .F^ FILE COPY 'N' 14 jL� �% I ',- 01 C6 41 r I ' - Charles A. Darden Jr. Florida Registered Professional Engine 1 910 TABLE OF CONTENTS Title Page Page 1 Table of Contents Page 2 Scope of Work Page 3-4 Scope of Work Attachments: Inspection Plan Page 5 Section 1 -Concrete Repair Specifications Page 6-8 Section 2-Corrosion Inhibitor Specifications Page 9-10 Section 3-Waterproofing System Specifications Page 11&Attached Section 4-Steel Reinforcement Protection Specifications Page 12&Attached Section 5-Sacrificial Anode Specifications Page 13&Attached Section 6-ICRI Standards Page 14&Attached Restoration Location Drawings: Unit 1002 Restoration Location Drawings Attached pages 11 Key Notes and location map S-1.1 Notes S-1.2 Notes S-1.3 Notes S-1.4 Notes S-2 Plan View S-3 Elevation View S-4 Unit 1002 D-1 Details D-2 Details D-3 Details D-4 Details D-5 Details .� A. DqR No.76910 -_- ='U x STATE OF i COR1D, � NAL At Ir I\ Charles A. Darden Jr. Florida Registered Professional Engine 76910 C i 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 2) Protection of Existing Conditions: 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) Railings and Screen, Shutter Systems, Sliding Glass Doors,Doors and Windows: a) Removal, protected storage and reinstallation of existing railings and screens, shutter systems, sliding glass doors,doors and windows as required for the WORK and as directed by ENGINEER. Where possible,the existing enclosures shall be left in place,rather than removed. b) All permanently installed fastener materials shall be stainless steel and shall be approved by ENGINEER. c) ,Removal and disposal of existing railings and screens, shutter systems, sliding glass doors, doors and windows as required for the WORK and as directed by ENGINEER. 4) Dust Walls: a) Installation, maintenance and removal of Dust walls and protection systems for exposed building interior spaces and surfaces as directed by ENGINEER. 5) Tile Removal: a) Removal and disposal of existing tile and other floor finishes,including adhesives,as required for the WORK and as directed by ENGINEER. 6) 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. 7) Waterproofing System: a) Apply 2 coats of Redgard in accordance with manufacturer's specifications. 8) Stucco Repairs: a) Prepare all damaged stucco surfaces and apply stucco finish to match existing adjacent stucco surfaces. 9) Painting: 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. 10) Demobilization REFERENCED CODES AND STANDARDS The latest guidelines,recommendations and requirements of the following entities shall govern all work,workmanship and materials as they apply: UL—Underwriters Laboratories ASTM—American Society of Testing Materials ACI—American Concrete Institute FBC—Florida Building Code ICBO—International Conference of Building Officials ICRI—International Concrete Restoration Institute INSPECTION PLAN CONTRACTOR shall coordinate the above WORK with ENGINEER and OWNER. All designated repairs to be investigated and/or excavated shall be identified and marked out by ENGINEER prior to any excavation being performed. The attached Inspection Plan defines the requirements for inspection of CONTRACTOR'S work by ENGINEER. SCHEDULE CONTRACTOR shall provide sufficient personnel and other resources to diligently and continuously pursue completion of the WORK in accordance with the attached Schedule. Time is of the essence of this contract. Note: The attached Schedule will be developed later based on successful bidder's proposed schedule. 1! 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 superintendant 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 manor 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 wit the building department. 3. The contractor is responsible to request and submit the inspection dates to the building department as needed. 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. PART2-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 %" 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 Y?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. 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 b ENGINEER prior to application of an coatings on the concrete.An cracks in the Y P PP Y g Y 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. 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 %". 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 1'/z"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 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. 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/cm-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 ft'-/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 SURFACE PREPARATION REDGARD° PRICE WATERPROOFING AND CRACK PREVENTION MEMBRANE ■ Convenient— ready to use ■ Apply by roller, trowel or sprayer ■ Quick Dry Formula — 30% faster drying ■ Elastomeric— Isolates cracks up to 1/8" (3 mm) .a �w PRODUCT DESCRIPTION SURFACE PREPARATION Ready-to-use,elastomeric,waterproofing and crack prevention All exterior and wet areas are to have proper sloping to drains. membrane for all interior or exterior commercial and residential All surfaces must be structurally sound,clean,dry and free tile and stone installations. Easily applied with roller,trowel from contaminants that would prevent a good bond.Newly or sprayer producing a continuous moisture barrier with prepared concrete must be cured 28 days,finished with a steel outstanding adhesion.Reduces crack transmission in ceramic trowel and have a fine broom finish.Existing surfaces should tile or stone floors.Bonds directly to metal drains,PVC, be scarified,level and all defects repaired.Cracks in excess of stainless steel and ABS drain assemblies.Meets ANSI A118.10 1/8"(3 mm)should be treated as expansion joints. for waterproofing membranes and ANSI A118.12 for crack APPLICATION isolation membranes.Meets Uniform Plumbing Code As a Crack Prevention Membrane: specifications for use as a shower pan liner. Listed with IAPMO Force RedGard'into cracks with the flat side of the trowel, R&T,File#4244 UPC',ICC-ES ESR-1413.Can also be used as a slab-on-grade moisture barrier under resilient flooring. roller or brush.Then,using a 3/16"x (5 x 6 mm)V-notch trowel or 3/8"(9.5 mm)rough texturedd roller,generously apply AREAS OF USE additional material onto the substrate and spread with roller.If ■Concrete using a trowel,use the flat side of the trowel and flatten the ■ Backerboards such as WonderBoard®and EasyBoard® ridges to form a continuous,even coat of material.Membrane should extend beyond both sides of the crack a minimum of ■ Exterior grade plywood(interior,dry areas for the diagonal measurement of the tile.Gaps between plywood crack isolation only) sheets and where they meet walls should also be pre-filled ■ Exterior decks with membrane.For continuous crack isolation cover the ■ Gypsum drywall entire substrate with material.Material should be applied at least 30 mils wet film thickness. LIMITATIONS As a Waterproof Membrane: ■ Do not apply to surfaces that may go below 40'F(4°C) All cracks in concrete up to 1/8"(3 mm)should be pre-filled during the first 72 hours after application,over wet surfaces with membrane prior to application. Dampen all porous or surfaces subject to hydrostatic pressure. surfaces.Apply with 3/4"(19 mm)rough-textured synthetic ■ Do not use to bridge or cover over existing expansion, roller or 3/16"x 1/4"(5 x 6 mm)V-notch trowel.If using a control,construction,cold or saw-cut joints. trowel,spread the material with trowel held at a 45°angle then ■ Not for use as an adhesive. flatten the ridges.If using a roller,generously apply RedGard to surface and then spread with roller,applying a continuous, ■ Do not use as a wear surface.Membrane must be covered even film with overlapping strokes.Heavily pre-coat corners with tile. and where floors and walls meet extending it 6"(15 cm)on either side.RedGard that has been applied in accordance with the above instructions meets all the requirements of ANSI A118.10 without fabric reinforcement.For extra protection, embed 6"(15 cm)wide fiberglass mesh into the membrane for changes of plane and gaps 1/8"(3 mm)or greater.If using a trowel,spread the material with trowel held at a 45'angle then flatten the ridges.If using a roller,apply a continuous,even film with overlapping strokes. • CUSTOM® BUILDING PRODUCTS DS109 snOR Alternatively,an airless sprayer can be used.The sprayer ry_t ° WONDERBOARD°BACKERBOARD should produce between 1900 to 2300 psi,with a flow rate of TILE OR NATURAL STONE 1.0 to 1.5 gpm and have a tip orifice size of.025 to.029.Apply SILICONE SEALANT a continuous film with overlapping spray.Initial membrane I ANY CUSTOM` OR CAULK PP 9 POLYBLEND` appearance is pink when wet and dries to a dark red color. ANSI A118.4 GROUT =- ' MOflTAR After the first coat has turned red with no blushing or light ?; pink showing,about 1 to 1-1/2 hours,visually inspect the...- for integrity and fill any voids or pinholes with additional WEEP HOLEs material and apply a second coat at right angles to the first. SLOPED MORTAR BEO VJffH;METAL,LATH CRUSHED STONE Periodically check film thickness with a wet film gauge.For t general waterproofing,the combined dried coating needs to REOGARD"WATERPROOFING,AND be a minimum of 30 mils thick or 60 mils when wet and CRACK PREVENTION MEMBRANE REINFORCED WITH should not exceed 125 mils wet.For shower.pans meeting t FIBROUNDDERGLASS MESH P 9 1 CONCRETE SLAB SLOPED TOWARDS DRAIN AROUND DRAIN IAPMO/ICC requirements,a minimum of47 mils thick or 114"PER FOOT(6.4MM PER 30.5,CM) v 93 mils when wet is required. ,TO PROVIDE POSITIVE DRAINAGE Interior Change of Plane—Commercial Installations: Many commercial waterproofing installations require Drains: reinforcing of interior change of plane.Contact Technical Drains should have a clamping ring with open weep holes for Support prior to beginning any commercial installation for thin-set application.Apply membrane to the bottom flange. review and recommendations.These installations include, Drain should be fully supported without movement and even but are not limited to,the following: with plane of substrate.Apply membrane as outlined under ■All above grade pools,fountains and other poured in place APPLICATION.Embed 12"x 12"(30 x 30 cm)fiberglass mesh or free standing structures that will be required to hold into membrane making sure it does not obstruct the drainage water permanently. hole.Then apply an additional coat of membrane and smooth. After curing,clamp upper flange onto membrane and tighten. ■All commercial floors that are subject to continuous water Caulk around flange where membrane and upper flange make exposure(i.e.commercial kitchens,wash downs,periodic contact with a silicone caulk.A toilet flange can be handled in flooding,etc.) much the same manner. ■All above grade slabs that are either pre-stressed or post SEALANT OR CAULK tensioned. BETWEEN DRAIN ■All perimeters where the floor abuts a curtain or shear wall. STRAINER AND TILE SILICONE CAULK ■Around the perimeter of all through floor penetrations(i.e. TILE OR NATURAL STONE drain pipes,electrical conduit,etc.) Expansion Joints ANY CUSTOM' Do not bridge joints which are designed to experience = ;+::"` ANSI 118.4 MORTAR movement.Carry these types of joints through the tilework. DrainREDGARD WATERPROOFING Clean the joint and install open or closed cell backer rod to AND CRACK PREVENTION the proper depth as outlined in EJ 171 in the Tile Council MEMBRANE Handbook.Next,compress a sealant as specified by the REINFORCED WITH architect into the joint,coating the sides and leaving it flush FIBERGLASS MESH J g 9 CAST IRON GRAIN WITH CLAMPING RING FOR with the surface.After the sealant is dry,place bond breaker THIN-SET APPLICATION WITH WEEP HOLES CONCRETE SLAB SLOPED TOWARDS DRAIN 1/4" tape over joint.Apply a minimum 3/64"(1.2 mm)of RedGard FULLY SUPPORTED PER FOOT(6.4 MM PER over the joint and substrate following the instructions detailed 30.5 CM)TO PROVIDE in APPLICATION.Install the tile work onto the membrane but POSITIVE DRAINAGE do not bridge the joint.After the tile work is set properly, PROTECTION fill the joint with any specified color sealant,following the If tile is not going to be set immediately after curing,RedGard architect's and manufacturer's instructions. should be protected from rain,direct sunlight and inclement weather for 72 hours after application.If delays longer than 72 hours are expected,cover with felt paper.Care should be taken to prevent membrane from becoming soiled or punctured during and after application. TILE INSTALLATION Install tile or stone with a Custom'polymer-modified mortar meeting ANSI A118.4 or A118.11 standards. CURING TECHNICAL DATA The product is dry when it turns solid red with no pink Meets ANSI A118.10 for load-bearing,bonded,waterproof showing,normally 1 to 1-1/2 hours.Depending on ambient membranes for thin-set ceramic tile and dimensional stone conditions,drying time can take up to 12 hours.The applica- installations.Meets ANSI A118.12 for crack isolation tion area can be flood tested when fully cured.This can be as membranes.Meets Uniform Plumbing Code specifications short as 24 hours after the second coat of RedGard is applied for use as a shower pan liner.Listed with IAPMO R Fr T,File if the temperature is greater than 70'F(21'C)and the relative #4244 UPC .ICC-ES ERS-1413.Miami-Dade County Product humidity is low(RH<50%).Colder temperatures and/or higher Control Approved. relative humidity may require longer cure times. HIED G RD- CLEAN-UP WATERPROOFING AND CRAC Clean tools and hands with water before material dries.Clean EM PREVENTION MEMBRANE all spray equipment immediately after use. Pot Life Indefinite COVERAGE f Initial Set,ASTM C191 As a Crack Prevention Membrane @ 70-F(21°C) 1-1-1/2 hours 1 gallon(3.78 L)pail: 110 sq.ft. (10.2 M') Drying Time Before 1-1-1/2 hours at 30 mil thickness when wet €Tile Installation 3.5 gallon (13.2 L)pail: 385 sq.ft.(35.8 Mz) ,'ANSIFungus and and Micro-Organism at 30 mil thickness when wet Resistance(4.2) Passes As a Waterproof Membrane Seam Strength(4.2) 16 lbs./2 inch width 1 gallon(3.78 L)pail: 35-40 sq.ft.(3.25-3.7 Mz) (>7.3 kg/5 cm) at 93 mil thickness when wet,47 mils dry Breaking Strength(4.3) 484 psi (34.0 kg/cm') 3.5 gallon (13.2 L)pail: 123-140 sq.ft.(11.4-13 Mz) Dimensional Stability(4.4) 0.05% at 93 mil thickness when wet,47 mils dry Waterproofness(4.5) Passes STORAGE Shear Strength 12-week dry cure(5,6) 267 psi (18.8 kg/cm') Keep from freezing. 100-day water immersion(5.7) 89 psi (6.3 kg/cml) SAFETY %Elongation ASTM D-638 Wear rubber gloves and eye protection.Avoid eye contact.If 21-day dry cure 562% eye contact occurs,flush with water for 15 minutes and call a s 7-day dry cure/21-day wet cure 657% physician.Wash thoroughly after handling. N Robinson Floor Test 14 cycles KEEP OUT OF REACH OF CHILDREN. ASTM C627 Extra heavy rating DO NOT TAKE INTERNALLY. 1 IAPMO/Uniform Plumbing Code#4244 ORDERING INFORMATION Hydrostatic Pressure 8 Alkali Resistance Passes p Waterproofness Passes ITEM CODE SIZE -COLOR PACKAGE FHA 4900-1-615-5,Sections C B D Compliant USA LQWAFI 1 gallon(3.78 L) Pink Pail i Permeance Rating 0.06 USA LQWAF3 3.5 gallon(13.2 Q Pink Pail Water Vapor Transmission 0.02(grains/hr-sq ft)' j Canada CLQWAFI 1 gallon(3.78 L) Pink Pail Conforms to Wisconsin's performance requirements for Canada CLQWAF3 3.5 gallon(13.2 L) Pink Pail _ "safing material"as required by s.Comm 84.30(6)(f)of the Wisconsin Administrative Code. LIMITED WARRANTY Custom Building Products("Custom")warrants to the original consumer purchaser that its product shall be free from defects in material and workmanship under normal and proper usage for a period of one year following the date of original purchase. Custom's sole liability under this warranty shall be limited to the replacement of the product.Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty will not extend to any product which has been modified in any way or which has not been used in accordance with Custom's printed instructions.Custom makes no other warranties either express or implied.This warranty gives you specific legal rights,and you may have other rights that vary from state to state. CUSTOM® BUILDING PRODUCTS Seal Beach,CA Customer Support 800-272-8786 www.custombuildingproducts.com Manufacturing facilities nationwide. • h Product Data Sheet Edition07/02/2007 Revision no:0 Identification No 01 03 02 01 0010 000001 SikaTop®-Armatec 110 EpoCem® SikaTop°-Armatec 110 EpoCem° Bonding Slurry and Anti-Corrosive Rebar Coating Product Cement-based expoxy-modified three-component anti corrosive coating and Description bonding slurry. Uses As an anti-corrosion coating for reinforcement steel: ■ For repairs to reinforced concrete where there is corrosion of the underlying reinforcement steel ■ For the preventive protection of reinforcement steel in thin reinforced concrete sections As bonding slurry for use on concrete, mortar or steel: ■ For repairs to concrete using SikaTop patching and repair mortars ■ For bonding of new and old concrete Characteristics/ ■ Excellent adhesion to steel and concrete Advantages ■ Acts as an effective barrier against penetration of water and chlorides ■ Contains corrosion inhibitors ■ Provides an excellent bonding coat for subsequent application of repair mortars,cement and epoxy based ■ Pre measured,ready-to-use packs ■ May be spray-applied ■ Frost-and de-icing salt resistant ■ Non-flammable Test certificates LPM, Laboratory for Preparation and Methology, Beinwil am See, Switzerland Ibac Aachen A 3119/3 Product Data Technical Data Colours Mix:Grey Comp.A:White liquid Comp. B: Colourless liquid Comp. C: Dark grey powder Packaging 20 kg units(A+B+C) Storage Storage Conditions Store at temperatures between+5°C and+25*C. Comp. C must be protected from humidity. Shelf life 12 months from date of production if stored properly in unopened original packing. a 1 S1kaTop&Armatec 110 EpoCem® 1/3 Mechanical/Physical Properties Density(+23°C) Comp.A 1.05 kg/I Comp. B 1.03 kg/I Comp.A+B+C 2.00 kg/I(density of slurry when mixed) Bond strength(+23°C) On concrete(sandblasted):2-3 N/mm 2 On steel: 1 -2 N/mm w E-Modulus(static) —16.400 N/mm2 Index of resistance to diffusion of water vapour --700 (NN2O) Index of resistance —40.000 todiffusion of carbon dioxide(NCO2) Thermic coefficient of _18• 10-6 per°C expansion Application Details Mix ratio Parts by weight :A: B: C=1.14:2.86: 16 Parts by volume:A:B: C=1.14:2.86: 10 Pot life(8 kg) 3 hours(at an ambient temperature of+5°C to+30°C) Limitations Min.application temperature(ambient and substrate): +5°C Max.substrate temperature: +30°C The recommended dosage must be strictly adhered to. On no account should water be added to the mix! s; Coverage As an anti-corrosion coating —2 kg/m2for 2 coats,depending on method of application ; As a bonding slung: . c Depending on substrate conditions, not less than 1.5—2.0 kg/m2 Surface preparation Concrete,mortar,stone: Substrate must be clean,sound and free from all traces of loose material,laitance, x . . grease and oil. Min.substrate roughness 2mm Steel. Surface must be clean and free from all traces of grease and oil,rust and mill scale. x Degree of cleaning SA2. Application Instructions Mixing Shake component A and B vigorously before opening. Pour both liquids into a suitable mixing pan and mix for 30 seconds. Add Component C slowly while continuing to stir. Mix mechanically for 3 minutes, using a slow-speed electric stirrer (250 RPM) in order to entrain as little air as possible. Rest for 5—10 minutes, until the mixture exhibits a brushable low-dripping consistency. 2 SikaTop4Armatec 110 EpoCem® 213 Application When used as an anti-corrosion coating Apply a coating of approx. 0.5 — 1 mm thick to the cleaned and derusted reinforcement, using a stiff paintbrush, roller or spray gun. Leave to dry for 2— 3 hours (at an ambient temperature of+20 °C), then apply a second coat of similar thickness. Leave to dry for a similar period of time before applying patching mortar. It is inevitable that the anti-corrosion coating is applied as well on the surrounding concrete;this is by no means a disadvantage. When used as a binding agent for repair mortar or concrete: Wet down the prepared substrate (concrete) to saturated surface dry condition. Then apply a bonding coat not less than 0.5 mm thick, using a paintbrush, roller or suitable spray gun. For best results, work the bonding slurry well into the substrate to ensure complete coverage of all surface irregularities. Apply the freshly mixed patching mortar wet on wet to the bonding slurry. The application of slurry coat or patching mortar or may be applied wet in wet or up to a maximum waiting time of 6 hrs at+30°C 5 hrs at+20°C 4 hrs at+5°C Freshly applied SikaTop-Armatec 110 EpoCem should be protected from pollution and rain until next coat is applied. Cleaning Use water to remove uncured material from tools and mixing equipment. Once cured, SikaTop-Armatec 110 EpoCem can only be removed mechanically. Imported Notes When SikaTop-Armatec 110 EpoCem is used as bonding coat between old and new concrete, it is necessary to install connecting reinforcement for shear strength transfer as per the relevant guide lines. w' Notes All technical data stated in this Product Data Sheet are based on laboratory tests. Actual measured data may vary due to circumstances beyond our control Local Restrictions Please note that as a result of specific local regulations the performance of this product may vary from country to country. Please consult the local Product Data Sheet for the exact description of the application fields. Health and Safety irb For information and advice on the safe handling, storage and disposal of chemical Information products, users should refer to the most recent Material Safety Data Sheet containing physical,ecological,toxicological and other safety-related data. Legal Notes The information, and, in particular,the recommendations relating to the application and end-use of Sika products, are given in good faith based on Sika's current knowledge and experience of the products when properly stored, handled and applied under normal conditions in accordance with Sika's recommendations. In practice,the differences in materials,substrates and actual site conditions are such that no warranty in respect of merchantability or of fitness for a particular purpose, nor any liability arising out of any legal relationship whatsoever, can be inferred either from this information,or from any written recommendations,or from any other advice offered. The user of the product must test the product's suitability for the intended application and purpose. Sika reserves the right to change the properties of its products.The proprietary rights of third parties must be observed. All orders are accepted subject to our current terms of sale and delivery. Users must always refer to the most recent issue of the local Product Data Sheet for the product concerned,copies of which will be supplied on request. Sika Yapr Kimyasallan A.$. gamgesme Mah.Sanayi Cad. .�oar r�C, 34899 Kaynarca Pendik Istanbul TOrkiye t Tel +90 216 494 19 90 ry Li(R-) Faks +90 216 494 19 84 �- " �_ ➢s7LT www.sika.com.tr uA 9UfS5 3 SikaTopQArmatec 110 EpoCem® 3/3 IMBEDDED GALVANIC ANODE 2003 Nova Award Nomination 12 Galvashield® XP Embedded Galvanic Anode Galvashield XP is a patented sacrificial embedded galvanic anode that provides localized galvanic corrosion protec- tion in reinforced concrete structures. The anode consists of a zinc core surrounded by an active cementitious ma- trix. The 63mm diameter x 28mm high embedded anode is quickly and easily fastened to reinforcing steel. Once installed,the zinc core corrodes preferentially to the surrounding rebar,thereby providing galvanic corrosion protec- tion to the reinforcing steel. In the mid 1990s, Vector Corrosion Technologies,through research and development and in partnership with Fos- roc International Limited,a UK company, developed the Galvashield XP embedded anode as a breakthrough in the corrosion protection of concrete structures. The design philosophy behind the Galvashield XP embedded anode was to create a simple product that could be incorporated within a patch repair to minimize ongoing corrosion and extend the life of concrete repairs. Without protection, corrosion continues in the reinforcing steel immediately ad- jacent to the repair and results in premature failure. The anode has been designed to focus protection in the narrow zone directly adjacent to the repair. The size and discrete nature of the anode makes it convenient to install in a wide variety of repairs, and provides the specifier with complete control when targeting the areas that should receive protection. The anode is suitable for large or small repairs; a large repair will simply require the incorporation of multiple anodes. The convenience of the anode makes it a cost effective method of extending galvanic protection to repair scenarios that were not practi- cal just a few years ago. The Galvashield XP embedded anode is a non-hazardous product. Manufactured of common construction materials it is installed simply without complex equipment or processes. Depending upon a project's design parameters the anode will normally operate for a period of 10 to 20 years. Once installed its zinc is converted into a stable,non- hazardous zinc corrosion product. After its service life is complete,the anode remains are dormant and concealed within the concrete,having no maintenance or special disposal requirements. The Galvashield XP embedded anode has been in use in North America since 1998 in a wide variety of applica- tions: deck repairs,joint replacements, pre-stressed and post-tensioned repairs and interface applications between new concrete and existing chloride-contaminated concrete where accelerated corrosion can occur. The anode re- duces on-going corrosion activity and also reduces the effect of ring-anode corrosion commonly associated with concrete patch repairs in reinforced concrete. In order to verify the performance of the Galvashield XP embedded anode,periodic evaluation by various research and education foundations is conducted to provide an unbiased opinion of the effectiveness of this innovative tech- nology. In July 2001,following evaluation of the anode,The Concrete Innovations Appraisal Service issued CIAS Report 0 1-1 Galvashield Embedded Galvanic Anodes for Repair of Concrete. The principal use of this report is as neutral documentation to help technical committees of the American Concrete Institute(ACI)and users of the an- ode to better understand the technology. As stated in the report"The technology offers an easy-to-understand con- cept,which gives the client confidence in the capability of the repaired structure to perform its intended use."In July 2002,the ASCE/CERF Highway Innovative Technology Evaluation Center(HITEC) commenced evaluation of the Galvashield technology. For many contractors and engineers perhaps the greatest benefit of the Galvashield XP embedded anode is the fact that installation requires little or no change from existing concrete repair practices, and only a minimal addition in cost. Normal patching procedures simply shift the corrosion reaction to adjacent concrete areas,thus creating a continual battle in which repair crews chase the corrosion problem around the structure.The Galvashield XP em- bedded anode prevents this from occurring by mitigating the corrosion problem using a maintenance-free,cost- effective strategy. Contact: David W. Whitmore•Vector Corrosion Technologies, Inc. •417 Main Ave• Fargo, ND 58103 701-280-9697• Fax 701-235-6706 •davidw@vector-corrosion.com •www.vector-corrosion.com Construction Innovation Forum•43636 Woodward,Bloomfield Hills,MI 48302•248-409-1500•Fax:409-1503•E-mail:info@CIF.org•www.C]F.org EMBEDDED GALVANIC ANODE 2003 Nova Award Nomination 12 Galvashield® XP Embedded Galvanic Anode g Active carvashWXPAnode ? Ccmcntitious 3 �4 Matrix ..- ( Sacrificial Zinc Core Tie Wires r Cut-Away of Galvashield°XP Anode Concrete Girder Repair—Anodes tied to steel inside girder repair �� .W1t�>•Itry .,� GeNashidti"XP Anode r� f $� '� _ � �� 'calvasleea=%PPnode �t= Bridge Widening Project—Anodes tied Concrete Patch Repair—Anodes tied to reinforcing steel at joint between new around perimeter of repair and old concrete Surrouoding Reber°°'' ,°Anode Gahanicaily,,Protects ctiloridc mtnhmted' ' �hlodde-Free PA ch v •.Corrosion"isltetluced>a,, Surrounding.Rebar ►+`•, uric'rctc `Chloride Cootmii©tnl Coocycic Chioride•Frrt Patch % '� f ,.f4 !Potential Di Between Pafch•nnd _ — 4 Chl1.oride Contaminated Concrete • •• Results in-Accelerated Corrosion Ga1vashie10XPReduces"Ring Anode"Corrosion "RatgAnode"Corrosion(without Galvashield*XP) Construction Innovation Forum•43636 Woodward,Bloomfield Hills,MI 48302•248-409-1500•Fax:409-1503•E-mail:info@C[F.org•www.C]F.org TECHNICAL IDELIN { ; 7K .......... _ -4.. Prepared by the International Concrete Repair Institute December 2008 Q 000 o a 0 ao o o 01 G7 d Q a o O Q Q 0 w. o p o p o d Guideline No. 310.1 R-2008 (formerly No. 03730) Copyright©2008 International Concrete Repair Institute Guide 1Preparation f or the Repair of Deteriorated a -; Concrete Resulting from Reinforcing SteelCorrosion TECHNICAL GUIDELINES Prepared by the International Concrete Repair Institute December 2008 Guide for Surface Preparation for the Repair of Deteriorated Concrete Resulting from Reinforcing Steel Corrosion Guideline No. 310.1 R-2008 (formerly No. 03730) Copyright O 2008 International Concrete Repair Institute All rights reserved. International Concrete Repair Institute 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 IN T ERN A �1%r 1 r s r r About ICRI Guidelines Producers of this Guideline The International Concrete Repair Institute(ICRI) was founded to improve the durability of concrete Surface Preparation Committee repair and enhance its value for structure owners. Pat Winkler,Chair* The identification,development,andpromotion of the most promising methods and materials are Dan Anagnos primary vehicles for accelerating advances in Randy Beard repair technology. Working through a variety of Bruce Collins forums, ICRI members have the opportunity to William"Bud"Earley address these issues and to directly contribute to Peter Emmons* improving the practice of concrete repair. Andrew Fulkerson A principal component of this effort is to make Randy Glover carefully selected information on important repair Fred Goodwin* subjects readily accessible to decision makers. Kurt Gottinger During the past several decades, much has been Tyson Herman reported in the literature on concrete repair Dave Homerding methods and materials as they have been developed Bob Johnson and refined. Nevertheless, it has been difficult to David Karins find critically reviewed information on the state of Ken Lozen* the art condensed into easy-to-use formats. Jim McDonald To that end, ICRI guidelines are prepared by Beth Newbold sanctioned task groups and approved by the ICRI Jeffery Smith Technical Activities Committee.Each guideline is Sandra Sprouts designed to address a speck area of practice Rick Toman recognized as essential to the achievement of Patrick Watson durable repairs.AllICRIguideline documents are subject to continual review by the membership and *Contributing editors may be revised as approved by the Technical Activities Committee. Synopsis This guideline provides guidance on concrete Technical Activities Committee removal and surface preparation procedures for Kevin Michols,Chair the repair of deteriorated concrete caused by Jim McDonald,Secretary reinforcing steel corrosion. Removal geometry, Randy Beard configuration of the repair area,removal process, Don Caple edge preparation, reinforcement repair, surface Bruce Collins preparation and inspection necessary for durable William"Bud"Earley repairs are discussed.Special considerations for Don Ford concrete removal associated with column repair Tim Gillespie are included. Peter Golter Peter Lipphardt David Rodler Keywords Michael Tabassi anodic ring effect,bonding,bruising,corrosion, David Whitmore delamination, deterioration, reinforcing steel, Pat Winkler 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. 310.1 R-2008 GUIDE FOR SURFACE PREPARATION FOR THE REPAIR OF DETERIORATED CONCRETE RESULTING FROM REINFORCING STEEL CORROSION � ^ . ' ^ ` ° ar / rvrs K~������� o�.=""u~~..mm 1.0 Introduction..............................................................................................................................1 2.0 Definitions ...............................................................................................................................1 3.0 Exposure oK Reinforcing Steel..................................................................................................1 4.0 Anodic Ring(Hmb)Effect.........................................................................................................2 5.0 Removal Geometry .................................................................................................................2 6.0 Configuration of Repair Area...................................................................................................3 7.0 Concrete --------------------------...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 0N Reinforcing Steel .............................................................................5 9.0 Final Surface Inspection ---_''------''_—_------_---------.5 10.0 Special Conditions mK Columns................................................................................................O 11]0 Summary '—_—'__—_--'__'_.-------_—'''-------'----7 12.0 References...............................................................................................................................7 12.1 Referenced Standards and Reports....................................................................................7 GUIDE FOR SURFACE PREPARATION FOR THE REPAIR OF DETERIORATED CONCRETEnESU0NG FROM REINFORCING STEEL CORROSION 310R-2008 �B S T I T U T S 1 .0Introduction typically extends to a depth of 0.13 to 0.38 in. (3 to 10 mm) and, if not removed, frequently This guideline provides owners, design profes- results in lower bond strengths as compared with sionals,contractors,and other interested parties surfaces prepared with nonimpact methods. with a recommended practice for the removal of Carbonation:The conversion of calcium ions deteriorated concrete caused by the corrosion of in hardened cementitious materials to calcium reinforcing steel,including the preparation of the carbonate by reaction.with atmospheric carbon removal cavity to provide a clean sound surface dioxide. Carbonation reduces the pH of the to bond a repair material. concrete and its ability to protect reinforcing steel This guideline outlines removal geometry, and embedded metal items from corrosion. configuration,removal process,edge preparation, Chloride contamination: Contamination of reinforcement repair, surface preparation, and concrete with chloride ions commonly used in inspection prior to placing a repair material.An deicing salts and accelerating admixtures such as engineer should evaluate the impact of concrete calcium chloride and sodium chloride.Chloride removal on structural capacity prior to performing contamination above the threshold for corrosion concrete removal and repair.The repair methods can result in corrosion of the reinforcing steel. involve saw cutting and concrete removal using Chloride threshold:The amount of chloride impact tools,hydrodemolition,and other removal required to initiate steel corrosion in reinforced techniques. Special caution should be taken to concrete under a given set of exposure conditions; locate and avoid cutting or damaging embedded commonly expressed in percent of chloride ion reinforcing bars, prestressing strands, post- by mass of cement. tensioning tendons,or electrical conduits.Cutting Corrosion: Degradation of concrete or steel into these items can be life threatening and may reinforcement caused by electrochemical or significantly affect structural integrity. chemical attack. This guideline also contains a discussion of Microcrack:Acrack too small to be seen with concrete removal and preparation for the repair the unaided eye. of columns where the concrete is in compression. Tensile pulloff test:A test to determine the Special consideration must be given to the repair unit stress,applied in direct tension,required to of concrete in compression as the load-carrying separate a hardened repair material from the capacity of the element may be permanently existing concrete substrate.The test may also be compromised during the concrete removal and used to determine the maximum unit stress that preparation process. the existing concrete substrate is capable of While the procedures outlined herein have resisting under axial tensile loading and the near- been used to successfully remove concrete and surface tensile strength of a prepared surface prepare the removal cavity on many projects,the (refer to ICRI Technical Guideline No. 210.3- requirements for each project will vary due to 2004[formerly No.03739]and ASTM C1583). many different factors. Each project should be Substrate: The layer immediately under a evaluated individually to ascertain the applicability layer of different material to which it is typically of the procedures described herein.Refer to ACI bonded;an existing concrete surface that receives 506R-05,"Guide to Shotcrete"for surface prepar- an overlay,partial-depth repair,protective coating, ation prior to shotcrete application. or some other maintenance or repair procedure. 2.0 Definitions 3.0 Exposure of Anodic ring effect:Corrosion process in which Reinforcing Steel the steel reinforcement in the concrete surrounding a repaired area begins to corrode preferentially The practice of completely removing the concrete to the steel reinforcement in the newly repaired (undercutting) from around the corroded area(sometimes referred to as the halo effect). reinforcement,no matter what degree of corrosion Bruised surface(micro-fracturing):Asurface is found,is key to achieving long-term performance layer weakened by interconnected microcracks of surface repairs. In most cases, complete in concrete substrates caused by the use of high- removal of the concrete from around the impact, mechanical methods for concrete reinforcing steel is the best practice, where removal,and surface preparation;fractured layer protection of the reinforcing steel within the GUIDE FOR SURFACE PREPARATION FOR THE REPAIR OF DETERIORATED CONCRETE RESULTING FROM REINFORCING STEEL CORROSION 310.1 R-2008-1 .j.ICHNP�CONCRETE repair cavity is achieved by providing a uniform can result in accelerated corrosion of the chemical environment around the reinforcing surrounding reinforcing steel leading to future steel.If noncorroded reinforcing steel is exposed concrete deterioration.To assess existing concrete and the concrete is chloride contaminated, conditions beyond the repair area, chloride removal of the concrete around the reinforcing content and pH of the concrete at the level of the should occur or other corrosion-reducing means reinforcing steel should be determined. Where should be considered.Reinforcing steel partially the chloride content exceeds the threshold level embedded in chloride-contaminated concrete is for the initiation of corrosion or where the susceptible to future accelerated corrosion. reinforcing steel is susceptible to corrosion as a If,for structural reasons,the concrete cannot result of carbonation, a corrosion inhibiting be completely removed from around the corroded system should be considered to minimize future reinforcing steel or if a corrosion inhibiting corrosion.Othermeasures may also be considered, system is not used,the repair may be compromised such as the application of sealers and coatings,to due to continued corrosion.If there is a potential slow the corrosion process.In severely chloride- trade-off between durability and structural contaminated or carbonated concrete, the capacity,structural capacity should always take complete removal and replacement of the priority. When reinforcing steel is not fully contaminated concrete at and beyond the repair exposed through the concrete removal and area may be necessary to provide a successful preparation process,alternative corrosion inhib- long-term repair. iting systems should be considered. These systems may include use of corrosion inhibitors, �.0 Removal sacrificial anodes,or cathodic protection. 4.0 Anodic Rin Geometry gExamples of the removal geometry for several (Halo) Effect different types of reinforced concrete elements are shown in Fig.5.1 through 5.6.Repairs may The existing concrete surrounding a repair area be located on horizontal,vertical,and/or overhead in chloride-contaminated or low pH reinforced surfaces.The removal in Fig. 5.5 and 5.6 is for concrete is susceptible to accelerated corrosion. columns where the removal will not affect the This is due to the electrical potential differential structural capacity of the column. Removal of between the chloride contaminated or low pH concrete within the reinforcing or to expose the existing concrete and the chloride-free or reinforcing(concrete in compression)is a special high pH repair material.This anodic ring effect condition and is discussed in Section 10. 0 0 o Q O Q 9 0 O po0 p o a a QD� o 0 0 opoo �a o o ,o a o o oo O o 0 0 o o p o 0 p - o 00 0 o p o U CJ �� C) o 0 0 9 0 o a p C7 Q� o o o o o Fig.5.1:Partial depth repair,slab or wall,section Do Q a o ) 0 o0 000 C7 o p 0 0 0 CQ papo po o O o C7 0 Fig. 5.2:Full depth repair,slab or wall,section 2-310.1 R-2008 GUIDE FOR SURFACE PREPARATION FOR THE REPAIR OF DETERIORATED CONCRETE RESULTING FROM REINFORCING STEEL CORROSION r:Jlfxs, SLVinLujji� -10r4AI- s£�. kB.Ra 1 E c2S9SmtSSSt ��� o o pr 0 Do 6.0 Configuration p c (j�Cc:)' 0 0 � CD c7 0 �3 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 Fig. 5.3:Beam or rib repair, elevation 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 OO o O o o 0 O 0 ° o o o o rectangular with square corners(Fig.6.1).This may 0 0 QO o p o0 a o o�0-0 p� result in the removal of sound concrete.Reentrant corners should be minimized or avoided as they Q o are susceptible to cracking. 00 O O o -- 0 0 �0 Fig. 5.4:Beam or rib repair,section l 0 p O 0 p Fig.6.1:Areas of deterioration and recommended removal configurations 0 0 7.0 Concrete ° Removal/Surface � o Fig.S.S.•Column repair, elevation Preparation 7.1 Exposing and Do � a O �° ° Undercutting of � � oa o oop 9 a Reinforcing Steel �o °0oapo°o 0 pQ Remove concrete from the marked areas and o0 ��'o o fjv undercut exposed reinforcing steel(Fig.7.1)using O� 0 b °o o o 0 0 impact breakers, hydrodemolition, or another 0 0 0 0 � O p o suitable method. Undercutting will provide 0 O a c� O 8o clearance under the reinforcing steel for cleaning and full bar circumference bonding to the repair Fig 5.6:Column repair,section material and the surrounding concrete.Bonding GUIDE FOR SURFACE PREPARATION FOR THE REPAIR OF DETERIORATED CONCRETE RESULTING FROM REINFORCING STEEL CORROSION 310A R-2008-3 the repair material to the full circumference of the to minimize damage to the substrate,reinforcing reinforcing steel will secure the repair structurally. steel,and surrounding concrete. Provide a minimum of 0.75 in.(19 mm)clearance Concrete removal should extend along the between exposed reinforcing steel and surrounding reinforcing steel until there is no further delam- concrete or 025 in.(6 mm)larger than the coarse ination,cracking,or significant corrosion and the aggregate in the repair material, whichever is reinforcing steel is well bonded to the surrounding greater.Sound concrete may have to be removed concrete.Care should be taken to avoid significant to provide proper clearance around the reinforcing and sudden changes in the depth of concrete steel.If impact breakers are used for partial depth removal,as the repair material is more susceptible concrete removal,the breaker should not exceed to cracking at these locations. 30 lb(12 kg).A 15 lb(7 kg)breaker is preferred If noncorroded reinforcing steel is exposed during the removal process,care should be taken to not damage the bond to the surrounding o° p concrete. If the bond between the reinforcing 0 0 00o a steel and concrete is broken, undercutting of �a o the reinforcing steel is required. o a .. Remove all deteriorated concrete and additional ° o e o°moo concrete as required to provide the proper Q oa ° eaoa configuration and/or the minimum required o �o thickness of repair material as required by the manufacturer of the repair material and/or the project specifications. Fig. 7.]:Remove concrete to undercut �r and expose reinforcing steel and I.2 Preparation of the provide uniform repair depth Repair Perimeter The perimeter of the repair area should be saw o cut 0.75 in.(19 nun) deep to provide a vertical ono ou o edge(Fig.7.2)for the repair material.This will o° oo� �o� a'' 0 0 , avoid feathered in of the repair material. o g g P 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. o Care should be taken to avoid cutting the existing reinforcing steel. Fig. 7.2:Saw cut perimeter 7 3 Cleaning of the to provide vertical edge g Concrete Surface and o d Q o Reinforcing Steel 0 o p o The use of high-impact,mechanical methods to O�o c remove deteriorated concrete will result in a 0 o o surface layer weakened by interconnected micro- 0 opo cracks in the concrete substrate. The fractured o o (bruised)layer can extend to a depth of 0.125 to 00 0�0 0.375 in.(3 to 10 mm)into the resultant concrete 0 6 0 o substrate and may result in reduced bond strength. o a oo moo 0 0 AC Remove the bruised layer and bond-inhibiting 0 materials such as dirt,concrete slurry,and loosely Fig. 7.3:Abrasive blasting to clean bonded concrete by oil-free abrasive blasting substrate and reinforcing (Fig. 7.3) or high-pressure water blasting. The 4-310.1 R-2008 GUIDE FOR SURFACE PREPARATION FOR THE REPAIR OF DETERIORATED CONCRETE RESULTING FROM REINFORCING STEEL CORROSION \,�;�^��iF i:•, :. S T 1 T 11 T E saw-cut edge of the repair area should also be damaged/deteriorated steel or placing supple- blasted to roughen the polished vertical surface mental reinforcing steel in the affected section caused b the saw-cutting. (Fig.8.1 .Supplemental reinforcing steel may be Y g �g ) pP g Y All concrete, corrosion products, and scale lap-spliced or mechanically spliced to existing should be removed from the reinforcing steel by reinforcing steel. The supplemental reinforcing oil-free abrasive blasting or high-pressure water steel should extend (lap length) beyond the blasting. Verify that the reinforcing steel and damaged/deteriorated area in accordance with concrete surface are free from dirt, oil, cement ACI 318, "Building Code Requirements for fines(slurry),or any material that may interfere Structural Concrete." with the bond of the repair material.Inspect the repair cavity to verify that all delaminations and 9 0 Final Surface deterioration have been removed. If hydro- demolition is used,cement fines(slurry)must be completely removed from the repair surface.A Inspection tightly-bonded light rust build-up on the reinforcing Immediately prior to placing the repair material, surface is usually not detrimental to bond. If a inspect the repair cavity to verify that all bond- protective coating is applied to the reinforcing inhibiting materials(dirt,concrete slung,loosely steel,follow the coating manufacturer's recom- bonded aggregates, or any material that may mendations for steel surface preparation. interfere with the bond of the repair material to the existing concrete)have been removed. If bond- 8.0 Inspection inhibiting materials are present,the repair cavity should be recleaned as previously described. and Repair of To verify the adequacy of the prepared concrete surface and completeness of bond- Reinforcing St e e' inhibiting material removal,a tensile pulloff test (ICRI Technical Guideline No. 210.3 2004 or Loose reinforcement should be secured in its ASTM C1583)should be considered to evaluate original position by tying to secure bars or by the bond strength capacity and tensile strength of other appropriate methods to prevent movement the existing concrete substrate.This test may also during placement of repair material. be performed after the repair is complete. The If reinforcing steel has lost cross-sectional pulloffstrength requirement should be established area, a structural engineer should be consulted. by the engineer and included as a performance Repair reinforcing steel by either replacing the specification for the repair. Affected Length Loss of Cross Section Required Lap Required Lap Supplemental Bar Affected Length Fig. 8.1:Repair of damaged1deteriorated reinforcing GUIDE FOR SURFACE PREPARATION FOR THE REPAIR OF DETERIORATED CONCRETE RESULTING FROM REINFORCING STEEL CORROSION 310.1 R-2008-5