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Engineering 3-19-20
III MATHERS ENGINEERING CORPORATION PRE -BUILDING PERMIT ADDENDUM Date: March 03, 2020 To: St. Lucie County Building Department 2300 Virginia Avenue Fort Pierce, FL 34982 2431 SE Dixie Highway Stuart, FL 34996 Phone: (772) 287-0525 EB#004456 MAR 14 2020 t?.rn+l�rw oeparonent st, Wdermntq Referenced Project: Concrete Restoration for Exterior Balconies (decks, beams & columns) For Unit Numbers for Stack 1(101, 201, 301, 401, 501, 601 and 701) Unit Numbers for Stack 2 (102, 202, 302, 402, 502, 602 and 702) Unit Numbers for Stack 3 (103, 203, 303, 403, 503, 603 and 703) for Oceanrise Condominium Located at 10310 S. Ocean Drive, Jensen Beach, FL 34957 Contractor: DMF Construction 312 S. Old Dixie Hwy. Jupiter, FL 33458 Background: The removal and restoration of deteriorated concrete and steel within beams, columns, decks and adjacent walls will comply with the IRCI Guideline No. 03730 (a copy of which is attached hereto) or as modified by Engineer as work progresses. The anticipated work involves the initial demolition, and then the removal, replacement and restoration of concrete and reinforcement as required. The degree of restoration is currently unknown, until such time as the initial demolition has begun. The anticipated sequence of repairs is as'follows: • Shoring required for repairs of all columns, beams and decks (if required by engineer) • Removal and restoration of concrete and reinforcement steel within beams, columns and decks. (ICRI Guideline No. 03 73 0) • Minor chipping and patching of areas not requiring full depth repairs. • Applied deck coating. The following materials are approved for anticipated use in this restoration (see attached manufacturers specifications): • Sikacrete 211 Concrete Mix. • Sika.Quick 1000. • Sika Armatec 110 EpoCem bonding agent and rebar coating. • Sika FerroGard 903. • Sikagard 701 W. • SikaTop 123 PLUS. F'LE®O • TREMCO Vulkem® 350NF Wig2431 SE Dixie Highway O Stuart, FL 34996 MATHERS ENGINEERING Phone: (772) 287-0525 EB#004456 CORPORATION See enclosed plan showing location of restoration. The above sequence is general in nature and will be modified as restoration work progresses. Observations of the initial demolition will determine any required modifications to the above procedures and materials... selected for the final restoration process. Based on initial visual observations, repairs will not require shoring; however, in the event the demolition work reveals that shoring will be required, the engineer will instruct the contractor to shore the area as well as the number of levels required. The instructions given to the contractor will be submitted to the Building Department with the final close-out documents. We have been authorized by the Association to work with the contractor during the restoration and, will inspect work partially completed as well as observe results of the new demolition prior to field authorizing the repairs to be completed. The proposed concrete restoration work, except as authorized by the engineer's modified instructions, will comply with specifications outlined in the IRCI Guideline No. 03730, as well as the applicable minimum building codes and the applicable fire safety standards as determined by the local authority in accordance with Chapter 553 and Chapter 633 of the Florida Statutes where applicable to concrete restoration. Approved, J. Mq PE 19658 STATE OF William J. Mathers���;5'c� O-R1V�G������� Florida License.#1961Z S/pNAL Special Inspector FL Lic�%sAMiA r� Product Data Sheet Edition 7.14.2014 Sikacrete® 211 Sikacrete° 211 One -component, cementitious, pumpable and pourable concrete mix Where to Use Sikacrete® 211 is a 1-component, portland-cement concrete containing factory blended coarse aggregate. ■ Full depth repairs. ■ On grade, above, and below grade on concrete. ■ On horizontal, vertical and overhead surfaces. ■ As a structural repair material for parking facilities, industrial plants, walkways, bridges, tunnels, dams and balconies. ■ Filler for voids and cavities. ■ Pre -packaged coarse aggregate: Eliminates need to extend material in the field; Elimi- nates the risk of reactive aggregate. ■ High bond strength. ■ Compatible with coefficient of thermal expansion of concrete. ■ Increased resistance to deicing salts. ■ Simple -to -use labor-saving system. ■ Easily mixed. ■ Good freeze/thaw resistance. ■ Easily applied to clean, sound substrate. ■ Not a vapor barrier. ■ Not flammable Coverage Approximately 0.65 ft.3/unit Packaging 80 lb. multi -wall bag. PRIOR To FACH USE OF ANY SIKA PRODUCT, THE USER MUST ALWAYS READ AND rOL05W THE WARIMM-AND INSTRUCTIONS ON THE PRODUCT'S MOST CURRENT PRODUCT DATA SHEET, PRODUCT LABEL AND SAFETY DATA SHEET WHICH ARE AVAILABLE ONLINE AT HTTP:HUSA.SIKA.COM/ OR BY CALLING SIKA'S TECHNICAL SERVICE DE- PARTMENTAT 800.933.7462 NOTHING CONTAINED IN ANY SIKA MATERIALS RELIEVES THE USER OF THE OBLIGATION TO READ AND FOLLOW THE WARNINGS AND INSTRUCTIONS FOR EACH SIKA PRODUCT AS SET FORTH IN THE CUR- RENT PRODUCT DATA SHEET, PRODUCT LABEL AND SAFETY DATA SHEET PRIOR TO PRODUCT USE. A130 se Concrete, mortar, and masonry products. :paration Concrete: Remove all deteriorated concrete, dirt, oil, grease, and all bond -inhibiting materials from surface. Be sure repair area is not less than 1 in. in depth. Preparation work should be done by high pressure water blast, scabbier, or other appropriate mechanical means to obtain an exposed aggregate surface with a minimum surface profile of ±1/8 in. (CSP-7). Saturate surface with clean water. Substrate should be saturated surface dry (SSD) with no standing water during application. Reinforcing Steel: Steel reinforcement should be thoroughly prepared by mechanical cleaning to remove all traces of rust. Where corrosion has occurred due to the presence of chlorides, the steel should be high-pressure washed with clean water after mechanical cleaning. For priming of reinforcing steel use Sika® Armate& 110 EpoCem (consult Technical Data Sheet). For priming of reinforcing steel use SikaOArmatee®110 EpoCem (consult Technical Data Sheet). Place 4/5 of 1 gallon water in mixing container. Add Sikacrete® 211 while continuing to mix. Add additional water up to 1 gallon total. Mix to a uniform consistency, maximum 3 minutes. Mechanically mix with a low -speed drill (400-600 rpm) and paddle or in appropriate size mortar mixer or concrete mixer. i Form and pour or pump applications: Pre -wet surface to SSD. Ensure good intimate con- tact with the substrate is achieved. To accomplish this, material should be scrubbed into the substrate or other suitable means should be employed such as vibration of the material or pumping under pressure. Vibrate form while pouring or pumping. Pump with a variable pres- sure pump. Continue pumping until a 3 to 5 psi increase in normal line pressure is evident then STOP pumping. Form should not deflect. Vent to be capped when steady flow is evident, and forms stripped when appropriate. inishing As per ACI recommendations for portland cement concrete, curing is required. Moist cure with wet burlap and polyethylene, a fine mist of water or a water based" compatible curing compound. Curing compounds adversely affect the adhesion of following layers of mortar, leveling mortar or protective coatings. Moist curing should commence immediately after fin- ishing. Protect newly applied material from direct sunlight, wind, rain and frost. 'Pretesting of curing compound is recommended. ■ Application thickness: Minimum 1 in. (25 mm); Maximum 8 in. (200 mm) ■ Minimum ambient and surface temperatures 450F (7°C) and rising at time of application. ■ Using SikaLatexO, SikaLatee R or similar products•will result in loss of slump and slump retention. Field tests for suitability are strongly recommended. PRIOR TO EACH PRODUCT, THE U 3 READ AND FOLEOWTRETVAMUT0370 INSTRUCTIONS ON THE PRODUCT'S MOST CURRENT PRODUCT DATA SHEET, PRODUCT LABEL AND SAFETY DATA SHEET WHICH ARE AVAILABLE ONLINE AT HTTP://USA.SIKA.COM/ OR BY CALLING SIKA'S TECHNICAL SERVICE DE- PARTMENTAT 800.933.7452 NOTHING CONTAINED IN ANY SIKA MATERIALS RELIEVES THE USER OF THE OBLIGATION TO READ AND FOLLOW THE WARNINGS AND INSTRUCTIONS FOR EACH SIKA PRODUCT AS SET FORTH IN THE CUR- RENT PRODUCT DATA SHEET, PRODUCT LABEL AND SAFETY DATA SHEET PRIOR TO PRODUCT USE. KEEP CONTAINERTIGHTLY CLOSED. KEEP OUT OF REACH OF CHILDREN. NOT FOR INTERNALCONSUMPTION. FOR INDUSTRIALUSE ONLY. FOR PROFESSIONALUSEONLY. For further Information and advice regarding transportation, handling, storage and disposal of chemical products, users should refer to the actual Safety Data Sheets containing physical, ecological, toxicological and other safety related data. Read the current actual Safety Data Sheet before using the product. In case of emergency, call CHEMTREC at 1-800-424-9300, International 703-6273887. Priorto each use of any Sika product, the usermust always read and followthe warnings and Instructions on the product's most current Product Data Sheet, product label and Safety Data Sheet which are available online at httpJ/usa.sika.comi or by calling Sika's Technical Service Depart- ment at 800-933-7452. Nothing contained In any Sika materials relieves the user of the obligation to read and followthe warnings and Instruction for each Sika product as set forth In the current Product Data Sheet, product label and Safety Data Sheet prior to product use. SIKA warrants this product for one year from date of installation to be free from manufacturing defects and to meet the technical properties on the current Product Data Sheet if used as directed within shelf life. User determines suitability of product for Intended use and assumes all risks. Buyer's sole remedy shall be limited to the purchase price or replacement of product exclusive of laboror cost of labor. NO OTHER WARRANTIES EXPRESS OR IMPLIED SHALLAPPLY INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SIKA SHALL NOT BE LIABLE UNDERANY LEGAL THEORY FOR SPECIAL OR CONSEQUENTIAL DAMAGES. SIKA SHALL NOT BE RESPONSIBLE FOR THE USE OF THIS PRODUCT IN A MANNER TO INFRINGE ON ANY PATENT ORANY OTHER INTELLECTUAL PROPERTY RIGHTS HELD BY OTHERS. SALE OF SIKA PRODUCTS ARE SUBJECT SIKA'S TERMS AND CONDITIONS OF SALE AVAILABLE AT HTTP://USA.SIKA.COM1 OR BY CALLING 201-933-8800. Visit our website at usa.sika.com 1-800-933-SIKA NATIONWIDE Regional Information and Sales Centers. For the location of your nearest Sika sales office, contact your regional center. Sika Corporation Sika Canada Inc. Sika Mexicana S.A. de C.V. asi - 201 Polito Avenue 601 Delmar Avenue Carretera Libre Celaya Km. 8.5 Lyndhurst, NJ 07071 Pointe Claire Fracc. Industrial Balvanera e Phone: 800-933-7452 Quebec H9R 4A9 Corregidora, Queretaro RESPO SIDLE LIRE `00m Fax:201-933-6225 Phone:514-697-2610 C.P.76920 -"-" '^ `'9211 Fax: 514-694-2792 Phone: 52 442 2385800 Sika and Sikacrete are registered Fax: 52 442 2250537 trademarks. Printed in Canada. Product Data Sheet Edition 2.18.2015 SikaQuicke 1000 SikaQuick® 1000 hardening repair mortar with extended working time Where to Use SikaQuick° 1000 is a 1-6omponent, rapid hardening, early strength. gaining, cementitious, patching material for concrete. ■ Use on grade, above, and below grade on concrete. ■ Highway overlays and repairs. ■ Structural repair material for concrete roadways, parking structures, bridges, dams and ramps. ■ Full depth patching repairs. ■ Economical patching material for horizontal repairs of concrete and mortar. ■ Specialty suited for hot weather applications when extended working time is required. ■ Rapid hardening as defined by ASTM C-928. ■ Epoxy coatings can be applied as early as 6 hrs. On site testing is recommended for verification. Please consult coatings manufacturer for recommendations. ■ Freeze/thaw resistant ■ Easy to use, labor-saving material. ■ Not gypsum -based. ■ High early strength. ■ Open to foot traffic in 4 hours; to vehicle traffic in 6 hours (at 731F). ■ Easily applied to clean, sound substrate. ■ Not a vapor barrier. Typica1AWa (Material -and curial condidans 9t73`F'(23°CI and SOX RH:1{Watedpowder= 0.101 RESULTSA.AYDIFIE] BASED' UPON STATISTICALVARrriiIONSDEPENDINGUPON`AIMG;JWETHODSANDEQUWSIEN, TEMPEIIXtURJ IiPPUCATIONMETHODS..TESTMETHODS,ACTUAL:STMCONMMEO AND,CURINCiCCt4W ON& Shelf Life 1 year in original, .unopened. bag. Stmae O dltions Store dry at 40°-95°F (4°-35'C). For best results, condition material to 65' 75'F before. using. Color . Concrete gray. MixingRatio Approximately 4.5 - 5 pints of liquid per 50 lb. bag. Applicat owLite Approximately 30 minutes after adding povrderto the water. Compre5shreStrength, psi Mortar-ASTM. C6109 3 hours 1,250rpsi (&6.MPa) 1 day 4,000 psi (27.6 MPa) 7 days 5,000 psi.(34.5 MPa) .28 days 7,000 psi (4EL2.MPa) FlexuralZIttength, psi (ASTM C 78) 1 day. 700 psi .(4.8 MPa) 7 days 900 psi (6.2 MPa) 28 days 1,000psi (6:9.MPa) Splitting Tensile Strength, psi. (ASTM CA96) 1 day 300 psi (2A MPa): 7 days 4.00. psi (2.7 MPa) 28 days 500 psi (3.4 MPa) Bond Strength,. psi (ASTM 0-882) modified i day 1750.psi .(120 MPa) 7 days 20.00:psi (13.8 MPa) 28 days 2500 psi (17.2 MPa) Direct Tensile Bond, psi (ACI: 503) 28, days 300 psi (substrate failure) Drying Shrinkage; X (ASTM C-596) 28 days 0.06 Modulus°at`Elasticity psi-(ASTM CA69) 28 days 4.6x1.05 Chlorida Permeability; Coulombs (ASTM C 1202) 28 days < 1000 freeze -TULW Resistance, % (ASTM .C-666). 26 days 989A ScalinT.Resistance; IbJftz (ASTM C-672) 50 cycles 0.080 InitialSet Minutes .(ASTM' C-266) 4MO Final Sei; Minutes (ASTM C-266) 60-120 Abrasiorr fteMstance, Inches of Wear at 1 hr. (ASTM C-7791 28 days 0.026 Independent ced fcates avabbie upon request. PRIOR FO EACH USE OF ANY -51KA PRODUCT, THE USER MUSI ALWAYS READ AND FOLLOW THE WARNINGS ANU INSTRUCTIONS ON THE PRODUCT'S MOST CURRENT PRODUCT DATA SHEET, PRODUCT LABEL AND SAFETY DATA SHEET WHICH ARE AVAILABLE ONLINE AT HTTP:((USA.SIKA.COMI OR BY CALLING SIKA'S TECHNICAL SERVICE DE PARTMENT AT 800.933.7452 NOTHING CONTAINED IN ANY SIKA MATERIALS RELIEVES THE USER OF THE OBLIGATION TO READ AND FOLLOW THE WARNINGS AND INSTRUCTIONS FOR EACH SIKA PRODUCT AS SET FORTH IN THE CUR RENT PRODUCT DATA SHEET, PRODUCT LABEL AND SAFETY DATA SHEET PRIOR TO PRODUCT USE. A120 Coverage Approximately 0.42 cu. ft When extended.with 25 Ibs.. of 318 in. gravel yield is approximately 0.58 cu. ft Packaging 50 lb. mufti -wall bag. How to Use Surface Preparation Surface must be dean and sound. Remove all deteriorated concrete, dirt, oil, grease, and other bond-inhibfing materials from the area to be repaired. Be sure repair area is not less than 114 in, deep. Preparation work should be done by appropriate means. Obtain an exposed aggregate surface with a minimum surface profile oft 118 in. (CSP-6) on dean, sound concrete. To ensure optimum repair results, the effectiveness of decontamination and preparation should be assessed by a pull -off test Saw -cutting of edges.is.prefered and a dovetail is recommended. Saturate surfacelo.be repaired with clean water. Substrate should be saturated surface dry (SSD) prior to application. Priming For priming of reinforcing steel use SWArmatece 110 iepoCem (consult Technical Data Sheet). Concrete Substrate: Prime the prepared substrate with a scrub coat of SikraQuidte 1000 prior to placement of the mortar. The repair mortar has to be applied into the wet scrub coat before it dries. Mixing Mechanically mix in an appropriately sized mortar mixer. Wet down all tools and mixer to be used. With water. Start with 4.5 pints of water added to the mixing vessel. Add 1 bag of SikaQuu:ke 1 ODD while continuing to mix. Add up to another 12'pint of water to achieve desired consistency. Do not over -water. With Latex R: Pour 4.5 pints of SikaLatm e R into the mixing container. Slowly add powder, mix and adjust as above. With diluted Latex R: SikaLatexe R may be diluted up to 5.1 (water. SikaLatexe R) for projects requiring minimal polymer modification. Pour 4.5 pints of the mixture into the mixing container. Slowly add powder, mix and adjust as above. For applica- tions greater than 1 in. in depth, add 318 in. coarse aggregate. The aggregate must be non -reactive (reference ASTM CA 260, C-227 and C-289), dean, well graded, saturated surface dry, have low absorption and high density, and comply with ASTM C33 size number 8 per Table 2 Note: Variances in aggregate may result in differentstrengths. The addition rate is 25 ltss of aggregate per bag of SikaQuick °1000. (25 lbs. of 3M in, aggregate is approximately20 gallons by loose volume of aggregate).. Do not exceed a slump of 7 in. This may cause excessive bleeding and retardation and will reduce the strength and performance of the material. The prepared mortar must be scrubbed into substrate. Be sure to fill all pares and voids. Force material against edge of repair, working toward center. After filling repair, screed off excess. Allow concrete to set to desired stiffness, then finish. if a smoother finish is desired, a magnesium float should be used. Muting, placing, and finishing should not exceed 30 minutes maximum. To control setting times, cold water should be used in hot weather and hot water used in cold weather. fishing As per ACI recommendations for Portland cement concrete, curing is required. Moist cure with wet burlap and polyethylene,a fine mist of water or a curing compound meeting ASTM C309. Moist cure should commence immediately after finishing. if necessary, protect newly applied material from rain. To prevent from freezing, cover with insulating material. ■ Minimum ambient and surface temperatures 45°F and rising. ■ Minimum application thickness 1 /4 in. as a mortar and 1 in. extended with aggregate. ■ Maximum application thickness 1 in. as a mortar and 6 in. extended with aggregate. ■ Do not feadw edge. ■ Do not exceed 7 in. slump when extended. ■ Use only potable water. ■ Variations in aggregates may produce differences in strengths from the typical valuesstated in Sika's Technical Data. III. Aswithall cementbased materials, avoid contadwith aluminum to preventadverse chemical reaction and possible product failure. Insulate potential.areas of contact by coaling aluminum bars, rails, posts etc. with an appropriate epoxy such as Sik3dur8 Hi -Mod 32 ■ Do not use SikaeArmatece 110 EpoCem as a bonding agent with SikaQuicke 1 ODD. INSTRUCTIONS ON THE PRODUCTS MOST CURRENT PRODUCT DATA SHEET, PRODUCT LABEL AND SAFETY DATA SHEET WHICH ARE AVAILABLE ONLINE AT HTTP:IIUSA.SIKA.COM/ OR BY CALLING SIKA'S TECHNICAL SERVICE DE ARTMENT AT 80D.933.7452 NOTHING CONTAINED iN ANY SIKA MATERIALS RELIEVES THE USER OF THEOBLIGATION O READ AND FOLLOW THE WARNINGS AND INSTRUCTIONS FOR EACH SIKA PRODUCT AS SET FORTH IN THE CUR RENT PRODUCT DATA SHEET, PRODUCT LABEL AND SAFETY DATA SHEET PRIOR TO PRODUCT USE. KEEP CONTAINER TiGHM CLOSED. KEEP OUT OF REACH OF CH[WREK NOT FOR UMNALCONSUM7111O . FOR INDUSTRIAL USE ONLY. FOR PROFESSIONAL USE ONLY. For further Information and advice regarding transportation, handling, storage and disposal of chemical products, users should refer to the actual Safety Data Sheds cordainfng physical, ecological, toxicological and other safetyrelated data Read the currentactual Safety Data Sheet before using the product. in case of emergency, can CHEMTREC at 1-800424830D, International703d27-3887. Priortoeachuse ofanySltnproduct,theuser must always read andfollowfhewamings andinstructions.on the producesmost current Product Data Sheet, product label and Safety Data Sired which are available online at httpJlusa.sika.coml or by caging Sika's Technical Service Depart. mentat 800933-745L Nothing contained in any Sika materials relieves the user of the obligation to read and follow the warnings and Instruction for each Sika product as set forth in the current Product Data Shed, product label and Safety Data Sheet prior to product use. SIKA warrants this product for one year from date of installation to be freefrom manufacturing defects and to meet the technical properties on the current Product DataSheet if used as directed within shelf Nfe. Userdeterminres suitablGty of productfor Intended use and assumes an risk.. Buyer's sole remedysWbe8mitedtothepurchasepriceorteplaeementofproductexclusiveoflabororcostoflabor.NOOTHERWARRANTIES EXPRESS OR IMPLIED SHALLAPPLY INCLUgNGANY WARRANTY OF MERCHANTABILITY OR FITNESS FORA PARTICULAR PURPOSE. SIKA SHALLNOT BE I raR1=C.UNDERANYIJ:GALTHFARYFOR SPECIALtXR CONSEQUENTIAL DAMAGES SU(A SHALL NOT BE RESPONSIBLE FOR THE USEOFTHISPiIODI=INA.MMNERTOWERWGEONAItYPAMUORANYOTHERIN E11ECTUALPROPERTYRIGHTSHELDBYOTHERS. SALE OF SIKA PRODUCTS ARE SUBJECT SIKA'S TERMS AND CONDITIONS OF SALE AVAILABLE AT HTTP:/IUSA.SIKA.COIW OR BY CALLING 20143341800. Visit our website at usa.sika.com 1.800.933SIKA NATIONWIDE Regional Information and Sales Centers. For the location of your nearest Sika sales office, contact your regional center. Sika Corporation i 201 Polito Avenue Sika Canada Inc. W1 Delmar Avenue Sika Mexican S.A. de C.V. Carretera Libre Celaya Km. 8.5 � e Lyndhurst, NJ 07071 Pointe Claire Fracc. industrial Balvanera Phone: 800&33.7452 Quebec HSR 4A9 Conegidora, Queretaro arsroNsrerac+nr° Fax:2014I334D25 Phone:5144597--2610 C.P. 76920 Fax: 514-694-2792 Phone: 52 442 23858W Siia and S1keQuickare regiae trademaft Fax. 52 442 2250537 Printed In Canada. Product Data Sheet Edition 1.26.2017 Sika®Armatec®110 EpoCem Sika° Armatec° 11-0 EpoCem Bonding Agent and Reinforcement Protection Description Sika®Armatec° 110 EpoCem is a 3-component, solvent -free, moisture -tolerant, epoxy -modified, cementitious product specifically formulated as a bonding agent and anti -corrosion coating. Where to Use ■ As an anti -corrosion coating for reinforcing steel in concrete restoration. ■ As added protection to reinforcing steel in areas of thin concrete cover. ■ As a bonding agent for repairs to concrete and steel. ■ As a bonding agent for placing fresh, plastic concrete to existing hardened concrete. Advantages ■ Excellent adhesion to concrete and steel. ■ Acts as an effective barrier against penetration of water and chlorides. ■ Long open time - up to 16 hours. ■ Not a vapor barrier. ■ Can be used exterior on -grade. ■ Contains corrosion inhibitors. ■ Excellent bonding bridge for cement or epoxy based repair mortars. ■ High strength, unaffected by moisture when cured. ■ Spray, brush or roller application. ■ Non-flammable, solvent free. Coverage Bonding agent: minimum (theoretical) on smooth, even substrate 80 ft.z/gal. (=20 mils thickness). Coverage will vary depending on substrate profile and porosity. Reinforcement Protection: 40 ft.2/gal. (=20 mils thickness) (2 coat application). 3.5 gal. unit. (47.6 fl. oz. Comp. A+ 122.1 fl. oz. Comp. B + 46.82 lb. Comp. C) Comp. A + B in carton, Comp. C in multi -wall bag. 1.65 gal. unit. (22.7 fl. oz. A + 57.6 fl. oz. B + 4 bags @ 5.5 lb.) Factory -proportioned units in a pail. i C�a#a (Matenal and cng cona�/trohs @ 73a�and 50% R H} MAYDIEFRR BASEOUPONSTATIS7ICACVARIATIONS DEPENDING UPON MIXING NIETHODSAND EQUIPMENT, CURE APPLJCATION METH0 TEST METHODS,/ CTUAL SITE CtOND4T10NSAND CURING CONDITIONS noglna�ngpenelivpakagne yearu#7cig r y Store dry at 40 �95gFFiW 35°C Contlttton material to 55 75 F (18 24 G) before using If"componeptsA and are'frozen discard Protect Cornponent C from humidity ,; (Mlxed),N 1251ff (2 0 keg )toms` j Appr zlmately90 tTtinutes 7> ` sswe Strength (ASTNI C 109} 3 days 4500 psi (31--0 MPa} k } 7gd6ys 6500 psi (44 8 MPa) s` 28 days ` 8500r4. pst (58 6 MPa) Strerig 6 (ASTM�C 348J � 28 daps 1250 ps1 (8 6 MPa}2 Tensrle Strength BAST C-4961" . days 600 psi (41 MPa) it Data`fcrYSlka Armated,44 4 as a Coriuf Proiective Coating INater�(?ermeabihtyat 10`bar �14rsps� 892k 1015 ft/sec Ga�trol 4. 722-110 x° ft /sec UUatervaportl1 sior t coefficient p �20ti 110 x'sr Dioxlde�� XCarbon�tltoxtde d ffuston�coefficieni ll COZ 14000 1TA Time�tp'CorroslonSEudy���� x s�Armatec°110 more than tilpled to time to corrosion iuced co�roslokn rate byover�40°la���'x °` PRIOR TO EACH USE OF -ANY SIKA PRODUCT, THE' S READ AND FOLLOW THE WARNINGS AN5 INSTRUCTIONS ON THE PRODUCT'S MOST CURRENT PRODUCT DATA SHEET, PRODUCT LABEL AND SAFETY DATA SHEET WHICH ARE AVAILABLE ONLINE AT HTTP:11USA.SIKA.COM1 OR BY CALLING SIKA'S TECHNICAL SERVICE DE- PARTMENT AT 800.933.7462 NOTHING CONTAINED IN ANY SIKA MATERIALS RELIEVES THE USER OF THE OBLIGATION TO READ AND FOLLOW THE WARNINGS AND INSTRUCTIONS FOR EACH SIKA PRODUCT AS SET FORTH IN THE CUR- RENT PRODUCT DATA SHEET, PRODUCT LABEL AND SAFETY DATA SHEET PRIOR TO PRODUCT USE. se paration Cementitious substrates: Should be cleaned and prepared to achieve a laitance and contaminant -free surface prepared in accordance With the requirements specified by the overlay or repair material by blast cleaning or equivalent mechanical means. Substrate must be saturated surface dry (SSD) with no standing water. Steel: Should be fully exposed and have all corrosion removed by blast cleaning or other means of mechanical abrasion Shake contents of both Component'A' and Component'B'. Empty entire contents of both Component'A' and Component 'B' into a clean, dry mixing pail. Mix thoroughly for 30 seconds with a Sika paddle on a low speed (400-600 rpm) drill. Slowly add the entire contents of Component'C'while continuing to mix for 3 minutes until blend is uniform and free of lumps. Mix only that quantity that can be applied Within its pot life. As a bonding agent - Apply by stiff -bristle brush or broom. Spray apply with Goldblatt Pattern Pistol or equal equipment. 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 or concrete wet on wet, or up to the maximum recommended open time, onto the bonding slurry. Maximum recommended open time between application of Armate& 110 and patching mortar or concrete: 80°-95°F (26°-35°C) 6 hours 65°-79°F (18°-26°C) 12 hours 50°-64°F (10°-17-C) 16 hours 40°49T (4°-9°C) wet -on -wet For corrosion protection only -Apply by stiff -bristle brush or spray at 80 ft.2/gal. (20 mils). Take special care to properly coat the underside of the totally exposed steel. Allow coating to dry 2-3 hours at 73T, then apply a second coat at the same coverage. Allow to dry again before the repair mortar or concrete is applied. Pour or place repair within 7 days. ■ Substrate and ambient temperature: Minimum 40T (5°C). ■ Maximum 967 (35"C). ■ Minimum thickness: As a bonding agent 20 mils. ■ For reinforcement protection 40 mils. ■ (2 coats, 20 mils each). ■ Not recommended for use with expansive grouts. ■ Use of semi -dry mortars onto Sika® Armatec®110 EpoCem must be applied "wet on wet". ■ When used in overhead applications with hand placed patching mortars, use "wet on wet" for maximum mortar built thickness. ■ Substrate profile as specified by the overlay or repair material is still required. In As with all cement based materials, avoid contact with aluminum to prevent adverse chemical reaction and possible product failure. Insulate potential areas of contact by coating aluminum bars, rails, posts etc. with an appropriate epoxy such as SikadurO Hi -Mod 32. PRIOR TO EACH USE OF ANY SIKA PRODUCT, THE USER MUST ALWAYS R AD AND FOIL= THE WARNINGS AND INSTRUCTIONS ON THE PRODUCT'S MOST CURRENT PRODUCT DATA SHEET, PRODUCT LABEL AND SAFETY DATA SHEET WHICH ARE AVAILABLE ONLINE AT HTTP:11USA.SIKA.COM/ OR BY CALLING SIKA'S TECHNICAL SERVICE DE PARTMENTAT 800.933.7462 NOTHING CONTAINED IN ANY SIKA MATERIALS RELIEVES THE USER OF THE OBLIGATION O READ AND FOLLOW THE WARNINGS AND INSTRUCTIONS FOR EACH SIKA PRODUCT AS SET FORTH IN THE CUR- RENT PRODUCT DATA SHEET, PRODUCT LABEL AND SAFETY DATA SHEET PRIOR TO PRODUCT USE. KEEP CONTAINER TIGHTLYCLOSED. KEEP OUT OF REACH OF CHILDREN. NOT FOR INTERNALCONSUMPTION. FOR INOUSTRIALUSE ONLY. FOR PROFESSIONAL USE ONLY. For further information and advice regarding transportation, handling, storage and disposal of chemical products, users should refer to the actual Safety Data Sheets containing physical, ecological, toxicological and other safety related data. Read the current actual Safety Data Sheet before using the product. In case of emergency, call CHEMTREC at 1.800-424-9300, International 703-527-3887. Priorto each use of any Sika product, the user must always read and followthe warnings and instructions on the product's most current Product Data Sheet, product label and Safety Data Sheet which are available online at httpJ/usa.sika.com/ or by calling Slka's Technical Service Depart ment at 800-933-7462. Nothing contained In any Sika materials relieves the userofthe obligation to read and followthe warnings and instruction for each Sika product as set forth in the current Product Data Sheet, product label and Safety Data Sheet prior to product use. SIKA warrants this product for one year from date of installation to be free from manufacturing defects and to meet the technical properties on the current Product Data Sheet if used as directed within shelf life. Userdetermines suitability of product for intended use and assumes all risks. Buyer's sole remedy shall be limited to the purchase price or replacement of product exclusive of labor or cost of labor. NO OTHER WARRANTIES EXPRESS OR IMPLIED SHALL APPLY INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. SIKA SHALL NOT BE LIABLE UNDER ANY LEGAL THEORY FOR SPECIAL OR CONSEQUENTIAL DAMAGES. SIKA SHALL NOT BE RESPONSIBLE FOR THE USE OF THIS PRODUCT IN A MANNER TO INFRINGE ON ANY PATENT ORANY OTHER INTELLECTUAL PROPERTY RIGHTS HELD BY OTHERS. SALE OF SIKA PRODUCTS ARE SUBJECT SIKA'S TERMS AND CONDITIONS OF SALE AVAILABLE AT HTTP://USA.SIKA.COMI OR BY CALLING 201-933-8800. Visit our website at usa sika.com 1-800-933SIKA NATIONWIDE Regional Information and Sales Centers. For the location of your nearest Sika sales office, contact your regional center. Sika Corporation Sika Canada Inc. Sika Mexicana S.A. de C.V. ast - 201 Polito Avenue 601 Delmar Avenue Carretera Libre Celaya Km. 8.5 Lyndhurst, NJ 07071 Pointe Claire Fracc. Industrial Balvanera Phone: 8OD-933-7452 Quebec H9R 4A9 Corregidora, Queretaro aFsro s_�s rGrtE : owoy Fax: 201-933-6225 Phone: 514-697-2610 C.P. 76920 -^- ••- --• Fax: 514-694-2792 Phone: 52 442 2385800 Sika and Amwtec are registered Fax., 52 442 2250537 trademarks. Printed in Canada. T�E//KO. Vullremilo Neighbor Friendly - Low Odor, Low VOC Basecoat for Pedestrian and Vehicular Applications Product Description Compatible Vulkem Intermediate and Topcoats Vulkem® 350NF is a single -component, fast curing, low odor polyurethane basecoat that possesses tenacious adhesion primarily to clean and dry concrete, but also to wood and metal. Vulkem 35ONF is a versatile basecoat that can be applied underneath any Vulkem intermediate or topcoat or used under tile. Vulkem 35ONF is available in two viscosities, R (roller grade) for vertical or horizontal applications and SL (self - leveling) for horizontal applications. Basic Uses Vulkem 350NF is ideal for plazas, vehicular and recreation decks, balcony terraces, mechanical rooms, restrooms, kitchens, stadiums, ramp areas, elevated plenums and other primarily concrete surfaces. Please contact Technical Services for additional information on applications. Product Features • Fast cure - refer to chart on page 2 for cure rates. • Low odor • Unprimed adhesion to concrete • Less than 90 g/I of Volatile Organic Content • Low potential for out gassing • Low viscosity • Compatible with all Tremco intermediate and topcoats • No cure inhibition or adhesion issues when used with Tremco's Dymeric 240FC, Dualflex, Vulkem 45 SSL and Vulkem 116. • Can be used under tile - contact Tremco Services for application information. Product Benefits • Fast cure means quicker turnaround on jobsite • Low odor ideal for restoration and interior applications • Easy to apply • Compatibility with other Tremco products minimizes the risk of failure when it abuts other transitions or penetrations of the structure such as floor -to -wall transitions, detailing and drainage areas. Availability Immediately available from your local Tremco Sales Representative, Tremco Distributor or Tremco Warehouse. Tremco offers a,complete line of time tested, compatible Vulkem intermediate and topcoats that form a strong interlaminary bond to the Vulkem 350NF Compatible topcoats are Vulkem 351, 351 NF, 346, 951 NF and 950NF (indoor only for 950NF). Compatible intermediate coats are Vulkem 345 and 950NF. These Vulkem coatings, when used in conjunction with the recommended aggregate, create a tough, aesthetically pleasing, abrasion -resistant wearing surface over the Vulkem 35ONF basecoat. Additionally, Vulkem 350NF is ideal for use under file in bathrooms, kitchen, on balconies and other applications. Packaging 5-gal. (19L) pail 55 gal. (208L) drum Installation Refer to Vulkem 350NF Application Instructions for specific application details. The techniques involved may require modification to adjust to jobsite conditions. Consult your local Tremco Sales Representative or Tremco Technical Services for specific design requirements. Warranty Tremco warrants its Products to be free of defects in materials but makes no warranty as to appearance or color. Since methods of application and on -site conditions are beyond our control and can affect performance, Tremco makes no other warranty, expressed or implied, including warranties of MERCHANTABILITY and FITNESS FOR A PARTICULAR PURPOSE, with respect to Tremco Products. Tremco's sole obligation shall be, at its option, to replace or to refund the purchase price of the quantity of Tremco Products proven to be defective and Tremco shall not be liable for any loss or damage. Please refer to our website at www.tremcosealants.com for the most up-to-date Product Data Sheets. www.tromcosealants.com Page 1 of 2 TREE TYPICAL PHYSICAL PROPERTIES Property Test Method Vulkem 35ONF.(SL) Vulkem 35ONF (R) Tensile ASTM D 412 440-460 psi 220-240 psi Elongation ASTM D 412 600-700% 600-700% S100 ASTM D 412 220-260 psi 110-120 psi Hardness, Shore ASTM C 661-83 50-60 45-50 Peel Strength — On Concrete, ASTM C 794 25 — 30pli,100% Cohesive 20-25pli, Cohesive Failure Failure Permeability ASTM E 96 .15 perm -inches .1 perm -inches Vertical Hold N/A >50 mils Weight % Solids 90-92% 97-98% Non -Volatile Content ASTM D 1353 <90 g/I <20 g/I Viscosity, cps Brookfield C&P 4-6000 cps 15,000-20,000 Cure Time to Recoat @ 770F (25°C) 50% R.H. ASTM D 1640 4-6 hours 5-7 hours Flash Point Setaflash 1607 >200°F Pull -Off Adhesion ASTM D 4541 min 300 psi min 200 psi Temperature @ 50% Relative Humidity Cure Rate 40" - 55°F (4X-12.8°C) 48 hours 55- - .65T (12.8--18.3°C) 16-24 hours 65° - 85°F (18.3'- 29XC) 4-6 hours 85"F (29.4TC) < or = 4 hours Variations in temperature and humidity can affect the cure rate of the waterproofing membrane. The above chart should be used as a guide only to determine the approximate rate of cure. Other factors can also influence the cure rate such as substrate temperature and enclosed environments. For more information about proper application procedures please refer to the installation instructions or contact Technical Services. H Tremco Commercial Sealants &Waterproofing 3735 Green Road, Beachwood, OH 44122 Il Phone: 216.292.500011800.321.7906 220 Wicksteed Avenue, Toronto, ON M411 1 G7 // Phone: 416.421.3300// 800.363.3213 1451 Jacobson Avenue, Ashland OH 44805 11 Phone: 419.289.2050 // 800321.6357 An'1L Company www.tremcosealants.com 0512/V35ONFSD Page 2 of 2 Prepared by the International Concrete Repair Institute December 2008 Guide for Surface Preparation for the Repair of Deteriorated Concrete Resulting from Reinforcing . Steel Corrosion Guidellne No. 310.1 R-2008 (formerly No. 03730) Copyright © 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 sdr� INTERNATIONAL . II('$Ej CONCRETE REPAIR ®'� I N S T I T U T E About ICRI Guidelines The International Concrete Repair Institute aCRI) wasfounded to improve the durability ofconcrete repair and enhance its value for structure owners. The identification, development, andpromotion 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 methods and materials as they have been developed 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 speck area of practice recognized as essential to the achievement of durable repairs. All ICRIguideline 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 Goiter 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. 310.1 R-2008 GUIDE FOR SURFACE PREPARATION FOR THE REPAIR OF DETERIORATED CONCRETE RESULTING FROM REINFORCING STEEL CORROSION INTERNATIONAL �gBCEiH�: CS4tdCitE'�E REPAIR I N S T I T U T E 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 310.1 R-2008 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): A surface 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 INTERNATIONAL • gip°9' CONCRETE RUFTiE I N 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: A crack 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 key to achieving long-term performance 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 GUIDE FOR SURFACE PREPARATION FOR THE REPAIR OF DETERIORATED CONCRETE RESULTING FROM REINFORCING STEEL CORROSION 310.1 R-2008 -1 /'�' /.� INTERNATIONAL .1111c pi' CONCRETE REPAIR e�, ,% I N S T I T U T E Rip, 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 theremoval 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 2 - 310.1 R-2008 GUIDE FOR SURFACE PREPARATION FOR THE REPAIR OF DETERIORATED CONCRETE RESULTING FROM REINFORCING STEEL CORROSION 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 INTERNATIONAL `.�IIl7tly: CONCRETE REPAIR I N S T I T U T E 61:0 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 rectangularwith square comers (Fig. 6.1). This may result in the removal of sound concrete. Reentrant comers should be minimized or avoided, as they are susceptible to cracking. WD ty�jr[ L tyf f � it 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 GUIDE FOR SURFACE PREPARATION FOR THE REPAIR OF DETERIORATED CONCRETE RESULTING FROM REINFORCING STEEL CORROSION 310.1 R-2008 - 3 d�.� INTERNATIONAL 11CM0 REPAIR I NNSTI TS 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. ]: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 clear: substrate and rei..Iforcing 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 slung, and loosely bonded concrete by oil -free abrasive blasting (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 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 deteriorationhave 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 d/9'4\ �INTERNATIONAL .gYCYid�i CONCRETE REPAIR I N S T I T U T E ,01�fi 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. Affected Length Loss of Cross Section iig I MAR Fig. 8.1: Repair of damaged/deteriorated reinforcing GUIDE FOR SURFACE PREPARATION FOR THE REPAIR OF DETERIORATED CONCRETE RESULTING FROM REINFORCING STEEL CORROSION 310.1 R-2008 - 5 AAM-41k,1\1 INTERNATIONAL IT ,, A IculJ), CONCRETE REPAIR ,�It, , INSTITUTE Ivllwllp 10,0 Special Condition- at Columns lonflang afflong- M in 1 10-ya ONE ;7 Ulm It �g - a -iav W, R At URI iil T ..... ..... Tnl : I-E , 0"; '51 . . . . . . . ... Fig. 10. 1: Column load path Fig. 10.2a. Column repair Fig. 10.3: Column load path following repair Fig.',.10,2b:-.Co.!Umnje&.tion 6 - 310.111-2008 GUIDE FOR SURFACE PREPARATION FOR THE REPAIR OF DETERIORATED CONCRETE RESULTING FROM REINFORCING STEEL CORROSION 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 ofthe 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 altensile 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 to prevent displacements and corresponding stress redistributions during repairs. 40% INTERNATIONAL ICHI CONCRETE REPAIR I N S T I T u "r E ILA 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 C 1583, "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" GUIDE FOR SURFACE PREPARATION FOR THE REPAIR OF DETERIORATED CONCRETE RESULTING FROM REINFORCING STEEL CORROSION 310.1 R 2008 - 7 c .l A/ W\N PO% INTERNATIONAL aQE(`IIiIyi conic E rE REPAIR I NSTITUTE 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 8 - 310.1 R-2008 GUIDE FOR SURFACE PREPARATION FOR THE REPAIR OF DETERIORATED CONCRETE RESULTING FROM REINFORCING STEEL CORROSION ,