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HomeMy WebLinkAboutPERMIT PACKAGECIVIL • STRUCTURAL • MARINE LuirmSM St. CANNED ENGINEERING CSM ENGINEERING, LLC 2061 BE OCEAN BOULEVARD - SUITE 1 A STUART, FLORIDA 34996 O: 772-220-4601 W: WWW.CSM-E.NET PRINCESS CONDOMINIUM, UNIT 203 PERMIT PACKAGE Located At: The Princess Condominium 9650 S Ocean Dr. Jensen Beach, Florida 34957 Prepared For: The Princess Condominium Management Attn: Tim Erickson 0:772-229-9690 E: princesscondo@bellsouth.net Inspected: June 2016 Q 7— ST. LUfiffE COUNTY BUILDING DIVISION REVIEWED FOR COMPLIAN ID BY DATE MUST BE KEPT ON JOB OR NO INSPECTION WILL BE MADE THESC PLANS AND ALL PROPOSHD 4'V0jtwd ARE SUBJECT TO ANY CORRECTIONS REQUIRED BY FIELD INSPECTORS THAT MAY BE NECESSARY IN OI' M TO COMPLY WITH ALL APPLiC,4DtE CODES. ��Q'.•' ENSF• ,• J 0 .769Id ® 12 �r Charles Florida PAGE 1 OF 15 - - r 1 TABLE OF CONTENTS Title Page Table of Contents Scope of Work Scope of Work Attachments: Inspection Plan Section 1 - Concrete Repair Specifications Section 2 - Corrosion Inhibitor Specifications Section 3 - Waterproofing System Specifications Section 4 - Steel Reinforcement Protection Specifications Section 5 - Sacrificial Anode Specifications Section 6 - ICRI Standards Weather Wall Specification Drawings Restoration Location Drawings: Inspection Key 203 1 2 3-4 5 6-8 9-10 11-12 13 & Attached 14 & Attached 15 & Attached Attached 1 Page Attached 2 Pages 1 t�.�'21 .•,i� a �' S �s \\\1111111��� o.76910 i �� QNA1 \ �;•• 10 PAGE 2 OF 1 5 _ "' 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) Weather Walls: a) Installation, maintenance and removal of weather 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 Degussa Protectosil (corrosion inhibitor) over the repaired concrete deck and edge on walkways and balconies that are not enclosed within a weather tight system. b) In locations specified by ENGINEER, install Sika Sikalastic, STO Decocoat, or BASF Sonoshield waterproofing system consisting of primer, base coat and top coat (aggregate and backroll) 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 I L E0 OP"21 PAGE 3 OF 1 5 J � y ATTACHED INSPECTION DRAWINGS Inspection Drawings: Key Damage Key 203 Balcony Drawings (1 Page) ATTACHED AND DRAWINGS The above WORK shall be performed in accordance with the following attached Specifications and Drawings: Section I — Concrete Repair Specifications Section 2 — Corrosion Inhibitor Specifications Section 3 — Waterproofing System Specifications Section 3 — Steel Reinforcement Protection Specifications Section 4 — Sacrificial Anode Specifications Section 5 — ICRI Standards Weather Wall Specification Drawings Restoration Drawings PAGE 4 OF 1 5 - INSPECTION PLAN GENERAL A. ENGINEER shall review any work underway, as appropriate. All structural repairs, including reinforced concrete repairs at each location require specific engineering inspections and approvals. Non-structural work, such as stucco, overlays, waterproofing, and all non -reinforced concrete placements do not require inspections and approvals at each phase of work, but will be subject to ongoing engineering observations and approvals during the work. B. CONTRACTOR shall notify ENGINEER at least 2 business days prior to any required inspection. C. During the onsite inspections, ENGINEER shall review any work underway, regarding work locations, methods, shoring, forms, safety, property protection, concrete placements, proper curing of newly placed concrete, OWNER concerns, or any other items as appropriate. D. CONTRACTOR's site superintendent shall maintain a set of inspection drawings and spreadsheets marked up to indicate the current work status. Theses shall be available for review by ENGINEER and OWNER upon request. E. ENGINEER shall submit a written report to the Building Department at the end of construction. CONCRETE RESTORATION A. ENGINEER shall identify and mark out all areas to be investigated and / or excavated by contractor prior any excavation being performed. B. EXCAVATION LIMITS: ENGINEER shall inspect and approve, as required, all limits of concrete removal and all steel reinforcement repairs. ENGINEER shall verify contractor measurements and approve or disapprove, as required, all contract chargeable quantities for all repairs. C. APPROVAL TO PLACE CONCRETE: ENGINEER shall inspect all areas prior to concrete placement and give approval, as required, for all concrete placements. ENGINEER shall inspect all prep work, including forms, shoring, safety, steel bar repairs, sheathing installation and any adjustments to excavation limits. D. PLACEMENT OF CONCRETE: All design mix truck placements of concrete require on site engineering and shall be inspected by ENGINEER during placements. Approval of design mix placement based on slump results, environmental conditions, etc. shall be at the discretion of ENGINEER. ENGINEER may also require inspections of bag goods concrete placements. E. FINAL: ENGINEER shall inspect and approve, as required, the completion of all repairs, including any correction or punch list items for each work area as appropriate. ASSOCIATED WORK A. ENGINEER shall approve all removal of existing rail and screen enclosures, exterior and interior glass systems and doors, shutter systems, tile and other floor coverings prior to any removal work being performed. B. ENGINEER, with OWNER'S approval, shall designate the disposition of all building components to be removed prior to its removal. C. CONTRACTOR shall document the condition and functionality of all building components to be removed and reinstalled and ENGINEER shall approve same prior to removal. D. ENGINEER shall inspect the reinstallation of existing building components to verify that it is in accordance with the manufacturer's recommendations and that the condition and functionality have not been degraded. ENGINEERING APPROVALS A. ENGINEER shall approve all work completed. B. ENGINEER shall approve or disapprove, as required, specifications for all contractor -supplied materials at least 7 days prior to planned material use or placement. C. ENGINEER shall determine any disputes regarding reasonableness of repairs involving structural integrity. END OF SECTION PAGE 5 OF 1 5 --' SECTION - 1 CONCRETE REPAIR SPECIFICATIONS PART I - 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 observation PART 2-PRODUCTS I:E COPY 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 Y? 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 V? in depth. G Prepare all concrete surfaces to receive the repair material, including the saw -cut, to achieve a minimum surface profile depth of 3 ", where possible, with a new fractured aggregate surface to adequately anchor the patch material. H Remove all rust and scaling of the reinforcing thoroughly by media blasting and/or mechanical wire brushing. PAGE 6 OF 1 5 I Thoroughly clean the exposed concrete surface to receive the patch of all traces of dirt, grease, oil, dust, and other contaminants which may prevent proper bonding of the repair materials. J The prepared concrete surface shall be saturated surface dry (SSD), but free of standing water. Apply a bond coat of slurry, prepared with the repair concrete, with a stiff bristle brush covering all exposed steel and all concrete surface areas. K While scrub coat is still wet, place repair concrete mix design in accordance with ACI 301 in a continuous pour and in accordance with ICRI. 3.5 CURING. A Apply water mist to repaired area (i.e. form work, patches) or burlap or carpet remnants to surface. Misting involves any method to maintain the exposed patch or repair area, in a wet condition to prevent surface cracks and reduce moisture loss during cure. B All concrete shall cure a minimum of 28 days prior to application of any coatings or finishes. C An observation shall be conducted by ENGINEER prior to application of any coatings on the concrete. Any cracks in the repair areas shall be repaired in accordance with the requirements for crack repairs. Repair of cracks shall be at no additional cost to the Owner. 3.6 REPAIR MORTARS A Repair mortars may be used in lieu of ready mix concrete for partial depth repair areas of less than one (1) cubic foot of material and as accepted by ENGINEER. 1 The prepared concrete surface shall be saturated surface dry (SSD), but free of standing water. Apply a scrub coat of slurry prepared from the repair mortar to all surface areas, filling all pores and voids. 2 While scrub coat is still wet, apply acceptable polymer modified cementitious repair compound in maximum lifts of 3" and 1-1/2" for use on vertical and overhead surfaces, respectively. If forms are to be used, depths well in excess of these can be achieved in any one application. For large and/or deep repairs, mechanical anchors, studs, reinforcing dowels, etc., shall be provided where existing reinforcing does not provide mechanical anchorage. The top surface of each lift shall be scratched and reprimed with slurry prior to application of subsequent lifts. 3 The use of aggregate is not allowed except as otherwise recommended by the manufacturer. 4 The following repair mortars may be used: a Sika — Sika Full Depth 211 SCC Plus. STO products acceptable upon Engineer approval. IN'll 41 PAGE 7 OF 1 5 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: I 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: l Sika—Armatec 110 EpoChem (Preferred) 2 BASF - EMACO P-24 3 BASF —ZincrichRebarPrimer 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 '/4". 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 %" 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. 1:0903&1MN11910I PAGE 8 OF 15 SECTION - 2 CORROSION INHIBITOR TREATMENT SPECIFICATIONS PART 1-GENERAL 1.1 SUMMARY A Section Includes: I 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 Ibs/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. R. 'U h � -- - - - PAGE OF 15 --- 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: l Unless inhibitor does not affect adhesion of sealants, paints and patching materials all adjacent surfaces shall be protected as necessary in accordance with the manufacturer's recommendations. 2 Follow the manufacturer's recommendations regarding condition of concrete surfaces before, during and after application. B Surface Preparation: 1 All caulking, joint sealants, repairing, and patching of concrete surfaces shall be installed and cured before application of inhibitor. If specified by ENGINEER, apply corrosion inhibitor to routed cracks prior to application of sealant. Confirm with Inhibitor Manufacturer compatibility of materials. 2 Prior to application of corrosion inhibitor, concrete surfaces shall be dry and cleaned of all dust, dirt, debris, grease, oil, grout, mortar, and other foreign matter. Concrete patches and all existing surfaces shall be prepared as recommended by the corrosion inhibitor manufacturer and acceptable to ENGINEER. 3.3 FIELD QUALITY CONTROL A Test Applications: Before application of inhibitor will be accepted, a test panel will be applied to the concrete to verify performance under the warranty provisions. 3.4 APPLICATION A Product shall be applied as supplied by the manufacturer without dilution or alteration. B Corrosion inhibitor shall be applied in accordance with the use of either spray, brush, or roller as per manufacturer's recommendations. Corrosion inhibitor shall be applied at a net coverage rate of 75-100 ft2/gallon, in two or three equal coats, with a minimum one hour dry time between coats. C Follow manufacturer's recommendations concerning protection of glass, metal and other non -porous substrates. Contractor will be responsible to clean all surfaces that are contaminated by the corrosion inhibitor. D Follow manufacturer's recommendation concerning protection of plants, grass and other vegetation. Contractor will be responsible for replacing all plants, grass or vegetation damaged by the corrosion inhibitor. 3.5 CLEANING A As Work Progresses: Clean spillage and overspray from adjacent surfaces using materials and methods as recommended by corrosion inhibitor manufacturer. B Remove protective coverings from adjacent surfaces when no longer needed. 3.6 COMPLETION A Work that does not conform to ENGINEER'S specifications shall be corrected and/or replaced as directed by the Owners Representative at the contractor's expense without extension of time. END OF SECTION 2 '- - -- - - PAGE t 0 OF 15 SECTION - 3 WATERPROOFING SPECIFICATIONS BASF SONOGUARD SONOSHIELD SYSTEM PART 1-GENERAL 1.1 SUMMARY A Section Includes: 1. Waterproofing and decorative pedestrian traffic coating system for interior and exterior elevated decks as scheduled. 1.2 SYSTEM DESCRIPTION A A combined system providing a decorative pedestrian surface with the added benefit of a waterproofing membrane, with crack bridging capabilities. B The waterproofing membrane is a fluid -applied polyurethane waterproofing coating consisting of moisture curing mechanism. Materials have low odor and are VOC compliant. C The waterproofing system consists of the following components: 1. SONOGUARD BASE COAT, a one component, moisture -curing polyurethane. 2. SONOGUARD SECOND COAT, a one component aliphatic moisture -curing polyurethane. D System Performance Requirements: Provide material complying with the following requirements: 1. Hardness (Base Coat): Shore A (60) per ASTM D 2240. 2. Hardness (Top Coat): Shore A (89) per ASTM D 2240. 3. Tensile strength (Base Coat): 752 psi (5.2 MPa) per ASTM D 412. 4. Tensile strength (Top Coat): 2,500 psi (17.2 MPa) per ASTM D 412. 5. Elongation (Base Coat): 595 percent per ASTM D 412. 6. Elongation (Top Coat): 502 percent per ASTM D 412. 7. Tear strength (Base Coat): 74 PIT per ASTM D 1004. 8. Tear strength (Top Coat): 199 PIT per ASTM D 1004. 9. Weight loss (Base Coat): 16 percent. Max: 40. 10. Weight loss (Top Coat): 17 percent. Max: 40. 11. Low temperature flexibility and crack bridging: No Cracking of base or top coat. 12. Adhesion peel (Primer and Base Coat): Plywood 34 pli, Primed mortar 43 pli per ASTM C 957. 13. UL Class A Fire rating. E Weathering Performance Requirements: (ASTM C 957). 1. Elongation recovery: 94 percent. Minimum passing: 90 percent. 2. Tensile retention: 151 percent. Minimum passing: 80. 3. Elongation retention: 94 percent. Minimum passing: 90. 4. Abrasion resistance (CS-17 Wheel, 1,000 g load, 1,000 cycles): a 1 mg lost system passes. b Maximum oss: 50 mg. 5. Crack bridging (1,000 cycles): System passes. F Color and Texture Requirements 1. Color shall match adjacent surfaces 2. Texture shall matqh adjacent surfaces 1.3 SUBMITTALS A Product Data: Submit manufacturer's technical bulletins and MSDS on each product. B Quality Control Submittals: 1. Provide protection plan of surrounding areas and non -work surfaces. 1.4 QUALITY ASSURANCE A Qualifications: 1. Manufacturer Qualifications: Company with minimum 5 years of experience in manufacturing of waterproofing products and systems. 2. Manufacturer Qualifications: Company shall be ISO 9001:2000 Certified. 3. Applicator Qualifications: Company with minimum of 3 years experience in application of specified type products and systems on projects of similar size and scope, and is acceptable to product manufacturer. a Successful completion of a minimum of 3 projects of similar size and complexity to specified Work. --- -' - -- - - - PAGE 1 i OF 1 5 -- -- - B Field Sample: 1. Install at Project site or pre -selected area of building an area for field sample. a Provide mockup of at least 10 square feet to include surface profile, sealant joint, crack, flashing, and juncture details and allow for evaluation of slip resistance and appearance. b Apply material in strict accordance with manufacturer's written application instructions. 2. Manufacturer's representative or designated representative will review technical aspects; surface preparation, application, and workmanship. 3. Field sample will be standard for judging workmanship. Maintain field sample during construction for workmanship comparison. 4. Do not alter, move, or destroy field sample until Work is completed and approved by ENGINEER. 5. Obtain ENGINEER's written approval of field sample before start of material application, including approval of aesthetics, color, texture, and appearance. 1.5 DELIVERY, STORAGE, AND HANDLING A Comply with manufacturer's ordering instructions and lead-time requirements to avoid construction delays. B Deliver materials in manufacturer's original, unopened, undamaged containers with identification labels intact. 1.6 PROJECT CONDITIONS A Environmental Requirements: 1. Minimum application temperature is 50 degrees F and rising. 2. Do not apply in rain or when rain is expected within 24 hours. Do not apply above 90 degrees For when temperatures are expected to fall below 50 degrees F within 24 hours. PART 2-PRODUCTS 2.1 MANUFACTURERS A Subject to compliance with requirements, provide products from the following manufacturer: 1. BASF Building Systems 889 Valley Park Drive Shakopee, MN 55379 Customer Service: 800- 433-9517 Technical Service: 800-243-6739 Direct Phone: 952-496-6000 Internet: www.BASFbuildinasystcros.com B Specifications and Drawings are based on manufacturer's proprietary literature from BASF Building Systems. Other manufacturers shall comply with minimum levels of material, color selection, and detailing indicated in Specifications or on Drawings. ENGINEER will be sole judge of appropriateness of substitutions. 2.2 MATERIALS A Acceptable Product: 1. Base Coat: Sonoguard Base Coat. 2. Second Coat: Sonoguard Second Coat 3. Aggregate: Sonoguard Aggregate or equal. 4. Cementitious and epoxy patching materials: BASF Building Systems Repair mortar and Epoxies. 5. Sealant primer: Sonnebom Primer 733. 6. Sealant: Sonnebom SL-2 or Sonnebom Ultra. 7. Deep joint sealant: Sonnebom SL-2 or Sonnebom NP-2. 8. Acryseal HS PART 3 — EXECUTION 3.1 EXAMINATION 3.2 SURFACE PREPARATION A Substrates must be sound and free of dust, dirt, laitance, paints, oils, grease, curing compounds, or any other contaminants. B Verify substrate has properly cured. If efflorescence is present, mechanically remove it before proceeding. For extreme cases where this is not adequate, contact Technical Service. Concrete should have a minimum compressive strength of 5,000 psi (21 MPa) and be cured for a minimum of 28 days or 80 percent of design strength. 3-0: et ilocclnM F! ,*`7r IMA "--"- - - -- - -- - PAGE 1 2 OF 1 5 -- i SECTION 4 STEEL REINFORCEMENT PROTECTION SPECIFICATIONS See attached Product Data Sheet PAGE 1 3 OF 1 5 ---- - -- -' - - -'- -- ---" - Ediflon07/02/2Q7' Revision no: 0 ' Identification Nu' 01 03 02 01 001 0 000001 SikaTopR&Annatec 110 EpoCem® SikaTop%Armatec 110 EpoCem° Bonding Slurry and Anti -Corrosive Rebar Coating - 1 Product Cement -based expoxy-modified three -component anti corrosive coating and Description bonding slurry. Uses As an anti -corrosion coating for reinforcement steel: ft For repairs to reinforced concrete where there is corrosion of the underlying i reinforcement steel 0 For the preventive protection of reinforcement steel in thin reinforced concrete sections 1 As bonding slurry for use on concrete, mortar or steel: t El For repairs to concrete using SikaTop patching and repair mortars E3 For bonding of new and old concrete Characteristics / 0 Excellent adhesion to steel and concrete Advantages 13 Acts as an effective barrier against penetration of water and chlorides 2 Contains corrosion inhibitors {I El Provides an excellent bonding coat for subsequent application of repair a mortars, cement and epoxy based R Pre measured, ready -to -use packs M May be spray -applied 10 Frost- and de-icing salt resistant 0 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: Coloudess liquid Comp. C: Dark grey powder Packaging 20 kg units (A+B+C) ,:,...I Storage Storage Conditions Store at temperatures between +5 °C and +25 *C. Comp. C must be protected from g humidity. Shelf life 12 months from date of production if stored properly in unopened original packing. , NO MKIMIN FA e jy y Mechanical/F,T- - al Properties j Density (+23 °C) Comp. A 1.05 kg/I Comp. B 1.03 kg/I Comp. A+B+C 2.00 kg/1(density of slurry when mixed) Bond strength (+23°C) On concrete (sandblasted): 2-3 N/mm2 On steel: 1 -2 N/mm2 E-Modulus (static) —16.400 N/mmZ Index of resistance to diffusion of water vapour — 700 (NH2O) Index of resistance — 40.000 I todiffusion of carbon dioxide (pCO2) Thermic coefficient of _ 18 101 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! Coverage As an anti -corrosion coating: — 2 kg/m2for 2 coats, depending on method of application As a bonding slurry: 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, 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. 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. Apply a coating of approx. 0.5 -• im thick to the cleaned and derusted reinforcement, using a stiff paintbru ter 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 i,. j 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 s ' new concrete, it is necessary to install connecting reinforcement for shear strength t transfer as per the relevant guide lines. Notes m 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 from product may vary country to country. Please consult the local Product Data Sheet for the exact description of the application fields. Health and Safety Information For information and advice on the safe handling, storage and disposal of chemical products, users should refer to the most recent Material Safety Data Sheet containing physical, ecological, toxicological and other safety -related data. - r 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 -i 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 „P 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 j of its products. The proprietary rights of third parties must be observed. All orders E` 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. :' x Opy t =1 L E e� z # m; Sika Yapi 10myasallan A $. Qamge$me Mah. Sanayi Cad. 34899 Kaynarca Pendik — — ', Istanbul Turkiys- ..+ d" Tel +90 216 49419 90 a � 4 + Faks +90 216 49419 84 +� ` m = , ,. ® 1�3i n u- 'J ..sika.com.tr ,� ,n,,,;� qd,m SECTION 5 SACRIFICIAL ANODE SPECIFICATION See attached Product Data Sheet PAGE 140E IS 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. _y PY F I LE 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.ClRorg EMBEDDED GALVANIC ANODE 2003 Nova Award Nomination 12 Galvashield® XP Embedded Galvanic Anode Aco"e :4tdtrl[ SclificWl Zinc Cmc Cut -A way ofGalvashieltf XPAnode Bridge Widening Project —Anodes tied to reinforcing steel at joint between new and old concrete Concrete Girder Repair —Anodes tied to steel inside girder repair Concrete Patch Repair —Anodes tied around perimeter of repair (ld Nde Caumudaattd 'CLLoddepFrce PStN: ` °` �CuvcreteT .s J PotenNal'Rifferenee EVtWeeO P �tch and' Chloride Contain mated. Concrete �^ Results in Acccicrated Cnrrusion -- Galrashidtl ' XPRedaees "Ring Anode" Corrosion "RitrgAnode" Corrosion (without GalvashielJy3XP) t 4s Construction Innovation Forum • 43636 Woodward, Bloomfield Hills, M148302 •248-409-1500 • Fax: 409-1503 • E-mail: info@CIF.org • www.ClF.org See attached Product Data Sheet SECTION 6 ICRI STANDARDS M—=m g mqt: ta w I EMMA N"RI, PAGE 1 5 or 1 5 "8. Jpwu k f � Y S 1 Rsmm `4 M x " r h 4 } rim' <• t GUIDELINES ndCtcc1 (re ssucd March 1995 f- w� ✓ f TIL Guideline No. 03730 Cuy ? � H.: . 2� Coles , a Removal Geometry Exposing and Undercutting of Reinforcing Steel Cleaning and Repair of Reinforcing Steel Edge and Surface Conditioning of Concrete Technical Guidelines Committee Commifiee members durim, the p",eparauva of'4;,e 1989 ed;fij;nr Peter H. Emmons, Chairman Don Gardonic Structural Preservation Systems, lrtc_ Facca Construction, !no, Baltimore, Maryland Ma,-idstone, Ontario, Caraca Kermit D. Bright Robert Tracy Structural Engineering associates Tracy Restoration Engineers Kansas City, Nfissour; Ann Arbor Michigan Richard P. Detargey Douglas G. White Structural Maintenance Systems, Inc, Thomas Downey, Ltd, Extort, Pennsylvania Ar3inglon, Virginia Ci:rrewconunittee irenzbers who pi-ovidedfiurther inple., 1`01- the j995 e&ft' Wn Peter H. Emmons, Chairman Jack A. Morrow Structural Preservation Systarrs, Inc. Jamor Engineenng Baftimore. Marvitnd Calgary, AS, Canada Tom Kline Ken Lazar: Structural Preservation Systems, Inc. NITH Consuftanm Ud- �ilber!s, Et incis Farmington Hifis, Mchigan James E. McDonald Robert R. Cain Watoways Experiment Station KRC Associates Vicksburg, Mississippi tAillord, Ohio AIR MR MM A L International Concrete Repair institute Introduction This document is the result of a process of distribution. commentary, and revision by the Technical Guidelines Committee and the mernher- ship of the International Concrete Repair Institute, it was submitted to the vorin;l metnbcrrs of the Association forapproval oft August 1. 1984, and approved by over T;% of the resnordents. Several of the comments of the voting r,.embers, both from those who voted for approval and those who voted against approval. are worth noting and are reprinted below. Even though a guidelineexists for dote-nining the aniount of allowable corros ion before replacing or suppiementi n e a rebar, it is Liways wise to consult a structural engineer if any corrosion exists. Special caution should be taken to locate and avoid buried electrical conduits or prestressing or post- tensioning tendons when per otan- ing removals. Cutting into either can be a life threarenin2 %;tuation. U dercutrng the rebar should not be count-d on to secure the repair structurally in lieu of proper methods of bonding a repair to the existing substrate. A sawcut can and. possibly should, be greater than the 11in. i 13 mnl) f noted, as Iong as the reinforcing steel is not cut into. This document is intended a.; a voLmary guideline for cite owner. de>ian Professional and concrete repair contractor. It is not intended [o reiievs: iitc. professional enuitteertsr designer of;tit;responsibility fa, the specification of concrete repair met isods, materials or practices. 'role we believe the information contained herein represents the proper metals to achieve quality restilts. the international Concrete Repair lns:ituw must dischtini anyliab:lity or responsibility to those who miry choose to rely on all or any par, of this guiduaire. :ices p•. it l,. � i Surface Preparation Guide 03730-1 Removal Geometry Caalical Before starting removals, review effe-ct of removals on structural integrity. Provide shoring of memberas necessary. Particular rare snall be exercised at slabibeam connections to columns, Section Elevation Elevation Ream or Rfb Section Column Corner . ........ . . Slab or Wall Partial Depth Slab or Wall Full Depth ------ --- - IF I L E C 0" Y 03730-2 international Concrete Repair Institute J M Exposing and Undercutting of Reinforcing Steel 'lhese details are applicable to httrizomal, vertical, and overhead locations. 1-hey are also applicable to removal by hydro -demolition, hydrol-milling. and elec- tric, pneumatic or hydraulic impact beakers. 0 Remove loose or delaminated concrete above cor- coded reinforcing steel. ID Once initial removals are made, proceed with the undercutting of all exposed corroded bars. Under- cutting will provide clearance For under bar clean- ing and full 'Liar circumference bonding to surrounding concrete, and will secure the repair structurally. Provide minimum'14 inch (19 tmn) clearance between exposed rebars and surrounding concrete or-7- inch (6 mm) larger than largest aggregate in repair material, whichever is greater. j Concrete removals shall extend along the bars to locations along the bar free of pond inhibiting corrosion, and where the nor is well bonded to surrounding concrete. 0 If non-corrotied reinforcing steel is exposed dur- ing the undercutting process, care shall be taken not to damage the bar's bond to surrounding concrete. if bond between bar and concrete is broken. undercutting of the bar shall be required. Any reinforcement which is loose shall be secured in place be tying to other secured bars or by other approved methods, r Surface Preparation Guide 03730-3 Gleaning and Repaly of Reinforcing eel Cleaning of Reinforcing Steel All heavy corrosion and scale should be removed from the hams necessary to promote maximum bond'of replacement material. O8 free abrasive blast is the preferred method. A tightly bonded light rust build-up on the surface i< usually not de�rintental to bond. unless a protectivc coating is being applied to the bar surface. in which case the coatinz manuf .-cturer's recommendations for sur- face preparation should be followed. .cxrete ,.,•- - _Rpinforoirx,� steel �•_a5r- .e' :wale l . �- _ At+raSrn- " Pa:hs Gear i. g �alrcvien , ; ee?Wed sim Jf; FILE Repair of Reinforcing Steel Due to Loss of Section If reinforcing steel has lost significant cross section. a structural cnginecr should be consulted. If repairs are required to the reinforcing Steel. one of the following repair methods should be used: • Complete bar replacement, or • Addition of supplemental bar over affected section. \cw bass may be mechanically spliced to old bars orplacedparallel toandapproximately', in, t19mm1 from existing bars. Lap lengths shall be determined in accordance v4ih ACI 318: also refer to CRS1 and AASHTO manual. Affected Length Loss of Section ,— Supptemcntal Bar Required LapRequired Lap Affected Length 03730-4 International Concrete Repair Institute r �•� �l Yji� 9 These details are applicable to horizontal, vertical, and overhead locations. They are also applicable to removal tryhl:dro-demolition, hvdromilling, and e:lec- tne, pneumatic or hydraulic impact breakers. Do not use these rtetail5 fnr shorrrere rppiic cu ons— titr shcrtcrerte r'e;puirs refer to t1C1 ?QG Er r,>e Prepcnzt- tien Guidelines. ® Remove delaminated concrete, undercut rein- forcing steel (refer to "Exposing and Undercut- ting of Reinforcing Steel- oat page 3)_ remove additional concrete as required to provide mini- mum required thickness of repair material, At edge locations. provide right angle cuts to the concrete surface with either of tite following methods: - Sawcut 1/2" (13 mm) or less as required to avoid cutting reinforcing steel. • Us;:ptnverequipnlentsuch ashydrodemolition or impact breakers. Avoid feather edges. �} Repair configurations should bekept assimpleas possible, preferably with squared corners. G After removals and edge conditioning are com- plete. remove bond inhibiting materials (dirt, concrete slurry, loosely bonded aggregates] by abrasive blasting or high pressure waterblastin« with or without abrasive. Check the concrete surfaces after cleaning to insure that surface is ftae from additional loose aggregate, or that ad- ditional delaminations are not present. (� if hydrodemolition is used, cement and particulate slurry must be removed from the prepared surfaces before slurry hardens. A-14 I , s 6cundary of loose Recommended and deaminated layout concrete ------------- ras.a� Surface Preparation Guide 03730-5 /45i INTERNATIONAL igq RIM CONCRETE REPAIR I N S T I T U T E i 1321 Shepard Drive. Suite D Sterling. VA 20164-4428 phone 703-734-0116 Fax 703-450-0114 Email: info@icri.org NVeb: www.icri-ora its : l y r '1 3 t i Y Y•`: �i J �h ti + - S r i 4 i. x ry • 5 S i •.t C . t r { 2 S � is T{ k [ J DXt a -'t .mow �P5'®�tn��• Yaa�e` = �A'`. rrara er frr Y F f vY. Ix 44 r 1 1 E C"H N I C A L GUIDELINES-m pin-a,IeA i T� Guideline No. 03731 fI 57 Fil i Xt -g I z I sow d. General description: Repair nnrterial is placed dry or slightly damp into .hnterete machine and mi;ud u-ith .: arnpressed air. The mixture i> trinsponed tia ho,c to the sit nozzle where water wd adrilixturcs. if anv a a introduced. The nigredienti are propelled onto the prepared substrztc by the r«r,e of the corn- presI d air. Best application: Large vertical and overhead areas u-ith 7mzll bars, No. 6 (19 vun)}'i or des , snd minimal congestinn of embedded reinforcement, Material requirements: Welt -graded aggregate with ne 3,arybinders1usuallyportlandcemenu.4iix- tarc i ,u•,t bc proportioned to compensate far rebound Iils.cn Admixtures are frequently used to shorten set time, ;and/or to allow thi::ker lavers tube built-up in a single pass. Reference: ACI 500.2. '-Guide to Shotm—.re" Jet -mix shoterete General description: Pre -batched and thoroughly mixed repair material is placed into a concrete,pump and transported via pump line to sn exit nozzle where compressed airand adtnixturas, if any - are introduced. The repair rnawrial is propelled (into the surface by the cutnpressed air. Best application: Large vertical areas ws,njj :canon bar:, \,o. 6 1I9 trunP9 or less, and minin.al conzestion of embedded reinforcement. Material requirements: Purnpable. lose -slump mix- ture which does not sag, when unp;_cted ore the pre- pared substrate. ReferedCe: AC2 506.2. "Guide to Shotcrete" 131As there are presently no generaliv i-,e, ted rcnvervon =Sandard, Tar remf,,rcing Neel. !hc M1 I'al.A6 75 �6 has been nnvrued to tttc ncarc>i mdhurrter. t�rs�rws r�er rc€(3 r,r _ rewind i i4i Imo®-camc;� 03731.6 GUIDE FOR SELECTING APPLICATION METHODS FOR THE REPAIR OF CONCRETE SURFACES r ,� �.� fi_ ,� '� � I m m LA z`de for .a`°,\2m � © � . Methods � ,. . Application %:fulls fo �h Repair of Concrete c Surfaces Graphic »K » c m *.-3 1096 InlemaTirmil Concrete a a;_ All ; . 1 Shepard Drive. Suitem Vzrg + axe . yam— am+ , aw -1 / !t 1 //i/^ ! 171, In" rnxional (emercie Reprnr 1,!,:Rn%tr f 1CRI) Walv foundiedit, i ifrove ihe durabil - 'T"' . ptur wze! erihanci- irs t awjief V, 7*1fe Jae mo, Prnvutifig fnelho'!s illild fnazvrhiI(c is G p, injan, i elthle ; adi., In t Ir's If! repair o'f hwoh'g', 1b�11-k firg a varh TV itf 'foniffix, 1('R" tnelnberu fiat't, Svf[)fo'fUf!nY If) addwsthese istwea a)ltl 10 uut- triixr'e art* aragtrar; fray plaefice ofnmrn,te repait: -ipal ( oinpollenr of this ejTor is u, ifiatte care- uh!Se lecied inforpluvieny »t hn,,)oqfojj rttp jr ,b- to de( ifion maker.%. During the Bair <etvral decadew, mach bas been reported in the on concrete repair tne!hofs and nunen- rl"S as ihev have been developed and rqineL Verer- thelets, uleas heen dijju Wj tt)jhzJvrPjk-,j!',. ri, jet,.rj to acre formicat- Ti th,ji eittJ1, ICRI 1,Uidel wies ere pre- oured d bY sunraionrxl tav'- qroz?p,: hY thr XR1 7,4tnhwl Acrii-me, Capitinintee. Each, guide[hie adjresve.5 an area (0fivieuvice recogflia", as U.IVewial w.,Fee fochieiomen' ICRI.qaide- hire docwpew5 are subject to (oriinhaf review bv the MCInhership and ilia, he rentsed as appmivd by the Techtzbrfd 'A"fiviries cflntnfiffee. Thi, a 'ohimar, pvjcliiio lot Ific its, 1!I1Te.!1d%,! the 11"T the 'fleei f-" CII11on 'ffa "Xicretc I Crew flmh- 'MN' maieiuly or practices_ %Vhilccst leltih, aI-xc hilcmatiortal C mcwte Rerim lnt.ehite aims di, rely on ail of ;jnN part ill Sht> guidclinc. Peter H. Emmons, Chairman Kermit D. Bright Richard P. Delargey Don Gardortio Robert Tracy Douglas G. White approved for reissue by the Technical Activities Committee: Jack A. Marrow, Chairman Peter H. Emmons Robert J. Gulyas Thomas R. Kline Kenneth M. Lozen James E. McDonald Randall W. Poston April 1996 GUIDE FOR SELECTING APPLICATION METHODS FOR THE REPAIR OF CONCRETE SURFACES The cause of many concrete repair failures and in- stances of cost overruns can be traced to The selection of uia; pmpriate repair methods. This document has been prepared to help visualize the methods -commonly used for the repair ofdeteriorated coneretesurfacesand to survey the applications for which each is considered to be u3ast suitable. It is nor ir,rended t<t be a detailed :and comprehensive "how-io- guideffor the various rncthnw described, or a substftu:e for the recam- niendations of an experienced aril gualilhled repair specia!ist, This guideline summarizes current practice for plac- ing cement -based repair materials. It provides owners, engineers. material suppliers- and repair contractors with a quick reference to assist in the selection of suitable methods of piacament. While this guideline covers only the selection of suitable application meth- ods, ozhr guidelines covering related repair subjects are available from fCRi. Consiseut success in concrete repair begins with the reeognition that each repair situation is defined by a unique combination of circumstances shared by en; i- neeriao-cxposur e. constructibihty, cost, and time con- sidcrations. With this is in mind, userseo; this guide are encouraged to make the best use of itadustry resources by bringing the expertise and experience of the cn i- ncering conioluni ty, product manufacturers, and quali- fied contractor_, into the planning process. The insi ;!(anon mcihod amtst del it crthesclected repair m nr r;ad to Elie incpiared vubsL7tc with predicable results. Tlie propertie" (if repair inwcriais ,*eucrally' specified arc coanpressi ve strength. hood etringth. shear ctrcngth. and iho7e properties which influence volume chimaes, such as d n i m , shrinkage, modul us of claetic- ity,and cc>cfflcien t ofthermal expansiot3. ©tlierprcrper- tics such t.c resistance to freczine and thawing. low pentieabilicv. or ?ulfate rcniswiice may be specified. The repair material must fully encapsulate exposed rennforcine steel. achieve satisfactory pwnd with the substrate, and ill dtc prepared cavity w ithout segregai- iag. If these requirements are not achieved. the repair will not perform its intended purpose, Bonding of the repair material with the existing subsrratc depends upon the repair material reactin,. with, and interlocking to. the profile of the prepared concrete surface. Some materials tnay require a bond- ing agent to ensure intimate contact with prepared surfaces. If the repair material is self -bonding, it must have sufficient binder (e.g, cement paste. epoxy resin) to thororahly wet out the substrate. Force trust be applied to drive the repair material into intimate contact with the prepared surface. The type of force; will vary with the application method. In trowel applied systams. the repair material is forced into the prepared surface by the pressure applied to the trow-elbythe tinisherorcement mason. tncast-in-place systems, the pressure is provided by internal vibration. or hydraulic; pressure developed by the concrete or grout pump, High velochy pneumatic placement tech- niques develop exceptional force through impact. The dry packing process generates pre„utr when the roddi ng tool pounds the material against the substrate. The requirement that repair materiatsbe mixed and applied without segregating is equally important. Any segregation of material components will alter physical properties and reduce or negate the: ability of the repair to fulfill its primary function —to restore the structure to its ori<zirialcondition to the fullest extent pu;sible. Contciiiiy - Before finalizing the selection of the repair m:uurial and the tic aliation proccclnre.::heck like systcin's consrructihility. To determine comtructibility, Elie fol- lowing questions should be addressed: CottidlebtriftErirhina.erunsrrzrirrtssjlec;J erihrtire Or ineer arid the oN'wrj • Mh the.speci&ed installation rec'bnique allow rhe repairs to ;o i.faa aetvice within the :line s'lre: fed'' , GUIDE FOR SELECT IRG APPLICATION METHODS FOR THEREPAIR OF CONCRETE SURFACES 03731.1 WI r f a: ah • Is the, worAin ; environment coarrfucireto ahtr,,;xeei- lied iaciaalhl,ion technique? Are experienced contractors avadabte for rile pi'viec" If the ansver to any of these questions is no car mavise then the choice of repair mater,::i and installation method should he reassessed. T'he Selectian ofa suitable repair materud and applica- hor, method should proceed in this setluctree: 1 Sclecttbercpairmaterial providing the stren.gdiand durability properties which hest restore the i itegrhv of the oriwainal design. 2 Select a method of placement which will ucccss- fully place the repair material onto the. prepared cottcret,. 3 Reviow €tic phy:,ical properties and piacernent re- quiretnents for the repair material to ensure the construability of the selected repairsystem. 4 Change the materialorapplication methodasneeded to provida a constructible repair. When irtc!e--offs nee�7 to be made. th-e itzng-term durability of the repair sl'stern is far more imponjua than the ea sc bf appiicat }n. 'rhe combination o'dic working conditions, the repair contractor. tiie existing concrete material.lhesiruetrarr design. and the repair material, is unique to cvery proieet. Much san go wrong, without proper quality assurtmcc and routine quality control. Start by,5eiaeiine a qualified contractor who can dcmom,tratesuccc ss€ul igngremtre as nsn�the.nuende(linstallationntethod. If any que-Nih ns remain unanswered regarding the contractor's qualifications, the repair material -.or the installation technique, consider at pilot project. F)uring the actual repairs, develop a feedback sys- em to verify compliance with zhe engiaccring; rcquire- rnrnts establFjhed 4cr the project_ Physic�li pre'.+potties r>f the materials can be confirmed by sampling ai ells time of phwentent, by in -place testing, or by usine core sampling techniques. iioudstrengthscan beveri ieedbye caring through the repair and into th., substrate, fol- lowed by applying a Icns!e force to the core"t Consol i- dation of the materials can be verified whh visual observations of extracted cores and in -place testing. I i ; 5ttit3ble d[reca =,-n 1. tact rWth+xly rra de..-ii>zd in ACt 3tp3R "Llsc Of Gpoxa Cetsx PUttad,�xith Crmerara' App%fit Ak I'est Methatlw 4tan�sa n€Cor:crutc f'=ecti:.e. I 03731.2 GUIDE FOR SELECTING APPLICATION 41ETHODS FOR THE REPAIR OF KRUMM Trowel applied General description: Repair material is mix-d into a u owch:bic. non -sag coneistency.1 rowels orcitherstiit- able placing io ois arc used to transport the repair material to she prepared substrate. The repair material is pressuiinto Ihr sabirrsre to develop intimate contact wtdloul void"'. Best application: Surface restoration when reinforc- ing steci is not encountered. Material requirements: Fine-grained material easily finished. with nor -sag properties to stay in place in vertical or overhead apphcauons. General description: Repair material is mixed into it unifomt; cohesive plastic state. then €cans; ariad to a confined space and compacted with ridding, twls to produce a dense repair material. Best application: Post -tensioning grout pockcis: tie holes; par, joist bouoms: waffle pan joists: vertical, overhead and horizontal locations. Material requirements: Morar with corsi,tenev ca- pable of being molded into a bail without sagtafng. Reference: Headquarters. United Suaes Army Corps of Engineers 1 (995). "Evaluation. and Repair of Con- crete Strucmres. " EM 1110-2-2t702. tv ashington. D.C. fnrirvtE3 k rw"it irss"s-l'.i dry ;ask "t re;reir m N7 radaL^.a twls FILE COPY - GUIDE FOR SELECTING APPLICATION METHODS FOR THE REPAIR OF CONCRETE SURFACES 63731-3 a i Form and cast -in -place 7 Gen a ral descri ption: Tire placement of repair material into a :o tfined space with formwork defining all exposed boundaries. Repair materials are deposited into the formwork and consolidated by rodding or comentionul vibration. Best application: Columns, walls, and exterior slab edges. Material requirements: Castable concrete or mortar with proper bond properties, low shrinkage, low wa- terrcement ratio, and a highly Plowable mixture. Referense:ACI 304R '>"Guide forassuring. Mix- ing, l'ransporting, and Placing Concrete r: L t ,r .. �E General description: In lieu or partied -depth repairs, the mentixr in question can be removed and replaced in fatal. Placement inethoeisshould follow 'good con- crete practise. Best application: Whaa deterioration i3 extensive thronuhout the; naenaben Material requirements: Conventional cast -in -place concrete with toes ilirinka-c. low water -cement ratio. and a highly° workable mixture. Reference: ACI 3(9R. "Guide Itor A3easurmn Mixing. 1'rans orting, and Placing Concrete' - I'_I Retcrenccs tried in this manner are from the ACI k1unaal of C'oncratr Pnsokv, American Concrete Institute. Detroit. xtichigan, r 'a e sinnag anti `rnn'-work FIL"' }.�Nj t,�liIt TLa_1 to r. 03731-4 GUIDE FOR SELECTING APPLICATION METHODS FOR THE REPAIR OF CONCRETE SURFACES I h c: General descripti0n: RepUir material i, iniyed ark! u,;Uiax M yt1 {YAI�' pumped ri:. aoncreze line cannectcxl Its the timnnrurt . uri = t -ercti in a fiUvo astai t rep; uric c. Cs.r,"ulid.a:wu _ and noncang i prm illt d br ifio antes al form jnciw n :a - Best appliCalien Ov; rhea.d un,l v: rtc<al apt tir.tntara. Micro 'onuestcd reinforcin, i< lxe enz-. Beam bot- nt�. ribs. v( ah soffit'. or ettiun:d'ir l sago'. Material requirements: Pumpabie. gcxfd iikm chartc- tcrlsnc., "cli--bondirs;, a _•reti.:ate aitr compaiihie wah sirs ur;'Zyas :Ind bars. ReterenCe: ACI 3t{ ?ti. `Placing Concrew by Pump - General description: cap -graded aggrr:tate is place3 into formed cavrty. Green i> then pumped into form via grout pump until :all vokis :nv tilled and ShrinkauL is minimal ixe zusi. O 1^RG^rep G- .Mte, Contact itch ' volume. Best EMPliratiOR: Vertical and Overhead applications where exiremcly loin shrinkage o; repah material is rcquird: column cnlargement,- Materiat requirements. Gap -graded aggregate (40- 50r°5 VoW ratio). puntpahle grout. if-Xiatding port - land ccin—ut or re4in-b-,Ncd binder, Cane inch (75 min) or larger aggregate typically used in cementihous app lications- Reference:ACl3thJ.tR."GuidefordteU.� ofPreplaced .Aggregate Concrete for Structural and Mays Concrcw Applications # a3 T"Wr" ,r n wit I ,.^mmmp ; t GUIDE FOR SELECTING APPLICATION METHODS FOR T HE REPAIR OFCONCRETE SURFACES 03731.5 WEATHER WALL SPECIFICATION ATTACH 2,4 TOP LEDGER TO CONCRETE WITH (1) 1/4"0xl-1/2" MIN. EMBEDMENT TITEN CONCRETE SCREWS ® 32" O.C. 2X4 WOOD STUDS 0 16" ON CENTER TOE NAILED TO EACH LEDGER WITH (2) 10—d NAILS UNFINISHED INTERIOR WALL 6 MIL PLASTIC WRAP OVER 1/2' COX PLYWOOD. TAPE ALL SEAM JOINTS IN 6 MIL PLASTIC WRAP 2X4 WOpq ATTAC F,D TO SLAB WRH 1 4 dx1-1%2 MIN. EMBEDMENT TITEN ONCREFE SCREWS ® 32 O.C. FIN, FLOOR CONT. CAULK BEAD ALONG BOTTOM TYP. STANDARD FLOOR WEATHER WALL mu r. TUTS. 2x4 WOQq ATTACHI� TO SLAB WITH 1/44x1-1/2 MIN. EMBEDMENT TITEN CONCRETE SCREWS ® 32" O.C. —TYP. TOP AND BOTTOM 1/2' CDX PLY —WOOD ATTACHED TO FRAMING W/ #10 WD. SCREWS AT 12' O.C. AT FIELD AND 6" O.C. AT EDGES OPTIONAL ATTACHMENT FOR 1/2" CDX PLY —WOOD ATTACHED TO FRAMING W/ 10—d NAILS AT 12' O.C. AT FIELD AND 6" O.C. AT EDGES 6 MIL PLASTIC OVER CDX PLYWOOD TAPE ALL SEAMS GENERAL NGTES: 1. ALL 20 STUDS, SILL PLATES, AND PLANKING TO BE SOUTHERN YELLOW PINE, GRADE 2. 2. DIMENSIONS SHOWN PROVIDED AS A GUIDE TO CONTRACTOR. ACTUAL FIELD CONDITIONS AND LOCATION MAY VARY. 3. INSTALL ALL WEATHER WALLS MIN. 24" FROM THE AREA OF REPAIR. 4. SUITABLE PROTECTION AGAINST DAMAGE BY WEATHER, CONSTRUCTION DEBRIS, AND TRAFFIC SHALL ALSO BE PROVIDED (INSTALLATION AND REMOVAL) FOR EXPOSED INTERIOR SURFACES, SUCH AS TILE FLOORS, DRYWALL, ETC, AS REQUIRED AND IS INCLUDED IN THE UNIT PRICING FOR WEATHER WALLS. 5. DAMAGE TO INTERIOR SURFACES BY INSTALLATION OF WEATHER WALLS SHALL BE AVOIDED. SHOULD DEVIATIONS FROM STRUCTURAL ATTACHMENTS SHOWN ON PLANS BE REQUIRED, THE ENGINEER SHALL BE NOTIFIED AND SHALL APPROVE SUCH DEVIATIONS. 6. CONTRACTOR SHALL BE SOLELY RESPONSIBLE FOR REPAIRING ALL DAMAGES TO UNIT INTERIORS AS A RESULT OF THE REMOVAL OF EXISTING COMPONENTS (DOORS, VTINDOWS, EFC.) AND/OR THE INSTALLATION AND REMOVAL OF WEATHER WALLS. 20 TOP LEDGER i WALL STUD PER PLAN 3 fI 2x4 BOT. LEDGER) CONT. 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