DIVISION 3 HEAVY DUTY CONCRETE FLOOR TOPPING SECTION 03340 PART 1 - GENERAL 1.01 GENERAL REQUIREMENTS A. The General provisions of the contract, including GENERAL CONDITIONS, SUPPLEMENTARY CONDITIONS AND DIVISION I, GENERAL REQUIREMENTS apply to the work specified in this section. B. DEFINITIONS 1.02 DESCRIPTIONS 1. Heavy Duty Concrete Floor Manufacturer: A-H EMERY Aggregate Topping as manufactured by Anti-Hydro International, Flemington, NJ, 08822, (908)284-9000. A. Work includes: Furnish all necessary materials, labor and equipment required to install heavy duty topping. B. Related work specified elsewhere: 1. Cast-in-Place Concrete, see Section 03300. 2. Reinforcing steel, see Section 03200 3. Integral Hardener, see Section 03320 4. Concrete Finishing, see Section 03346 5. Concrete Curing, see Section 03370 6. Joint Sealants, see Section 07900 1.03 QUALITY ASSURANCE A. Manufacturer's Qualifications 1. Obtain heavy duty floor topping materials from a single manufacturer with a minimum of twenty-five (25) years of experience providing materials of the type specified in this section. 1
2. The heavy duty floor topping manufacturer shall provide a representative who will instruct the applicator's crew on the proper techniques of applying the heavy duty floor topping. B. Applicator's Qualifications 1.04 GUARANTEE 1. Installation shall be performed by a concrete contractor with not less than years of satisfactory experience in the application of the type of system as specified in this section, and shall be approved by the manufacturer of the heavy duty floor topping. A. The contractor shall furnish the manufacturer's standard maintenance guarantee of the heavy duty concrete floor topping for a period of five years after installation. This maintenance guarantee includes the bond and hard, non-dusting qualities of the floor. Not included are damage due to Acts of God or other elements beyond the scope of protection of this system. B. The integral hardening manufacturer shall review the proposed concrete mix design for all concrete containing integral hardening admixture and shall submit, in writing, acceptance of proposed mix. C. The contractor shall notify the heavy duty concrete floor topping manufacturer seven working days prior to system placement. D. Anti-Hydro International shall furnish daily inspections and reports of each day's placement furnished to the architect and/or engineer. The cost of the inspections is to be borne by the contractor. 1.05 SUBMITTALS A. Product Data 1. Submit manufacturer's technical data on specified products of the heavy duty concrete floor topping. 2
2. Submit a letter from the manufacturer certifying compliance with the requirements of sections 2.01.B and 2.01.C of this specification. 3. Submit independent test data using X-ray diffraction or other accepted method on EMERY aluminum oxide and ferric oxide contents. 4. Submit a list of three installations where this system has been in use for five years or greater. 5. Submit a specimen copy of the Daily Inspection Report and Five Year Maintenance Guarantee. 1.06 MATERIAL DELIVERY, HANDLING AND STORAGE A. Primary system materials shall be delivered in the manufacturer's undamaged, unopened containers. Each container shall be clearly marked with the following: 1. Product name 2. Manufacturer's name 3. Lot/Batch numbers B. Provide equipment and personnel to handle the materials by methods which prevent damage. C. The contractor shall promptly inspect all direct jobsite deliveries to assure that quantities are correct and that materials comply with requirements and are not damaged. D. The contractor shall be responsible for all materials furnished by him, and he shall replace, at his own expense, all such material that is found to be defective in manufacture or that has become damaged in transit, handling or storage. E. Store materials in accordance with manufacturer's instructions, with seals and labels intact and legible. Maintain temperatures within the required range. Do not use materials which have been stored for a longer period of time than the manufacturer's maximum recommended shelf life. All materials containing portland cement or 3
1.07 JOB CONDITIONS other hydrating powders are to be kept dry until use to prevent damage. A. During material application, care should be exercised to comply with the temperature and humidity limitations of the materials used as defined by the manufacturer. PART 2 - MATERIALS 2.01 PRODUCTS A. Concrete Base Slab: For concrete materials, see Section 03300, Cast-In-Place Concrete and provide additional items as required by this section. 1. Concrete base shall have a maximum of 3% air content. Do not use air entraining admixtures. 2. Concrete mix shall contain a minimum of 5.6 bags of Type I portland cement per cubic yard and not more than 32 gallons of total liquid. Add "ANTI-HYDRO" Integral Admixture at the rate of 1.5 gallons per cubic yard. 3. Do not use fly ash, cement substitutes or slag cement in mix design. B. Integral Hardening Admixture: "ANTI-HYDRO" Integral Hardening Admixture. The integral hardening admixture shall conform to the following requirements: 1. The admixture shall have a twenty year history of successful use in similar applications. 2. The admixture shall have been tested by an independent testing laboratory according to ASTM C-501 and shown to increase abrasion resistance of a 4000 psi concrete by 75%, minimum over a control mix without the admixture. 3. The admixture shall increase compressive strength of the concrete mix design at 28 days by 5%, 4
minimum a control mix of the same design without the admixture. 4. The admixture shall have been tested by an independent testing laboratory in accordance with ASTM E-96-80 and shown to reduce water vapor transmission by one-half, minimum, over a control mix without the admixture and shall produce concrete with a perm rating of 0.04, minimum. C. Topping Aggregate: A-H EMERY, size A1, as manufactured by Anti-Hydro International, conforming to the following requirements: 1. Emery aggregate shall conform to Corps of Engineers CE-204 and shall consist of not less than 58% aluminum oxide and 24% ferric oxide. 2. Emery aggregate shall not be effected by freezing, moisture or cleaning compounds. 3. Emery aggregate shall be tested for conductivity and shall have a value of not more than 6.0 x 10-5 ohm-cm at room temperature. 4. Emery aggregate shall be crushed, factory graded, polyhedral in form and shall conform to the following gradation: Sieve Size %Retained 3/8 2-3 #4 30-50 #8 20-30 #16 10-25 #30 2-10 #50 0-5 #100 Trace D. A-H EMERY A1 PREMIX 1. A-H EMERY Aggregate shall be supplied "premixed", proportioned at the rate of 300 pounds of A-H EMERY 5
aggregate, 94 pounds of Type I portland cement, and workability agents. 2. A-H EMERY A1 PREMIX shall be mixed using clean equipment. Mixing liquid shall consist of "ANTI- HYDRO" integral floor hardener added with the mixing water. Use in accordance with the manufacturers' recommendations. NOTE TO SPECIFIER: SECTION 2.01 E.1. / Optional System E. A-H EMERY A1 AGGREGATE END OF NOTE. 1. A-H EMERY Aggregate shall be mixed at the site at the rate of 300 pounds of A-H EMERY Aggregate to 94 pounds of Type I portland cement. Mixing liquid shall consist of 1 quart "ANTI-HYDRO" Integral Hardening Admixture and not more than 4 gallons of total mixing liquid per bag of cement. 2. Compressive strength shall be tested in accordance with ASTM C-109 and shall produce minimum compressive strengths as below: 1 Day 6,000 psi 3 Days 8,000 psi 28 Days 14,000 psi 3. Flexural strength shall be tested in accordance with ASTM C-293 and shall produce minimum flexural strengths as follows: Flexural Strength: 7 Days 1,000 psi 28 Days 1,600 psi F. Bonding Agent: A-H EPOXY BONDING #125 or "ANTI-HYDRO" SLUSH COAT admixture, as manufactured by Anti-Hydro International. 6
G. Curing: A-H 3 WAY SEALER AIM as manufactured by Anti- Hydro International, consisting of a liquid type membrane-forming curing compound complying with ASTM-C- 309, Type I, Class A. Moisture loss not more than 0.055 grams per square centimeter when applied at 200 square feet per gallon. H. Joint Sealant: Saw cut joints shall be filled with A-H GROOVE & CRACK FILLER #250, elastic type modified epoxy filler, per Section. I. Materials for this specification are based on products of Anti-Hydro International and terminology used may include reference to manufacturer's proprietary product. Such reference shall be construed only as establishing the quality of material and workmanship to be used under this section and shall not be construed as limiting competition. PART 3 - EXECUTION 3.01 CONCRETE PLACEMENT A. For concrete base slab placement, see Section 03300, and provide additional items required by this section. 3.02 SLAB SUB-BASE 1. Concrete base shall be placed at 3" maximum slump. 2. Add integral hardening admixture to the mixing water or to the partially mixed concrete and continue mixing for an additional 30 revolutions at mixing speed. A. The base to receive the concrete slab for the heavy duty concrete floor finish shall be well drained, uniformly well compacted and free of frost and foreign materials. The base shall be damp but free of standing water. B. No concrete shall be placed on wet or soggy ground without first laying and compacting a bed of broken stone or gravel of adequate thickness to prevent the mud from mixing with the concrete. 7
3.03 CONCRETE BASE SLAB A. NEW CONCRETE BASE SLAB 1. Place concrete base slab between screed points to minimize handling. Concrete shall be placed and screeded using proper tools and equipment to prevent segregation. Use square tipped shovels to move concrete into place; do not use rakes. 2. Surface of base must be textured before concrete achieves final set. Texturing is done by cutting ribs in the surface with a coarse wire broom. The presence of laitance on the hardened base slab shall not be permitted. Water cure only. B. EXISTING CONCRETE BASE SLAB 1. Clean, and prepare existing concrete floor slabs with scarifying, shotblast, or waterblast equipment to a sufficient depth beyond the point of any contamination and loose materials. 2. Remove debris from jobsite. Powerwash the prepared surface to remove loose material. Cover base slab with polyethylene sheets if the topping application is delayed for more than 48 hours or the base slab is subject to debris or contamination from other trades. 3.04 APPLICATION OF TOPPING A. Surface Preparation: The concrete base slab shall be cleaned, dampened and treated with a slush coat consisting of 1 part "ANTI-HYDRO" Admixture, 3 parts water and enough Type I portland cement to make a creamy slurry. 1. Scrub slush coat into base surface with a stiff broom and place topping while slush coat is still wet. 8
B. Follow manufacturers instructions for epoxy bonding application. C. Topping: Mix topping as specified under section 2.01.5, and in accordance with manufacturer's instructions. D. Emery topping shall be straight edged or rolled level, immediately followed by bull floating or "darbying" for secondary leveling and compaction. 3.05 FINISHING A. After the topping has been allowed to stiffen (sustain foot pressure with no greater than 1/4" indentation), the first floating operation shall start. After completion of this operation, the topping shall be allowed to stiffen further. A second floating operation shall be done perpendicular to the first float. B. For subsequent trowelings, the blades of the power trowel shall be slightly tilted to produce a hard, smooth, finished surface free from chatter marks or blemishes. For further burnishing, continue troweling operation. 3.06 JOINTS A. Control Joints 1. Control joints shall be spaced in accordance with ACI Standard 302 - Concrete Floor and Slab Construction. All joints in base concrete must be carried through the topping. 2. Control joints shall be saw cut a minimum of 1/4 of the thickness of the concrete base slab and 2/3 the thickness of the A-H EMERY Topping. Cuts must be made as soon as the concrete or topping can be cut without raveling the edge, but not more than 24 hours after finishing. 3. Joints shall be filled with A-H GROOVE & CRACK FILLER #250, elastic type modified epoxy joint 9
filler per Section, at a minimum of 28 days after concrete placement. B. Construction Joints 1. Construction joints shall be keyed or doweled for load transfer as shown on the drawings. Construction joint edges in the topping should be compacted with a small radius edging tool. 2. Joints shall be filled with A-H GROOVE & CRACK FILLER #250, elastic type modified epoxy joint filler per Section, at a minimum of 28 days after concrete placement. 3.07 CURING AND PROTECTION A. The base Concrete and topping should be wet cured for a minimum of seven days in accordance with the provisions of ACI 302.1R-30, Section 8.1. B. As soon as the topping has been finished according to the provisions of section 3.05 of this specification, apply A-H 3 WAY SEALER AIM at the rate of 200-300 square feet per gallon. Allow to dry and immediately flood the topping with water. Cover with wet burlap and polyethylene. Maintain wet cure for a period of 7 days, minimum. C. Concrete base and topping shall not be placed in temperatures over 80 deg. F, in the direct rays of the sun, or are exposed to drying winds. Care should be taken to prevent water loss. Erect wind barriers, finish the concrete promptly and start wet curing immediately. D. Floor topping should not be subjected to traffic during the 7 day water curing period. If the slab is to be subjected to heavy traffic during the first two weeks, it should be protected by plywood sheets or planking. 3.08 QUALITY CONTROL TESTING DURING CONSTRUCTION 10
A. Quality control testing of base concrete shall conform to the requirements of Section 03300, "Cast In Place Concrete," section 3.16. B. Quality control testing of EMERY aggregate topping shall conform to the requirements of this section. C. The Owner will employ an inspector and testing laboratory approved by the Architect/Engineer to perform tests and to submit test reports to the local authorities, Owner, Architect, Engineer and Contractor. D. Sampling and testing for quality control during placement of topping may include the following, as directed by Owner's inspector. E. Compressive Strength of Hydraulic Cement Mortars: ASTM C-109-80. 1. Emery Aggregate Topping Temperature: Test hourly when air temperature is 50 degrees Fahrenheit and below, and when 80 degrees Fahrenheit and above; and each time a set of compression test specimens are made. 2. Compressive Strength Tests: ASTM C-109-80, one set (6 cubes 2" x 2" x 2") for each 3 cubic yards of EMERY aggregate topping placed for each day's pour; two specimens tested at 3 days, two specimens tested at 7 days, and two specimens tested at 28 days. Mold and store cubes for laboratory cured test specimens. 3. Strength level of cubes will be considered satisfactory if averages of sets of strength test results equal or exceed specified compressive strength, and no individual strength test result falls below specified compressive strength by more than 85%. F. Test results will be reported in writing to Architect, Structural Engineer and Contractor within 24 hours after tests. Reports of compressive strength tests shall contain the project identification name and number, date 11
3.09 JOB COMPLETION REV.8/14 HDCFT.DOC of topping placement, name of concrete testing service, location of topping batch in structure, and design compressive strength at 28 days. A. The Heavy Duty Floor Topping manufacturer shall inspect the completed hardened floor according to the manufacturer's guarantee provisions. The contractor shall correct all defects to meet this specification and those of the EMERY topping manufacturer. B. Clean up all debris, excess materials and equipment and remove from site. C. Guarantee paperwork must be processed within 60 days from the date of substantial completion. END OF SECTION 12