Guide Specification Epoxy.com Products #409/#407

SPECIFICATION FOR EPOXY.COM PRODUCT #409/407

TRAFFIC BEARING MEMBRANE SYSTEM

PART 1  GENERAL

1.1   Scope of Work

A. This specification covers workmanship, materials, and equipment required for the removal of existing coating or asphalt, treatment of cracks, repair of spalls, expansion joint repair, partial depth and full depth deck repairs, shotblasting and application of resilient traffic bearing membrane to existing concrete parking deck and removal of existing wall and ceiling coatings and application of new wall and ceiling coatings.

1.2   Submittals

A. Product Data:  The contractor shall submit to the Engineer, catalog information sheets for each material specified and shall state the specific usage for each product submitted. Surface preparation, mixing, and application instructions shall be included.

B. Installation Methods:  The contractor shall submit to the Engineer, manufacturer’s recommended procedures for mixing, application and curing of all products.

1.3  Quality Assurance

Quality Control shall be by the responsibility of the Contractor and shall follow all applicable standard codes.

The manufacturer shall clearly mark all containers with the following information:

1. Name of Manufacturer

2. Manufacturer’s product identification

3. Date of expiration of shelf life

4. Warning for handling and toxicity

The manufacturer shall have a knowledgeable technical representative available for assistance to the Contractor during material application procedures if and when required.

1.4         Delivery

All materials shall be delivered in sealed containers with labels legible and intact.

1.5   Storage of Materials

A. The Contractor shall store all materials at temperatures between 60 - 80°F unless otherwise recommended by the manufacturer.

1.6         Handling of Materials

A. Handle all materials in a safe manner and in a way to avoid breaking container seals.

B. Keep containers closed until just prior to use. Check materials for skinning and use any partially used containers before opening new containers. If material has been open to the atmosphere longer than 1 week, discard material.

C. Contractor shall provide all necessary protective equipment, clothing, goggles, etc., for work around chemicals, polymers, etc. that may cause skin and eye irritation.

PART 2  CONTRACTOR QUALIFICATIONS

A. Contractor must have a minimum ________years experience in this type of project.

B. A list of these projects shall be submitted to the engineer for approval prior to award of the bid.

PART 3  PRODUCTS

3.1 Crack Sealer Material

A. The material for sealing concrete cracks shall be a two (2) component, 100% solids, flexible epoxy adhesive. The material shall be Epoxy.com Product #701 by Epoxy.com a division of Epoxy Systems, Inc. of Dunnellon, Florida. or approved equal.

3.2 Spall Repair Material – Small - Flatwork, Vertical & Overhead

A. The primer for exposed reinforcing steel shall be a single component zinc rich primer meeting SSPC Paint Specification 20, Type II Organic Zinc Rich Primer. The material shall be Epoxy.com Product #1200 by Epoxy.com a division of Epoxy Systems, Inc. of Dunnellon, Florida or approved equal.

B. The epoxy bonding agent shall be a two component, 100% solids, epoxy resin system meeting the requirements of ASTM C-881-90, Types I and II, Grade II, Class B and C. The material shall be Epoxy.com Product #7 Epoxy Bonding Agent, by Epoxy.com a division of Epoxy Systems, Inc. of Dunnellon, Florida. or approved equal.

C. The patching mortar shall be a one component, trowelable, patching mortar, designed for overhead, vertical, or horizontal use.  This material shall be a modified cement mortar, fiber reinforced and contain a migratory corrosion inhibitor. The material shall be Epoxy.com Product #1000 Rapid Hardening Trowelable Mortar, by Epoxy.com a division of Epoxy Systems, Inc. of Dunnellon, Florida or approved equal.

D. The coarse aggregate shall be a dry-bagged ½” nominal aggregate.  This material shall be Coarse Aggregate as supplied by Epoxy.com a division of Epoxy Systems, Inc. of Dunnellon, Florida or approved equal.

 

3.3 Expansion Joint Repair

A. The joint filler shall be a two component polysulfide, chemically cured elastomeric.  Material shall has Shore A Durometer of 25.  The material shall meet ASTM C-920-95 NS Grade, Class 25 for non-sag applications and ASTM C-925-95 Grade P, Class 25 for self leveling applications.  The material shall be Epoxy.com Product #900/ Product #901 Polymeric Joint Sealant Epoxy.com a division of Epoxy Systems, Inc. of Dunnellon, Florida or approved equal.

3.4 Partial Depth Repair

A.    The primer for exposed reinforcing steel shall be a single component zinc rich primer meeting SSPC Paint  Specification 20, Type II Organic Zinc Rich Primer. The material shall be Epoxy.com Product #1200 by Epoxy.com a division of Epoxy Systems, Inc. of Dunnellon, Florida or approved equal.

B.   The epoxy bonding agent shall be a two component, 100% solids, epoxy resin  system meeting the requirements of ASTM C-881-90 , Types I and II, Grade II, Class B and C. The material shall be Epoxy.com Product #7 Epoxy Bonding Agent, by Epoxy.com a division of Epoxy Systems, Inc. of Dunnellon, Florida. or approved equal.

     

C.    The patching material shall be a shrinkage compensated, fiber reinforced, silica fume enhanced cement mortar that contains a migratory corrosion inhibitor. The material shall be Epoxy.com Product #1010 Repair Mortar by Epoxy.com a division of Epoxy Systems, Inc. of Dunnellon, Florida or approved equal.

3.5 Resilient Traffic Bearing Membrane

A. Primer – The primer material shall be a two component polyurethane primer that prepares concrete surfaces to accept resilient membranes The primer shall be Epoxy.com Product #844 Membrane Primer, by Epoxy.com a division of Epoxy Systems, Inc. of Dunnellon, Florida or approved equal.

B.  Epoxy.com Product #409 Traffic Bearing Membrane – The base/intermediate coat and finish/top coat shall be a 100% solids, ambient cure, impermeable elastomer coating. The membrane shall be resilient and accommodate movement in concrete substrates. The coating shall be Epoxy.com Product #409 Traffic Bearing Membrane for areas not exposed to UV or Epoxy.com Product #407 Aliphatic Traffic Bearing Membrane, for exterior areas exposed to resist ultra violet breakdown by Epoxy.com a division of Epoxy Systems, Inc. of Dunnellon, Florida or approved equal..

C. Broadcast Aggregate for the intermediate coat shall be Epoxy.com Product #75 Filler by Epoxy.com a division of Epoxy Systems, Inc. of Dunnellon, Florida or  approved equal (20/30 rounded silica sand).

D. Finish coat – The finish coat shall be  Epoxy.com Product  #409 (for non-UV exposed areas) or Epoxy.com Product #407 Traffic Bearing Membrane by Epoxy.com a division of Epoxy Systems, Inc. of Dunnellon, Florida or approved equal.

3.6 Parapet Coatings

A. The brick parapet coating shall be a one component water based silane material that produces a hydrophobic water shedding effect when applied to concrete masonry brick or stone surfaces.  The brick parapet coating shall be Epoxy.com Product #39 Silane Penetrating Sealer (Waterbased) or Product #41 Penetrant Sealer (Solvent based) by Epoxy.com a division of Epoxy Systems, Inc. of Dunnellon, Florida or approved equal.

     

PART 4  EXECUTION

4.1 Remove Existing Coating

All existing coating shall be removed by best field practices to expose the existing concrete.

4.2   Crack Sealing

Cracks greater than 1/16” wide shall be routed and sealed in the following manner:

A. Route cracks to a minimum width of ¼” and minimum depth of 1/2” 

B. Remove routing dust and debris using air blower and vacuum equipment.

C. Seal cracks with Epoxy.com Product #701. Mix ratio is 1 to 1 by volume. Mix only what can be applied in 10 minutes.

4.3   Spall Repair – Small - Flatwork, Vertical & Overhead.

A. Remove unsound concrete to ¾ inch below steel reinforcing bars where practical.

B. Protect exposed rebar with Epoxy.com Product #1200 Zinc Rich Primer

C. Apply Epoxy.com Product #7 Epoxy Bonding Agent

D. Rebuild to original profile with Epoxy.com Product #1000 Rapid Hardening Trowelable Mortar. Coarse Aggregate shall be added where depth of repair exceeds 2”.

4.4 Expansion Joint Repair

A. Remove existing joint

B. Install proper joint sealant to accommodate movement, Epoxy.com Product #900 or Epoxy.com Product #901 Polymeric Joint Sealant.  Joint sealant material to be designated by the Engineer dependent upon calculated joint movement.

 

4.5 Partial Depth Concrete Deck Repair 3/8” minimum

A. Remove unsound concrete to ¾” below existing reinforcing steel where practical. 

B. Clean all reinforcing steel by sandblasting, power wire brushing or other method that will yield a similar result.

C. Replace reinforcing steel where necessary with epoxy coated rebar.

D. Apply Epoxy.com Product #7 Epoxy Bonding Agent

E. Place Epoxy.com Product #1010 Repair Mortar in such a manner that will return the area to its original thickness and shape. For economical purposes, when depth of patch exceeds 2”, up to 25 lbs of Coarse Aggregate may be added to each 50 lb bag of Epoxy.com Product  #1010.

F. Cure concrete according to ACI 3.08-5  -2.2.3 Wet Curing

4.6   Shotblasting

Prior to shot blasting concrete, the surface shall be free of all oil, grease, dirt, laitance, and other contaminants prior to mechanical preparation to provide maximum chemical and mechanical bond. The prepared concrete must be treated to provide a profiled substrate to meet the CSP ranking of 4 to 8.

Shot blast the entire concrete deck to receive membrane system with S-330 blast media. Blasting should be performed so as to leave, clean, “white” concrete with a uniform stipple finish. This method is limited to horizontal surfaces not within four (4) inches of walls, columns, or other fixed obstructions. Additional mechanical methods must be used to supplement preparation for areas not within reach of shot blast equipment. Use best field practices with appropriate power tool equipment for these areas.

Care must be taken to carefully remove all spent abrasive media and loosened concrete particles following the shot blast process. The use of magnetic roller to collect spent shot is recommended. Sweep entire concrete area and follow this by vacuuming concrete to insure other loose contaminants are removed prior to application of any repair products or membrane application.

Care shall be taken to protect and keep the shot blasted areas clean and contaminant free. Paper or plastic may be used to cover and protect concrete from other trades, applications, procedures and traffic. Foot covers are required for those walking on prepared, cleaned concrete to insure cleanliness levels are maintained.

 Post Blast Track Quality Assurance

After shot blast is completed perform moisture testing on concrete deck. The installer is required to test and record all areas prior to substrate repair and membrane installation. Two (2) testing methods are acceptable. The first method is a pass/fail test using an Elcometer 118 Moisture meter. Levels indicating 5% or less on Concrete Scale are acceptable to proceed with substrate repair and primer and membrane installation. In the event that borderline, marginal or inconsistent or unacceptable levels are identified, then proceed with the following additional testing. Verify the areas to be tested are accessible for both placement and recovery of testing at least 60 to 72 hours after placement. Make sure the ambient temperature and substrate temperature will resemble that of when the finishes will be applied. Lower temperatures slow or stop the moisture transmission and will produce misleading results. Test results will be most accurate when the slab surface is above 65F. Install at least one Vaprecision Vapor Emission Test  Cartridge for each 1,000 feet of deck area. At end of test, weigh the cartridge within one (1) hour of removal from test location. Record all data in a booklet as well as on dish lids. The allowable upper threshold shall not exceed 5.0 pounds per 1,000 square feet. The number of pounds refers to the actual weight of water passing through a 1,000 square foot surface. If any readings exceed 5.0 pounds, immediately report to manufacturer of repair products and membrane system for technical directions and procedures. Do not proceed with any work until directed.   

4.7  Traffic Bearing Membrane Application

All substrates to receive membrane shall be clean, sound, and dry.  The surface shall have a moisture content of 5% or less using a Elcometer 118 Moisture Meter. Attention must be paid to relative humidity and dew points.  The dew point shall not exceed 5 degrees above ambient temperature and relative humidity levels shall be less than 85%.

A. Primer – Epoxy.com Product #882Primer  -  Apply immediately after mixing. Apply primer by brush, roll or spray at a rate of 3.0 to 4.0 WFT (@ 350 square feet per gallon) to achieve 3.0 to 4.0 mils DFT.  Allow primer to dry a minimum of four (4) hours at 70°F. Maximum recoat shall not exceed 36 hours at 70?F. If maximum recoat interval is exceeded solvent wipe the primed area and lightly abrade. Follow this with a solvent wipe to remove all contaminants. Apply another light tack coat of FX-545 at a rate of 2.0 to 3.0 mils WFT (@ 500 square feet per gallon) to achieve 2.0 to 3.0 mils DFT. At this point take all means necessary to meet the necessary minimum and maximum recoat intervals.

B.    Base Coat - Apply base coat of Epoxy.com Product #409 Traffic Bearing Membrane (Gray) with notched squeegee or straight block squeegee and back roll with ½” nap roller at a rate of 22.0 to 25.0.0 mils WFT (@ 64 square feet per gallon) to achieve 22.0 to 25.0 mils DFT. Spike rolling is also recommended.  While coating is still wet broadcast FX-701 Filler at a rate of ½ pound per square foot. Allow to cure a minimum of eight (8) hours at 70°F or above. Maximum recoat interval shall not exceed 24 hours at 70°F. If maximum recoat interval is exceeded solvent wipe area and lightly abrade. Follow this with a solvent wipe to insure all contaminants are removed. Following this procedure the installer may proceed with the final application after sweeping, vacuuming or blowing down any and all loose aggregate.

C. Finish Coat - Apply Epoxy.com Product #409 Traffic Bearing Membrane (Gray) or Product #407 Traffic Bearing Membrane (Gray) with notched squeegee or straight block squeegee and back roll with ½” nap roller at a rate of 22.0 to 25.0 mils WFT (@ 64 square feet per gallon) to achieve 22.0 to 25.0 mils DFT. Allow to cure a minimum of twelve (12) hours at 70°F or above prior to subjecting to foot traffic and 48 hours prior to opening to vehicular traffic.  Total DFT of System shall be approximately 44.0 to 60.0 mils DFT upon completion. Good painting practices shall be employed when applying primer, base / intermediate coat, finish / topcoat to prevent runs and imperfections after each coat.

D. Membrane shall be open to pedestrian traffic after 12 hours cure and vehicular traffic after 48 hours cure at 70°F or above.

4.80 Parapet Flashing

A. Remove existing parapet flashing.

B. Prep area to be flashed by sandblasting or other method that will yield a similar result.

C. Provide a cant between parapet wall and roof deck using Epoxy.com Product #900 or Product #901 duel component  Sealant.  If a void exists between the parapet wall and the roof deck, place - Round Backer Rod into the void to create a ½” thick joint to be sealed with Epoxy.com Product #916 duel component Polyurethane Joint Sealant.

4.90 Parapet Coating

A. Brick Parapets

1. Surface preparation  -- Prepare brick parapet surfaces by high pressure water washing, minimum 3500 psi. Allow areas to dry minimum 24 hours. 

2. Brick Parapet Coating  - Apply two coats of Epoxy.com Product #39 Silane Penetrating Sealer (Water based) at a rate of 200 square feet per gallon per coat.

PART 5  ENVIRONMENTAL

A. Do not perform membrane work when the quality of the work could be impaired by the prevailing work or weather conditions. All trades associated with concrete repairs, surface preparation and installation of membrane system shall conform to all local, state, and federal regulations including those set forth by OSHA, EPA and owner.

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