SECTION 03730

CONCRETE REPAIR WORK

PART 1 GENERAL

1.01 DESCRIPTION:

A. Provide materials labor and equipment necessary to repair concrete as specified

and indicated.

B. Complete cementitious repair mortar system installation in accordance with these

specifications and the mortar system manufacturers most current printed
instructions regarding surface preparation, application, inspection and
requirements for safety.

C. The areas of concrete repair shall be determined by the Contractor and the CM/CS
and shall include any location where acidic attack of the concrete surfaces has
reached a depth of [12 mm] or deeper and at any air voids, bugholes or
poorly consolidated concrete areas where the specified filler/surfacer materials
cannot be used for filling or surfacing of the concrete.

D. If repair work is required for an area indicated to receive protective lining or

coating, provide such repair in accordance with the requirements of this
specification and the related lining specifications.

E. The repair work specified herein is intended to cover the requirements for repair
of concrete only, to a maximum depth of approximately 1-1/2 [38 mm]. If after
blasting and cleaning, an area is discovered that requires a repair greater than 1-
1/2 [38 mm] deep, or an area is discovered that requires repair or replacement of
reinforcing steel, notify the CM/CS so that details may be provided to the
Contractor to complete the repair.

1.02 RELATED WORK:

(NTS: Select and list specification sections for inserting into this subsection based
on the following:
1. Specification sections that contain products and construction that the reader
might expect to find in this section BUT are specified elsewhere.
2. Specification sections referenced in the body of this section.)
A. Section 01025: Measurement and Payment.

B. Section 01070: Abbreviations and Definitions.

C. Section 01090: Reference Standards.

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 D. Section 01100: Special Project Procedures.

E. Section 01300: Submittals.

F. Section 01400: Quality Control.

G. Section 01500: Construction Facilities and Temporary Services.

H. Section 01600: Material and Equipment.

I. Section 01700: Contract Closeout.

J. Section 02050: Demolition and Alterations.

K. Section 03200: Concrete Reinforcement.

L. Section 03300: Cast-In-Place Concrete.

1.03 REFERENCES:

A. NACE (National Association of Corrosion Engineers):

1. NACE Publication 6D-173, A Manual for Painter Safety.

2. NACE Publication 6F-163, Surface Preparation of Steel or Concrete Tank

Interiors.

3. NACE Publication TPC2, Coatings and Linings for Immersion Service.

B. ASTM (American Society for Testing and Materials):

1. ASTM C33: Standard Specifications for Concrete Aggregates.

2. ASTM C150: Standard Specification for Portland Cement.

3. ASTM C321: Standard Test Method for Bond Strength of Chemical-Resistant

Mortars.

4. ASTM C882: Test Method for Bond Strength of Epoxy Resin Systems.

5. ASTM D570: Test Method for Water Absorption of Plastics.

6. ASTM D638: Test Method for Tensile Properties of Plastics.

7. ASTM D695: Test Method for Compressive Properties of Rigid Plastics.

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 8. ASTM D790: Standard Test Method for Flexural Properties of Unreinforced
and Reinforced Plastics and Electrical Insulating Materials.

9. ASTM D4262: L.R. Standard Test Method for pH of Chemically Cleaned or

Acid Etched Concrete Surfaces.

10. ASTM E337: L.R. Standard Practice Test Method for Measuring Humidity
with a Psychrometer.

C. Equivalent British/European codes and standards may be used; however, the

equivalency shall be demonstrated and submitted by the Contractor and approved
by the CM/CS.

1.04 QUALITY ASSURANCE:

A. Provide in accordance with Section 01400 and as specified.

B. Adhere strictly to the manufacturers current printed recommendations regarding

temperature at time of application for all work involving epoxy, cement base
coating and protective coating. Do not use epoxy materials when either the
temperature of the concrete to be repaired or the ambient temperature is below 50
degrees F. [10 deg. C], 24 hours before, during, or for a period of 48 hours after
the completion of the repair. Temporary heat may be used to meet the specified
requirements.

C. Use new epoxy, cement base coating, and protective coating materials and use
within the shelf life limitations set forth by the manufacturer. Clearly mark the
shelf life limitations of each container.

D. Epoxy Adhesive Application: Epoxy injection work shall be performed by an

organization or person who is an experienced applicator which has been
successfully used on at least three similar structural repairs at installations that
have operated for a minimum of five years. Any foreman or epoxy gun operator
assigned to the work must have had at least two years experience in this type of
work within the past 5 years, and in the specified duty to which he is assigned.

E. Use only products of the specified Repair Mortar System Manufacturer(s) or

equal.

F. The Contractor is ultimately responsible for the concrete repair work. Inspections
by the CM/CS or others do not limit the Contractors responsibility.

G. Make all parts of the work accessible for inspections by the CM/CS or others.
Any conditions found to not be in conformance with the specifications shall be
corrected when notified by the CM/CS at no additional cost to the Owner.

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 H. Provide a Project Manager on site at all times when work is ongoing who is
thoroughly familiar with the work in progress. This Project Manager shall
represent the Contractor and shall have authority to receive and execute all
instructions given by the CM/CS.

I. Any changes in the specified repair mortar work methods shall be allowed only
with the written approval of the CM/CS.

J. Technical field support or training services required by the approved material

manufacturers shall be provided at no additional cost to the CM/CS.

1.05 SUBMITTALS:

A. Provide in accordance with Section 01300:

B. Submit the following prior to commencing any phase of the work covered by this
section:

11. Procedures proposed for the accomplishment of repair work. Include a

detailed description of the methods and equipment to be used for each
operation, and the sequence of operations to be coordinated with other
works in progress.

12. Manufacturers current printed recommendations and product data sheets for
all repair mortar system products including performance criteria, surface
preparation, ambient condition requirements and applications, volatile
organic compound (VOC) data, and safety requirements.

13. Material Safety Data Sheets (MSDS) for any materials brought on-site
including all repair mortar system materials, solvents and abrasive blast
media.

14. A list of five reference projects where the repair mortar system has been
installed for at least two years including customer names and current
telephone numbers.

15. Qualifications of foreman and epoxy gun operators and demonstration of

meeting the minimum requirements specified.

16. Certified copies of laboratory test reports, including all test data shall be
submitted for protective coating and epoxies.

17. Design Mixes: Provide concrete and cement mortar in conformance with
Section 03300 and as specified herein.

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1.06 DELIVERY, STORAGE AND HANDLING:

A. Provide in accordance with Section 01610 and as specified.

B. Provide shelter to store materials in area or areas designated by the Owner solely
for this purpose. Confine mixing, thinning, clean-up and associated operations
and storage of repair mortar materials debris before authorized disposal, to these
areas.

C. Mix all specified materials in the sheltered mixing operation and materials from
direct sunlight and inclement weather. Protect facilities from staining and
damage.

D. Waste materials shall not be disposed of on-site.

E. Store waste temporarily in closed, nonflammable containers until final disposal.

Keep no rubbish in Contractors area longer than 24 hours.

F. Deliver all materials to the job site in new, unopened containers. Each container
shall bear the manufacturers name and label.

1. Labels on all material containers shall contain the following information:

a. Name of product.

b. Federal Specification Number if applicable.

c. Manufacturers batch number.

d. Manufacturers name.

e. Generic type of material.

f. Hazardous material identification label.

g. Shelf-life date.

2. Clearly mark all containers indicating any safety hazards associated with the
use of or exposure to the materials.

3. Materials shall be handled and stored to prevent damage or loss of label.

Protection of materials is the Contractors responsibility.

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1.07 JOB CONDITIONS:

A. Environmental Requirements:

1. Comply with the Cementitious Repair Mortar System Manufacturers

recommendations as to environmental conditions under which materials can
be applied and cured.

2. Do not apply materials when dust is being generated.

B. Protection:

1. Cover or otherwise protect finish work or other surfaces not being repaired.

C. Ventilation:

1. Provide ventilation as required to meet product requirements prior to, during,

and after application.

PART 2 PRODUCTS

2.01 CEMENTITIOUS REPAIR MORTARS:

A. The cementitious repair mortar system shall meet the following requirements:

1. Compressive Strength:

Method: ASTM C-109 for 7 days of curing.

Requirements: Minimum of 4,000 psi [28 MPa].

2. Bond Strength to Hardened Concrete:

Method: ASTM C-882 modified after 28 days.

Requirements: Minimum of 2,000 psi [14 MPa].

3. NonSag Thickness:

Method: Field Trial.

Requirement: [6 mm] minimum.

4. Color: Concrete Gray.

5. Flexural Strength:

Method: ASTM C-349.

Requirement: Minimum of 1,200 psi [8.5 MPa] after 28 days.

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 B. Products:

1. Provide a non-shrink cementitious repair mortar material as manufactured by:

a. EMACO S88CI manufactured by Master Builder, Inc., 23700 Chagrin

Boulevard, Cleveland, Ohio 44122.

b. Thorite manufactured by Thoroc, 7800 N.W. 38th Street, Miami, Florida

33166.

c. Underlayment F-120 by Sauereisen, Inc., 160 Gamma Drive, Pittsburgh,

PA 15238-2989.

d. Or approved equal.

2.02 EPOXY ADHESIVE:

A. Epoxy adhesive Concrete Crack Repair: Two-component, 100 % solids, 100%

reactive adhesive system with no dilutents, wetting agents or volatile solvents.
The specified material is a standard for the quality and type of epoxy to be used
on this project. The specific material to be used for the various crack widths
must be selected by the manufacturer with backup data submitted in the form of
a shop drawing transmittal defining the crack width limitation and temperature
restraints for each type of epoxy. The epoxy must meet or exceed the following
property requirements:

1. Tensile Strength:

Method: ASTM D638.

Requirement: 5,000 psi [35 MPa].

2. Tensile Elongation at Break:

Method: ASTM D638.

Requirement: 4% maximum.

3. Flexural Strength:

Method: ASTM D790.

Requirement: 10,000 psi [70 MPa].

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 4. Flexural Modulus:

Method: ASTM D 790,

Requirement: 550,000 to 700,000 psi [3800 to 4800 MPa].

5. Compressive Strength:

Method: ASTM D695,

Requirement: 10,000 psi [70 MPa].

6. Compressive Modulus:

Method: ASTM D695,

Requirement: 200,000 to 350,000 psi [1400 to 2400 MPa].

7. Bond Strength:

Method: ASTM C321

Requirement: 500 psi [3.5 MPa] in 6 hours @ 70 degree F [21 deg. C].

8. Heat Deflection Temperature:

Method: ASTM D648.

Requirement: 130 degree F [54 deg. C]. Test specimens must be cured
with peak exothermic temperature of the adhesive not
exceeding 77 degrees F [25 deg. C].

B. Products:

1. Provide an Epoxy Adhesive Concrete Crack Repair material as

manufactured by:

a. Epoxy to be Concresive 1380 manufactured by Adhesive

Engineering Company, Lawrence MA.

b. MetaBond JMLV as manufactured by American Metaseal

Company, Carlstadt, NJ.

c. Sikadur 52 as manufactured by Sika Chemical Corp., Lyndhurst,

NJ.

d. Or approved equal.

C. Epoxy Bonding Agent: Two-compound, 100% solids, 100% reactive epoxy

resin system. The epoxy to be Concresive 1011-LLp by Adhesive Engineering
Company, Lawrence, MA; MetaBond GP by American Metaseal Company,

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 Carlstadt, NJ; Sikadur 32 Hi-Mod by Sika Chemical Corp., Lyndhurst, NJ; or
approved equal.

D. Epoxy Mortar: Two-component, 100% solids, 100% reactive epoxy resin

system:

1. For horizontal surfaces the epoxy to be Concresive 1315 by Adhesive

Engineering Company, Lawrence, MA; MetaBond LM by American
Metaseal Company, Carlstadt, NJ; Sikadur 22 Lo-Mod LV by Sika
Chemical Corp., Lyndhurst, NJ; or approved equal.

2. For vertical and overhead surfaces the epoxy to be Concresive 1180 by

Adhesive Engineering Company, Lawrence, MA; MetaBond LM Gel by
American Metaseal Company, Carlstadt, NJ; Sikadur 23 Lo-Mod Gel by
Sika Chemical Corp., Lyndhurst, NJ; or approved equal.

E. Epoxy Grout: Two-component, 100% solids, 100% reactive epoxy resin

system. The epoxy to be Concresive 1184 by Adhesive Engineering Company,
Lawrence, MA; MetaBond HM by American Metaseal Company, Carlstadt,
NJ; Sikadur 35 Hi-Mod LV by Sika Chemical Corp., Lyndhurst, NJ; or
approved equal.

F. Chemical Grout: Chemical grout for sealing water leaks in cracks or holes to be
rapid expanding and fast curing. Chemical grout to be Scotch-Seal Brand
Chemical Grout 5600 (Foam) by Minnesota Mining and Manufacturing
Company, Minneapolis, MN; Sikafix Polyurethane Chemical grout by Sika
Chemical Corp., Lyndhurst, NJ; Durigel 120 by Avanti Products Company,
Houston, Texas; or approved equal.

G. Cement Mortar:

1. Portland Cement, Type II: Provide in accordance with ASTM C150. One
brand from only one source to be used throughout the work.

2. Provide fine aggregate in conformance with ASTM C33 and with Section
03300.

3. Provide water in conformance with Section 01500.

H. Surface Seal:

1. Concrete: Provide in accordance with Section 03300.

2. Reinforcement: Provide all reinforcement in accordance with Section

03200.

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2.03 MISCELLANEOUS MATERIALS:

A. Obtain blast material, primers and other products required by the concrete repair
system manufacturers to complete the repair work at no additional cost to the
Owner.

2.04 MIXES

A. Epoxy Mortar and Epoxy Grout: Mix with Ottawa silica sand or an aggregate
mix recommended or supplied by the epoxy manufacturer.

B. Cement Mortar: Proportion mortar to have compression strength of 4,000 psi

[28 MPa] at the end of 28 days.

C. Concrete: Provide air entrained concrete, proportioned to have compression

strength of 4,000 psi [28 MPa] at the end of 28 days. Slump to be in the range
of 2 to 3 inches [50 to 75 mm].

2.05 EQUIPMENT:

A. Equipment for application of the epoxy must be portable and consist of positive
displacement type pumps with interlock to provide positive ration control of
exact proportions of the two components at the nozzle.

B. Pumps must be electric or air powered and shall provide an in-line mixing and
metering system and must contain drawback plugs.

PART 3 EXECUTION

3.01 SURFACE PREPARATION REQUIREMENTS:

A. General Surface Preparation Requirements.

1. Used or spent blast abrasive shall not be reused on this project.

2. The compressed air used for blast cleaning shall be filtered free of
condensed water or oil. Clean moisture traps at least once every four
hours or more frequently if required to prevent moisture from entering the
supply air to the abrasive blasting equipment. Air compressors shall
comply with all applicable federal, state, and municipal codes and
regulations.

3. Install air separators immediately downstream of compressor discharge

valves and at the discharge of the blast pot discharges. Check these
separators with the same frequency as the moisture traps as defined in item
2 above.

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 4. Immediately repair or replace any regulators, gauges, filters, and
separators for all of the compressor air lines to blasting nozzles that fail.

5. Use abrasive blast nozzles of the venturi or other high velocity type
supplied with a minimum of 100 psig [700 KPa] air pressure to obtain the
specified degree of cleanliness.

6. Provide ventilation for airborne particulate evacuations to meet all

pertinent safety standards and to optimize visibility for both blast cleaning
and inspection of the substrate during surface preparation work.

7. Provide ground fault interrupters on all electrical equipment used for the
work covered by this Section.

B. Degreasing.

1. Degrease the surfaces prior to blast cleaning. Use alkaline cleaning

solutions, steam cleaning, or hot water with detergents for degreasing as
recommended by the repair mortar system manufacturer.

C. Surface Preparation of Concrete Substrates at Repair Areas Covered by this

Section.

1. Saw cut the perimeter of the repair area to a minimum depth of [12
mm] below the surface of the concrete. Chip all loose concrete in the
repair area to remove loose and degraded concrete until a sound substrate
is reached.

2. Perform abrasive blast cleaning or ultra high pressure water jetting as

required in Section 09942.

3. Install cementitious repair mortar as specified in this Section in 3.03.

4. Once sufficient cure of repair mortar has been achieved (3 days @ 70

degrees F [21 deg. C] minimum), abrasive blast clean of all areas that have
received concrete repair mortar to remove all existing protective coating
materials, and to produce a sound, clean substrate free of laitance, surface
contaminants, and loose materials, including calcium sulfate (Gypsum).
Preparation shall provide a surface profile that is similar to 60 grit sand
paper and is uniform.

5. Vacuum clean all surfaces to remove all loose dust, dirt, and debris.

3.02 APPLICATION AND CURING OF THE CEMENTITIOUS REPAIR MORTAR

SYSTEM:

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 A. Mix the cementitious repair mortar material components in accordance with the
manufacturers instructions. Concrete surfaces should be surface saturated dry
(SSD) with no standing water prior to mortar application.

B. Work a wet scrub coat of the mortar per the manufacturers recommendations
into the pores and voids in the substrate, and over the substrate prior to mortar
application by trowel.

C. Apply the cementitious repair mortar using gunite, trowel or castable methods
and using a steel trowel work the material into the surface. Fill voids from
deepest to shallowest areas as the application work proceeds. Strictly follow the
manufacturers application requirements.

D. Once the repair areas are filled with repair mortar, strike off the mortar level
with the surrounding concrete substrate. Do not leave a broom finish. Finish
with a steel trowel until closed up at the surface and flat.

E. Cure the repair mortar in strict accordance with the manufacturers instructions.

3.03 QUALITY CONTROL INSPECTION AND TESTING:

A. Perform, verify, and record the inspection functions listed below for each work
shift, and submit to the CM/CS as specified in Part 1.05 of this Section in the
form of a daily inspection report. Comply with the following acceptance
criteria and include the following information in each report:

1. Inspect surfaces to be repaired at completion of surface preparation.

Provide sign-off by Contractors Project Manager that the surface meets
manufacturers requirements.

2. Measure and record the ambient air temperature twice each shift (at least 4
hours apart) using a thermometer and measure and record substrate
temperature twice each shift using a surface contact thermometer.

3. Verify that mixing of repair materials is in accordance with the

Cementitious Repair Mortar System Manufacturers instructions. Provide
sign-off by the Contractors Project Manager.

4. Verify that the pot life of repair materials is not exceeded during
installation. Retempering of the repair mortar will not be permitted.
Provide sign-off by the Contractors Project Manager.

5. Verify that curing of the cementitious repair mortar system is in

accordance with the Repair Mortar System Manufacturers instructions

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 and that the final surface is uniform and smooth. Provide sign-off by the
Contractors Project Manager.

6. Perform concrete substrate pH readings using pH indicating paper. The

required surface pH for the work covered by this section shall be between
7.0 and 12.0. If pH measurement is lower that 7.0, repeat surface
preparation work until the required surface pH has been attained. Provide
Contractors Project Manager sign-off.

B. Rework unacceptable areas until the CM/CS determines that the work is in
compliance with these specifications at no additional cost to the Owner.

3.04 EPOXY ADHESIVE CONCRETE CRACK REPAIR:

A. Pressure inject all indicated cracks with a continuous in-line meter and mix
device, capable if injection pressure up to a maximum of 300 psi [2.1 MPa] to
develop at least a 90% penetration of all cracks without the inclusion of air
pockets in the epoxy, and to achieve the specified bond-strength of the cracked
sections. Achieve 100% penetration of the vast majority of cracks.

B. Entry Ports: Space entry ports at a distance along the seal not greater than the
thickness of the cracked member. Space ports so that the injected material
travels between ports and the cracks are filled to specified requirements.

3.05 APPLICATION OF EPOXY ADHESIVE CONCRETE CRACK REPAIR:

A. Contractor must supply equipment and materials, and adjust the application
procedure to achieve at least a 90% filing of all cracks without drainout and
without the inclusion of air pockets or voids in the epoxy, and to achieve
structural bonding of the cracked section. Achieve 100% penetration in the
majority of the cracks.

B. Inject epoxy under pressure by use of a rubber tipped nozzle held tightly against
the port, or by the use of entry port fittings. Injection to begin at the lower entry
port and continue until there is a show of adhesive material at the entry port
directly adjacent to or above the port being pumped.

C. When adhesive travel is indicated at the next port, discontinue the injection on
the port being pumped and sealed, and transfer injection to the next adjacent
port. Injection must be continuous until the crack is completely filled. Fill all
small radiating cracks at the same time as filling prime cracks.

D. Report any condition which prevents penetration of the crack to the CM/CS.

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 E. Modifications to the above installation procedures, if necessary to obtain the
specified penetration, must be approved by the CM/CS before the crack sealing
work is started.

F. Apply epoxy bonding agent to all existing concrete surfaces which are to
receive new cast-in-place concrete and as indicated. Mix and apply compound
in accordance with the epoxy manufacturers current printed recommendations.

3.06 CONTRACT CLOSEOUT:

A. Provide in accordance with Section 01700.

END OF SECTION

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