32C-024 ej gare outline spec - 2015
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DIVISION 3
1.01 Summary of Work
A. This work consists of partial and full depth concrete tee repairs.
1.02 Related Documents
A. R‐1 through R‐6 provide plans and all details.
2.01 Materials
A. Horizontal repairs
1. MasterEmaco T1060 (10‐60 Rapid Mortar)
2. MasterEmaco T415 (Emaco T415) or MasterEmaco T430 (Emaco T430)
3. Conproco Express Set
B. Redi‐mix concrete: 5,000 psi, 28‐day compressive strength, structural normal weight 145
pcf; W/C ratio, 0.38 maximum; fiber reinforced at 1.5 lbs/yd; air content 6% ± 1%.
1. Submittals
a. Product data for all materials and items including admixtures, etc.
b. Mix proportion with compressive strength test results.
2. Qualifications: contractor shall have minimum 5 years experience in performing
similar work to that shown on drawings.
1.01 Execution
A. Install and cure all pre‐engineered products in accordance with manufacturer’s
published procedures.
1.02 Redi‐Mix Concrete
A. Bonding Grout
1. After the existing concrete surface has been cleaned, it shall be uniformly
saturated by pre‐wetting for 2 hours minimum. Surface must be wet to saturated
surface dry (SSD) condition, and any freestanding water shall be completely
removed prior to placing the bonding grout. Immediately before placing concrete,
a thin coating of bonding grout shall be scrubbed into the properly prepared
surface of the existing concrete. Proper workmanship shall be exercised to insure
that all existing surfaces receive a thorough, even coating and that no excess grout
is permitted to collect in pockets. The rate of progress in applying grout shall be
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limited so that the grout does not become dry before it is covered with new
concrete.
2. Bonding grout for patching concrete to existing concrete shall consist of equal
parts by weight of Portland Cement and sand mixed in a portable mechanical
mixer with sufficient water to form a stiff slurry. The consistency of this slurry shall
be such that it can be applied with a stiff brush or broom to the old concrete in a
thin, even coating that will not run or puddle in low spots.
3. Should the bonding grout dry before the concrete is placed, the Contractor will
remove the dried grout and sandblast clean the grouted surface, at his expense,
before placing fresh bonding grout.
4. Prepared surfaces shall be clean and free of laitance, foreign material and any
debris encountered during surface preparation. Do not allow cement to dry and
re‐adhere on the surfaces. The surface shall be uniformly saturated by wetting for
4 hours (min.) Surface will be saturated surface dry (SSD) condition, and any free
standing water shall be completely removed prior to concrete placement. No free
moisture or puddles on the surface will be permitted or accepted.
B. Placing and finishing: After the bonding grout has been applied, concrete shall be placed,
consolidated by vibration, and shall be finished by screening and bull floating to bring the
finished surface to specified elevation. The surface shall then receive a light broom finish,
as directed by the Engineer. The reinforcing steel shall have a minimum concrete cover as
shown on plans. The finished concrete shall be suitably protected, until the completion of
the required curing period. Provide tooled joints between new and existing concrete
surfaces.
C. Curing: The recommendations of ACI 308 Standard Practice for Curing Concrete, shall be
followed. When water is required to wet the surface of the newly placed concrete, it shall
be applied as a fine spray so that it will not mark or pond on the surface. Except where
otherwise specified, the curing period shall be at least 72 hours. If high early strength
concrete is approved by the Consultant, the curing period may be reduced as directed by
the Consultant. If fly ash or slag is approved in the mix by the Consultant, the curing time
will be extended. Curing shall be accomplished by wet curing only. The curing and sealing
compound shall only be used on floor and slab areas approved by the Consultant.
1. The surface of the newly poured concrete shall be covered with wetted burlap as
soon as the concrete has hardened sufficiently to prevent marring of the surface.
The burlap shall overlap six inches. At least two layers of wetted burlap shall be
placed on the finished surface. The burlap shall be kept saturated by means of a
mechanically operated sprinkling system. In place of the sprinkling system, two
layers of burlap may be substituted for one layer of burlap and impermeable
covering.
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The burlap sheets shall be placed so that they are in contact with the vertical faces
of concrete slabs after removal of slab forms, and that portion of the material in
contact with those faces shall be kept saturated with water.
2. Membrane Curing Method. Membrane curing will not be permitted unless
approved in writing by the Consultant. Concrete at these locations shall be cured
by another method as specified above.
After the concrete has been finished, the surface shall be cured with the specified
curing compound. The seal shall be maintained for the specified curing period.
The vertical faces of concrete slabs shall, likewise, be sealed immediately after the
forms are removed. This high solids curing and sealing compound shall be applied
at a maximum coverage rate of 250 square feet per gallon. These applications
shall be made with mechanical equipment.
At locations where the coating is discontinuous or where pin holes show or where
the coating is damaged due to any cause and on areas adjacent to sawed joints,
immediately after sawing is completed, an additional coating of membrane curing
compound shall be applied at the rate of one gallon per 250 square feet.
3. The Consultant may order curing by another method specified herein if
unsatisfactory results are obtained with a curing compound. Prior to starting The
Work, the Contractor shall have available, at the site of The Work, supply of one of
the other approved curing materials sufficient for curing one day's production.
4. The Contractor's construction operations including the management of traffic, shall
be such as to avoid damage to the coatings of curing compound for period of not
less than the curing period specified. Any curing compound that is damaged or
that peels from the concrete surface within the curing period specified, shall be
repaired by the Contractor without delay and in an approved manner. No
additional compensation will be allowed to the Contractor for performance of this
work.
DIVISION 5
1.01 Summary of Work
A. This work consists of welding failed tee connectors as per detail 4/R‐6.
DIVISION 7
1.01 Summary of Work
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A. This work consists of the following items.
1. Removing and replacing existing sealants and installation of new sealants at
level 4 precast joints.
2. Application of UV stable epoxy and sand ‘mortar’ repairs at precast connections.
3. Installation of new expansion joints at balance of level 2, and at levels 3, 4 and
roof.
1.02 Related Documents
A. R‐1 through R‐6 provide plans and all details.
1.03 Submittals
A. Submit specifications, installation instructions and general recommendations by the
manufacturer of specified materials.
1.04 Qualifications
A. Contractors shall be trained, approved and qualified by the product manufacturer.
B. Contractor shall have 5 years experience in application/installation of submitted
product.
2.02 Materials
A. Epoxy Mortar: Sikadur 22 Low‐Mod and Sika approved and recommended aggregate.
B. Sealants
1. The joint sealant to be used for cracks and construction joints shall be two
component polyurethane sealants of the chemically curing type containing no
asphalt, coal tar, or plasticizers. The sealant shall be used with a compatible
primer specified by the manufacturer. Approved products for use are:
a. "MasterSeal SL2 (Sonolastic SL2)” as manufactured by BASF Building
Systems (www.buildingsystems.basf.com)
b. "Vulkem 245/255 or THC‐900" as manufactured by Tremco
(www.tremcosealants.com)
c. "Iso‐Flex 880GB Sealant" as manufactured by LymTal International, Inc.
(www.lymtal.com)
d. “Sikaflex‐2C‐SL,” as manufactured by Sika Corporation
(www.sikausa.com)
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2. The sealant to be used shall meet or exceed the requirements of Interim Federal
Specification TT‐S0027‐E, Sealants Class A, Type 1 and 2. The sealant shall not
de‐bond or fail while elongated 25 percent in a water immersion test, according
to Federal Specification TT‐S‐0027‐E. When tested according to Paragraph
4.3.5. of Federal Specification TT‐S‐0027‐E, weight loss shall not be greater than
5 percent. Shore A hardness under standard conditions shall be 25‐30.
3. The cove/wall sealant to be used shall be a non‐sag, two component
polyurethane sealants of the chemically curing type containing no asphalt, coal
tar, or plasticizers. The cove joint sealant shall comply with Federal
Specification TT‐S‐00227E, Type II, Class A, Corporation of Consultants CRD‐C‐
506‐72; ASTM C‐920‐79, Type M, Grade NS, Class 25. Approved Cove Sealants
are as follows:
a. " MasterSeal NP2 (Sonolastic NP2)" as manufactured by BASF Building
Systems (www.buildingsystems.basf.com)
b. "THC‐901" as manufactured by Tremco (www.tremcosealants.com)
c. "Iso‐Flex 881 NS Sealant" as manufactured by LymTal International, Inc.
(www.lymtal.com)
d. “Sikaflex‐2C‐NS,” as manufactured by Sika Corporation
(www.sikausa.com)
C. Expansion Joint
1. The expansion joint seal system shall be a complete system of compatible
materials designed by the manufacturer to produce a waterproof, traffic‐
bearing expansion joint seal. The system shall also meet or exceed any fire
rating requirements set forth by the local building code requirements.
2. The gland elements shall be a continuous, factory extruded unit for the entire
straight run length of the joint. Changes in direction or elevation shall be
accomplished by factory molded elbows, tees, crosses and the like. The seal
shall be turned up a minimum of 6 inches (vertically) unless otherwise shown on
plans. The seal element shall not be mitered/jointed unless approved by the
Consultant in writing and shall meet the following performance criteria.
Tensile Strength ASTM D412 1,500 psi
Elongation at Break ASTM D412 175 % (Min.)
Hardness, Type A durometer ASTM D2240 64 ± 5
3. Expansion joint systems approved for use in one or more applications are
provided in the master list below. Due to variations in specific details of the
locations, expected movement, expected traffic exposure, availability, ease of
installation and existing blockout geometry, all systems are not suitable for one
particular project. The Contractor shall reference the specific expansion joint
detail on the specific project drawings and list of approved products shown on
the drawings, including gland size, etc. for the respective condition.
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4. Approved Products – Horizontal Applications
a. “Wabocrete/Membrane 201 system,” model as applicable,
manufactured by Watson Bowman Acme.
b. “Iso‐Flex Winged Expansion Joint Sealing System”, seal type J as
applicable, as manufactured by LymTal International, Inc.
(www.lymtal.com).
c. “Emseal Thermaflex,” model as applicable, manufactured by Emseal
Joint Systems, Ltd. (www.emseal.com).
3.01 Execution
A. Install all products in accordance with manufacturer’s published procedures to include
but not limited to surface preparation, primers, cure times, aggregate and protection.