3124Pfpeterfell Coloured Concrete and Sealers

3124PFPETERFELL COLOURED CONCRETE AND SEALERS

1.GENERAL

If you have pre-customised this work section using the "questions and answers" provided as part of the downloading process, it may be necessary to amend some clauses to suit the final project-specific version.

The section must still be checked and customised to suit the project being specified, by removing any other irrelevant details and adding project-specific details and selections.

This section relates to the supply and laying of Peter Fell Limited decorative concrete products designed for patio and paths, floors, driveways, pool surrounds, walls, and public and commercial applications.

It includes:

-coloured and plain concrete

-grout for concrete cuts

-concrete sealers and cleaning products

Modify or extend the above description to suit the project being specified.

1.1RELATED WORK

Refer to relevant concrete sections for concrete work.

Include cross references to other sections where these contain related work.

This section is to be used with a Masterspec integrated concrete section or with the Masterspec Structural & Civil 3105 CONCRETE COMMON REQUIREMENTS and its related sections 3121 CONCRETE PLACEMENT and 3129 CONCRETE PRODUCTION, 3131 PRECAST CONCRETE, SUPPLY, GROUND, SEALED OR POLISHED CONCRETE for concrete polishing and grinding.

Refer to 6122 FLOOR SCREEDS AND TOPPINGS for non-structural concrete toppings.

This section can be used to specify architectural concrete finishes, when the concrete is specified in a Structural Specification, but both specifications must cross reference each other. If the Structural Specification is a separate document, add cross references to a new clause headed RELATED DOCUMENTS.

Documents

1.2DOCUMENTS

Refer to the general section 1233 REFERENCED DOCUMENTS. The following documents are specifically referred to in this section:

NZBC C/AS1-AS7Protection from fire

NZBC D1/AS1Access routes

NZBC D1/VM1Access routes

NZS 3104Specification for concrete production

NZS 3109Concrete construction

NZS 3114Specification for concrete surface finishes

NZS 3121Specification for water and aggregate for concrete

NZS 3604Timber-framed buildings

AS/NZS 3661.1Slip resistance of pedestrian surfaces - Requirements

ISO 9239.1Reaction to fire tests for floor coverings - Determination of the fire burning behaviour using a radiant heat source

Delete from the DOCUMENTS clause any document not cited. List any additional cited documents.

The following are related documents and if referred to in the work section need to be added to the list of DOCUMENTS.

NZS 4121Design for access and mobility; Buildings and associated facilities

NZS 4251Code of practice for solid plastering

AS/NZS 4586Slip resistance classification of new pedestrian surface materials

AS/NZS 4663Slip resistance measurement of existing pedestrian surfaces

CCANZ IB18Architectural surface finishes

CCANZ IB33Specification and production of concrete surface finishes

CCANZ IB80Residential driveways and paths

CCANZAlkali-aggregate Reaction

CCANZ is the Cement and Concrete Association of New Zealand.

1.3MANUFACTURER/SUPPLIER DOCUMENTS

Manufacturer's and supplier's documents relating to this part of the work:

PeterFell General Information

PeterFell Technical Specifications

PeterFell Finishing Guide

PFL Acrylic Sealer Product Guide

PFL Coverseal Product Guide

PFL Non Shrink Product Guide

PFL Ovaboard Product Guide

PFL Anti-vap Product Guide

PFL Surface Preparation Product Guide

PFL Acid Gel Product Guide

PFL Neutraliser and Cleaner Product Guide

Manufacturer/supplier contact details

Company:Peter Fell Limited

Web:

Email:

Telephone:09 828 6460

Requirements

1.4QUALIFICATIONS

Workers to be experienced, competent and familiar with the materials and techniques specified.

1.5COLOUR VARIATION

Concrete can vary in colour due to differences in placement methods and treatment.

To minimise variations the contractor must ensure handling, placing and finishing of the concrete is consistent and that the following measures are taken:

1.6SLIP RESISTANCE FOR ACCESS ROUTES

Slip resistance to comply with NZBC D1/VM1 and NZBC D1/AS1, 2.0, Level access routes and 3.0 Ramps.

-when in place on a level access route, to have a mean coefficient of friction (µ) not less than 0.4 when tested in accordance with AS/NZS 3661.1.

-when in place on a sloping access route, to have a coefficient of friction (µ) not less than 0.4 + 0.0125S (S = slope of surface expressed as a percentage).

-when in place on stair treads, to NZBC D1/AS1, Table 2.

Provide certificates and any other evidence that the surface complies with the standard of performance specified.

Use this clause when NZBC D1/AS1 Table 2 requires the surface finish to be tested for slip resistance, and you require the Contractor to organise the test. Consider who is capable of testing and adding a requirement for further samples to be tested. As testing facilities/capabilities are limited, this may need to be agreed with the BCA and Contractor in advance.

Note: Percentage slope S = vertical rise divided by horizontal distance and multiplied by 100. Example: 1:12 gradient = (1/12) x100 = 8.33%.

Slip resistance requirements are expressed in NZBC D1/VM1 and NZBC D1/AS1 to AS/NZS 3661.1. Although not recognised by the NZBC, when using NZBC D1/VM1for extreme situations AS/NZS 4586 may be more suitable. Modify the following clauses to suit.

NOTE: In NZBC D1/AS1, Table 2 concrete surfaces that have sufficient slip resistance when dry are unacceptable when wet or must be subject to testing.

Note: NZBC D1/AS1 defines access routes as those which the public have access to including walking surfaces such as decks, patios and steps on the approach to the main entrance to Housing (including single dwellings), and common areas of Communal Residential and Multi-unit dwelling accommodation. Also applies to commercial buildings.

1.7INFORMATION FOR OPERATION AND MAINTENANCE

Refer to the general section 1234 DOCUMENTATION for provision of the following maintenance information:

-Sealer to be re-applied as appropriate when subject to wear. Contact Peter Fell Ltd for re-application method.

-Surface to be cleaned with PFL Concrete Cleaner.

-Advise Principal of the requirement to apply one coat of Coverseal to interior concrete floor surfaces every six months, and /or as required in high wear areas. For interior floors only.

Use this clause to list requirements of information that is required but which does not warrant a separate specialist operation and maintenance manual.

Provide this information prior to practical completion.

The general section 1234 DOCUMENTATION (or 1239 OPERATION & MAINTENANCE if required) describes the process of submission and review of operation and maintenance information. Use this clause to describe the specific requirements, the required information and what it is to cover.

2.PRODUCTS

2.1READY-MIX CONCRETE

To NZS 3104.

As a general rule concrete with smaller aggregate size shrinks more, and so risk of cracking is greater. Smaller aggregate should be used only where a small pump is employed or where decorative effects are required e.g. (exposed or ground/polished/honed).

PeterFell recommend 25Mpa concrete as this concrete has more cement and so should provide an improved surface finish.

2.2DAMP-PROOF MEMBRANE

0.25mm minimum polyethylene to NZ 3604, Section 7.5.4.

Components

2.3COLOURED CONCRETE

PeterFell colours added to the concrete, preferably at the concrete plant and not on site. Refer to SELECTIONS for colour range.

2.4GROUT FOR CUTS

PFL Non-Shrink Grout, a shrinkage compensated, single component cementitious grout used in conjunction with PeterFell Grout Tape.

2.5SURFACE PREPARATION - FOR ACID WASH OF FLATWORK

PFL Surface Preparation comprised of an etching acidic solution used to prepare concrete flatwork surfaces for sealing.

2.6ADMIXTURES

Calcium chloride accelerating admixtures not to be used. Admixtures such as accelerators, retarders and superplasticisers can be used but they must be used in every load of the pour to maintain consistency of concrete.

2.7SURFACE RETARDER

Rugasol C by Sika to slow down the surface set for exposing aggregate.

2.8EVAPORATION RETARDERS - FOR FLATWORK

PFL Anti-Vap.

2.9FORM RELEASE AGENT - FOR VERTICAL SURFACES

Formol by Sika.

2.10PROTECTION BOARD

PFL Ovaboard cardboard-based protective board available in roll form 970mm wide, taped with PFL Vapourcure Tape (75mm wide) with butted not overlapping joints only.

3.EXECUTION

Conditions

3.1STORAGE OF MATERIALS

Take delivery of and store products, materials and components in accordance with codes of practice and the product manufacturer's or supplier's stated requirements.

Maintain the proper condition of any protection packaging, wrappings or supports during delivery, unloading and storage.

3.2RESPONSIBILITY

Take responsibility for determining the method of producing the specified finished surface.

3.3PROTECTION

Protect and maintain the specified finish where necessary during any handling, erection or subsequent construction operation to ensure a clean undamaged surface at completion of the contract works.

3.4GENERAL

Except where noted otherwise on the drawings or in the specification, tolerances in regard to colour and surface to the requirements of NZS 3114 for each finish specified.

3.5SURFACE TOLERANCES

Variations from a plane surface are defined as follows:

Abrupt:Steps or irregularities caused by displacement of form joints and measured between peak and hollow over a 200mm straight edge.

Gradual:Undulations over the surface and measured between rise and hollow over a 1500mm straight edge.

3.6SUB BASE PREPARATION

Dig out soft areas until ground is suitable. Substrate to be a minimum of 100mm of AP20 or AP40, well compacted and with a surface that evenly follows the final concrete surface± 5mm, i.e, no high or low points; 5mm sand blinding required.

It is important to plan and design the project in a way that reduces the risks of cracks forming that can mar the finish quality.

Application - general

3.7FALSEWORK AND FORMWORK - VERTICAL SURFACES

Apply Sika Formol to all vertical surfaces to help ensure clean surface.

3.8INSTALL DAMP-PROOF MEMBRANE

Install damp-proof membrane under all concrete in accordance with manufacturer's requirements.

Inclusion of damp-proof membrane reduces ingress of ground water and possible damage to sealer.

3.9PUMPING CONCRETE

Ensure that enough concrete with colour has been ordered to allow for that volume to be used in the length of the pump.

3.10ADDED WATER

Do not add water to the following unless absolutely necessary:

-Ready mixed truck to increase slump at any point during discharge - colour will be affected by changes in the water-cement ratio.

-Surface at any point during the screeding and finishing process - use PFL Anti-Vap evaporation retarder to retain bleed-water at the surface.

3.11PROTECTION OF OTHER SURFACES

Ensure other surfaces are protected from concrete splashes during placing, and/or ensure all surfaces are cleaned of splashes while concrete is still wet.

3.12COMPACTION

Compact concrete to NZS 3109.

3.13PENETRATIONS / FIXINGS

Apply a compressible layer such as polystyrene wrapped around any fixed penetrations such as posts or piping to allow movement of the slab which otherwise may restrain slab movement and promote cracking.

3.14FLOOR AND EXTERIOR PAVEMENT, UNFORMED FINISHES

U3 class:Use for direct wearing floors such as factories. Suitable for floors with thin sheet coverings. Suitable for accessible non-slip dry floors only NZBC D1/AS1 Table 2.Note: A steel float finish is not recommended for accessible routes, even under dry conditions, for surfaces that are intended for use by ambulant disabled or wheelchair-bound persons.

Coloured concrete

3.15COLOURED CONCRETE

Add coloured oxides to the concrete at the concrete batching plant. Order colour from PeterFell at least five days prior to the concrete pour date.

Surface finishing - general

3.16GENERAL

Achieve the standard of the specified finish required, direct from the formwork with a minimum of attention to the stripped surface.

3.17FINISHING METHOD

Confirm finishing method and tools to be used with the contract administrator, prior to commencing work.

The concrete surface finishes are to be marked on the drawings.

3.18MINOR SURFACE DEFECTS

Repair minor surface defects to match the shade and texture of the surrounding concrete. If repairs are required, prepare a sand cement mortar using the same cement and sand as used by the concrete manufacturer with the same colour. To test final colour, dry surface with a blow torch or hairdryer before application.

It is very difficult to match colour and texture exactly and so the likelihood of repairs matching is very low.

Surface finishing

3.19MACHINE OR HARD TROWELLED BY HAND FINISH

Before final set, machine or hard trowel concrete by hand to ensure a hard durable surface.
Finish to be class U3 in accordance with NZS 3114, part 3, tables 2 and 3.

Application - saw cuts

3.20CONSTRUCTION SAW CUTS

Refer to sections 3101 CONCRETE WORK - BASIC or 3102 CONCRETE WORK - STANDARD for placing of construction saw cuts.

Construction saw cuts should be indicated on the drawings, if not the tables in 3101 and 3102 give a brief selection of spacings, but if necessary must be amended to reflect project requirements.

Note: PeterFell offer a service to suggest correct placement of construction saw cuts.

3.21DECORATIVE SAW CUTS

Carryout decorative saw cuts after 10 days to ensure a clean cut. Use a 10-12mm blade to a depth of 10mm.

For internal floors, apply decorative cuts prior to wall framing being erected so cuts are continuous up to the wall line. Refer to SELECTIONS for options.

Decorative saw cuts should be indicated on the drawings.

Note: PeterFell offer a service to suggest correct placement of decorative saw cuts.

Curing of concrete

3.22CURING OF CONCRETE - INTERIOR

Pond concrete for a minimum of 7 days, as soon as practicable after the finishing process is complete. Do not use a curing compound.

Protection

3.23PROTECTION - INDOORS

Protect concrete after the curing stage with 0.25mm polythene and leave this in place until the building is enclosed.

Once building is enclosed remove polythene and cover floor with old carpet and/or Ovaboard from PeterFell which allows the floor to dry while still protecting from staining and surface contaminants.

Do not leave or store anything on the above protection as it will change the colour of the concrete below.

Clean up

3.24CLEAN UP

Prior to grouting and sealing clean concrete in accordance with the instructions in PeterFell Finishing Process Guide.

Grouting

3.25APPLY GROUT

Grouting to be completed before sealing.

Fill decorative cuts with PFL Non-Shrink Grout in accordance with PeterFell Finishing Guide.

Apply grout with PFL Grout Gun, or alternatively tape the cut with PFL Grout Tape and apply the grout with a trowel, allowing it to slightly overfill the cut so it sits slightly proud of the floor plane, and filling up to the arris or edge of the cut. Allow the grout to set slightly and then remove excess with a scraper, then leave flat or make concave with suitable tool. Allow grout to cure for a few days, then seal.

Specify flat or concave grout.

Sealing

3.26DRYNESS TEST - PRIOR TO SEALING

Before commencing sealing the concrete must be completely dry and not just surface dry. If in doubt perform the Plastic Sheet Test (for excessive moisture):

-Tape a plastic sheet 450mm x 450mm on to the concrete surface being tested; ensuring an airtight seal between the concrete and the plastic is formed. After 24 hours remove the plastic sheet. Concrete can be coated if no moisture / condensation is present on the underside face of the sheet, or if concrete has not darkened (compared to adjacent concrete). If moisture is present, re-test after another 14 days. Testing to be to Moisture Test ASTM D4263 "Plastic Sheet Method".

3.27SURFACE PREPARATION - PRIOR TO SEALING

Remove surface laitance using PFL Surface Preparation in accordance with PeterFell Product Guide. Do not allow to leave the concrete surface until fully spent.

Following the surface preparation process clean concrete with PFL Neutraliser and Cleaner to ensure all residual contaminants and acid is removed.

This stage is often omitted by contractors and can result in a yellow residue if not cleaned properly.

3.28APPLY SEALER

Apply the sealing process in accordance with the instructions in the relevant PeterFell Product Guide. Apply the sealer when the concrete is suitable dry. Remove concrete protection a week beforesealing to facilitate drying of slab.

Refer to SELECTIONS for options suitable for the particular application.

3.29APPLY COVERSEAL

Apply one coat of PFL Coverseal immediately prior to practical completion of the building in accordance with the instructions in PeterFell Finishing Guide.

4.SELECTIONS

For further details on selections go to

Substitutions are not permitted to the following, unless stated otherwise.

4.1INTERNAL FLOOR

Location:~

Finish:U3, machined finish

Cut pattern:~

Options:

Finish:Machine or hard trowelled by hand

Ground/honed/polished

- Visual appearance options: Salt & Pepper, Light grind, Medium grind, Heavy grind

- Final surface treatment: Ground or Polished or Rough grind

Cut pattern:As shown on the drawings

4.2COLOURED CONCRETE

Location:~

Manufacturer:Peter Fell Ltd

Colour:PFL~

Options:

Colour:Select from PeterFell colour range,Identified by code number or name

4.3SEALER

Location:~

Manufacturer:Peter Fell Ltd

System:PFL Acrylic, two coats

Options:

Location options are as follows. Refer to PeterFell for further advice on sealing system to suit the particular situation.