Concrete Resurfacing and Rehabilitation

Concrete Resurfacing and Rehabilitation

SECTION 03925

CONCRETE RESURFACING AND REHABILITATION

Display hidden notes to specifier. (Don't know how? Click Here)

** NOTE TO SPECIFIER ** MAPEI Corporation: hydraulic binders, self-leveling underlayments, decorative toppings, concrete material, grouts, wall coatings, waterproofing coatings, water repellents.
.
This section is based on the products of MAPEI Corporation, which is located at:
1144 East Newport Center Road
Deerfield Beach, FL 33442
Tel: (800) 42m-apei or (800) 426-2734
Fax: (954) 246-8801.
E-mail:
Web:
[ Click Here ] for additional information.
.
This section covers two primary applications: 1) underlayments and toppings, for repair and resurfacing of large floor and pavement areas, and 2) repair mortars, for patching relatively smaller areas, and for vertical and overhead surfaces. Other materials include adhesives, crack fillers, and specialty concrete repair products for both exterior and interior applications. Some applications of these products are obvious but non-typical concrete repair situations occur quite often. For suggestions on uses of these products see PART 2, APPLICATIONS/SCOPE and the manufacturer's product literature.
.

PART 1 GENERAL

1.1 SECTION INCLUDES

** NOTE TO SPECIFIER ** Delete items below not required for project.

  1. Resurfacing of exterior concrete pavements.
  2. Resurfacing of interior concrete floors.
  3. Repair of vertical and overhead horizontal surfaces.
  4. Repair of damaged structural members.
  5. Elimination of water bearing cracks.
  6. Moisture reduction barrier.
  1. RELATED SECTIONS

** NOTE TO SPECIFIER ** Delete any sections below not relevant to this project; add others as required.

  1. Section 03300 - Cast-In-Place Concrete: New concrete.
  1. REFERENCES

** NOTE TO SPECIFIER ** Delete references from the list below that are not actually required by the text of the edited section.

  1. AASHTO M148 - Standard Specification for Liquid Membrane-Forming Compounds for Curing Concrete (same as ASTM C 309).
  2. ASTM C 309 - Standard Specification for Liquid Membrane-Forming Compounds for Curing Concrete.
  3. ASTM C 1107 - Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Nonshrink).
  4. COE CRD-C 621 - - Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Nonshrink) (same as ASTM C 1107).
  1. SUBMITTALS
  2. Submit under provisions of Section 01300.
  3. [ Product Data ]: Manufacturer's data sheets on each product to be used, including:
  4. Preparation instructions and recommendations.
  5. Storage and handling requirements and recommendations.
  6. Installation methods.
  7. Shop Drawings:

** NOTE TO SPECIFIER ** Delete selection samples if colors have already been selected.

  1. Selection Samples:For each finish product specified, two complete sets of color chips representing manufacturer's full range of available colors and patterns.
  2. Verification Samples: For each finish product specified, two samples, minimum size 6 inches (150 mm) square, representing actual product, color, and patterns.
  1. DELIVERY, STORAGE, AND HANDLING
  2. Store products in manufacturer's unopened packaging until ready for installation.
  3. Store and dispose of solvent-based materials, and materials used with solvent-based materials, in accordance with requirements of local authorities having jurisdiction.
  4. QUALITY ASSURANCE
  5. Manufacturer Qualifications: Minimum 5 years manufacturing concrete resurfacing and rehabilitation products.
  6. Installer Qualifications: Minimum two years installing similar products.

** NOTE TO SPECIFIER ** Include a mock-up if the project size and/or quality warrant taking such a precaution. The following is one example of how a mock-up on a large project might be specified. When deciding on the extent of the mock-up, consider all the major different types of work on the project.

  1. Mock-Up: Provide a mock-up for evaluation of surface preparation techniques and application workmanship.
  2. Finish areas designated by Architect.
  3. Do not proceed with remaining work until workmanship, color, and sheen are approved by Architect.
  4. Refinish mock-up area as required to produce acceptable work.
  1. DELIVERY, STORAGE, AND HANDLING
  2. Store products in manufacturer's unopened packaging until ready for installation.
  3. Store and dispose of solvent-based materials, and materials used with solvent-based materials, in accordance with requirements of local authorities having jurisdiction.
  4. PROJECT CONDITIONS
  5. Maintain environmental conditions (temperature, humidity, and ventilation) within limits recommended by manufacturer for optimum results. Do not install products under environmental conditions outside manufacturer's absolute limits.

PART 2 PRODUCTS

2.1 MANUFACTURERS

  1. Acceptable Manufacturer: MAPEI Corp. U.S.A., which is located at: 1144 E. Newport Center Rd. ; Deerfield Beach, FL 33442; ASD. Toll Free Tel: 800-42-MAPEI; Tel: 954-246-8888; Fax: 954-246-8801; Email: ; Web:

** NOTE TO SPECIFIER ** Delete one of the following two paragraphs; coordinate with requirements of Division 1 section on product options and substitutions.

  1. Substitutions: Not permitted.
  2. Requests for substitutions will be considered in accordance with provisions of Section 01600.
  1. APPLICATIONS/SYSTEM

** NOTE TO SPECIFIER ** Since concrete resurfacing and rehabilitation involves many variables unknown to the manufacturer of repair products, carefully evaluate the situations on the project and the product literature to select appropriate products. The following is a sample of how to specify different products for different purposes. Delete applications, and products, not required or not appropriate. Add other applications required. Consult manufacturer on unusual situations.

  1. Refer to drawings for scope of Work.
  2. Repairing Damaged Reinforced Structural Members:
  3. Reinforcing primer: Rebar primer.
  4. Concrete primer: Epoxy adhesive.
  5. Repair material: Very fluid repair mortar.
  6. Patching Water Leaks in Concrete: Hydraulic plug mortar.
  7. Exterior Pavement and Slabs:
  8. For Overall Topping: Fast-setting topping.
  9. For Patching: Traffic surface repair mortar.
  10. Sealer: High-gloss sealer.
  11. Interior Floors:
  12. For Overall Topping:

** NOTE TO SPECIFIER ** Delete products not required.

  1. Fast-setting topping.
  2. Fluid topping.
  3. Self-leveling exposed topping.
  4. Self-leveling thick topping underlayment.
  5. Self-leveling thin topping underlayment.
  1. For Patching:

** NOTE TO SPECIFIER ** Delete products not required.

  1. Traffic surface repair mortar.
  2. Exterior/interior repair mortar.
  3. Interior repair mortar.
  1. For Sealing:
  2. High-gloss sealer.
  1. Patching Interior Non-floor Concrete: Interior Repair Mortar.
  2. Patching Exterior Non-pavement Concrete: Use Exterior/Interior Repair Mortar.

** NOTE TO SPECIFIER ** Miscellaneous Work tasks and products not typically detailed. Delete items not required.

  1. Anchoring Bolts, Rods, and Dowels, and Resetting Loose Anchors: Quick-Set Anchoring Mortar.
  2. Filling Small Cracks and Holes: Epoxy Adhesive in pure form, poured.
  3. Bonding New Concrete to Old Concrete: Epoxy adhesive.
  4. Waterproofing Concrete: Waterproofing coatings.
  5. Reducing Moisture Vapor Emission Rate (MVER): Moisture Reduction Barrier.
  1. INTERIOR/EXTERIOR PRODUCTS
  2. Fast-Setting Exterior/Interior Topping: Pre-blended, cementitious; for horizontal surfaces, allowing traffic or subsequent finishing within 3 to 4 hours.

** NOTE TO SPECIFIER ** Delete any of the following products that would not be suitable for the applications required. The products are listed in descending order of compressive strength; the strongest are listed first.

  1. Acceptable Product: MAPEI Mapecem 101; one-component, non-shrinking, self-curing; for horizontal surfaces, feather edge to 1 inch (25 mm) per coat.
  2. Acceptable Product: MAPEI Mapecem 102; one-component, non-shrinking, self-curing; for horizontal surfaces, 1/4 inch (6 mm) to 2 inches (50 mm) per coat, or aggregate extended to 8 inches (200 mm) thickness.
  3. Acceptable Product: MAPEI Mapecem 202; two-component, non-shrinking, self-curing; with corrosion inhibitor 1/4 inch (6 mm) to 2 inches (50 mm) per coat, or aggregate extended to 8 inches (200 mm) thickness. Refer to Technical Data Sheets for procedures.
  4. Acceptable Product: Concrete Renew or Concrete Renew Fine. Exterior Cementitious concrete resurfacers. Apply from 1/8 to 1/4 inch (3mm-6mm), light gray in color, suitable for a number of finishes, and suitable for foot or light wheeled traffic.
  5. Acceptable Product: MAPEI Spraytop RS, premium, white knockdown topping. Apply from 1/8 to 1/4 inch (3mm-6mm), suitable for a number of finishes, and for foot or light wheeled traffic.
  1. Fluid Topping for Exterior/Interior Traffic Surface or Industrial Flooring Repair: For horizontal surfaces, suitable for industrial flooring repairs and aggressive environments, high flow for easy placement 1/4 inch (6 mm) to 1 inch (25 mm) per coat.
  2. Acceptable Product: MAPEI Planitop 25 two-component polymer-modified high-strength flowable cementitious topping mortar with corrosion inhibitor; suitable for vehicular traffic; and industrial flooring repairs. Offers tremendous adhesion to existing concrete and resistance to freeze thaw and chlorides. Allows light traffic in 3 - 4 hours.
  3. Exterior Traffic Surface Repair Mortar: Pre-blended cementitious mortar suitable for vehicular traffic.
  4. Acceptable Product: MAPEI Planitop 18; one-component high-early-strength, shrinkage-compensated, with corrosion inhibitor allowing vehicular traffic within 60 minutes; for small area repairs.
  5. Exterior/Interior Repair Mortar: Pre-blended polymer-modified, cementitious patching mortar; for a variety of surfaces including vertical, horizontal, and overhead surfaces.

** NOTE TO SPECIFIER ** Delete any of the following products that would not be suitable for the applications required. The products are listed in descending order of compressive strength; the strongest are listed first.

  1. Acceptable Product: MAPEI Planitop X; one component fast setting, shrinkage compensated, fiber reinforced with corrosion inhibitor, horizontal, vertical and overhead repair mortar; feather edge to 4 inches (100 mm) per coat. Light grey in color.
  2. Acceptable Product. MAPEI Planitop XS, one component, extended working time version of Planitop X. Shrinkage compensated, fiber reinforced, with corrosion inhibitor VOH , feather edge to 4 inches (100mm) per coat, light gray in color.
  3. Acceptable Product: MAPEI Planitop 12; one-component, shrinkage-compensated, thixotropic mortar with fiber reinforcement and corrosion inhibitor; minimum 1/4 inch (6 mm) thickness.
  4. Acceptable Product: MAPEI Planitop 21; two-component; maximum 1/4 inch (6 mm) per coat.
  5. Acceptable Product: MAPEI Planitop 23; two-component, fast-setting, thixotropic, with fiber reinforcement and corrosion inhibitor; 1/8 inch (3 mm) to 1-5/8 inches (40 mm) per coat.
  6. Acceptable Product: MAPEI Tilt Finish. Professional Finishing compound for Concrete Surfaces. Very fine smoothing compound suitable for filling bugholes, correcting minor defects and resurfacing of vertical and overhead concrete surfaces, feather to 1/4 inch (6 mm). Light gray in color.
  7. Acceptable Product: Mapecem Quickpatch, Interior / Exterior fast setting high flow patch. Suitable from feather to 3 inch (76 mm) application in confined areas. Light gray in color and suitable as a wear surface.
  8. Primer: As recommended by manufacturer.
  1. Very Fluid Repair Mortar: Suitable for structural Form and pour repairs.
  2. Acceptable Product MAPEI Planitop 15. Pre-blended one-component shrinkage-compensated cementitious fiber-reinforced mortar suitable for pouring into forms and around reinforcing bars without segregation.
  3. Quick-Set Anchoring Mortar: Pre-blended cementitious quick-set hydraulic cement mortar.
  4. Acceptable Product: MAPEI Planiseal Plug.
  5. Hydraulic Plug Mortar: Pre-blended cementitious quick-set hydraulic cement mortar.
  6. Acceptable Product: MAPEI Planiseal Plug.
  7. Structural Grout:Pre-blended high-strength shrinkage-compensated cementitious grout; ASTM C 1107 Grade C and COE CRD-C 621 Grade C.

** NOTE TO SPECIFIER ** Delete products not required.

  1. Acceptable Product: MAPEI Planigrout 755. General Construction Grout, capable of being placed in consistencies from dry pack to very fluid.
  2. Acceptable Product: MAPEI Planigrout 712 High performance Construction Grout, with silica fume and corrosion inhibitor, capable of being placed in consistencies from dry pack to very fluid.
  3. Acceptable Product: MAPEI Planigrout 740; Precision and Tremie grout capable of being placed in consistencies from plastic to very fluid.
  1. Corrosion Inhibiting Coating for Reinforcing Steel:

** NOTE TO SPECIFIER ** Delete products not required.

  1. Acceptable Product MAPEI Mapefer 1K. New Technology 1 Component polymer modified cementitious coating for reinforcing bar. Meets and exceeds ASTM B117.
  2. Acceptable Product MAPEI Planibond 3C, three-component epoxy cementitious bonding agent and corrosion protection.
  1. Epoxy Adhesive: Two-component, non-shrink, solvent-free, moisture-insensitive epoxy adhesive or bonding agent.
  2. Acceptable Product: MAPEI Planibond EBA, 100 percent solids epoxy.
  3. Slurry Bond Coat: Portland cement, sand, and latex additive.
  4. Acceptable Product: MAPEI Planicrete AC or PM mix; proportions as recommended by manufacturer.
  5. Waterproof Coatings:

** NOTE TO SPECIFIER ** Delete products not required.

  1. Acceptable Product: MAPEI Planiseal 88 one-component, polymer-modified, cementitious waterproofing coating for concrete and masonry surfaces.
  2. Acceptable Product: MAPEI Mapelastic two-component, Acrylic modified, flexible cementitious membrane for concrete waterproofing and protection. Mapelastic protects concrete from chemical attack by de-icing salts, sulphates, chlorides and carbon dioxide that leads to deterioration and requires costly repair. Suitable as an exposed coating on industrial applications including water towers, dams, canals, bridges, tunnels and similar structures.
  3. Acceptable Product: MAPEI Mapelastic Smart, roller-grade, two-component acrylic-modified flexible cementitious membrane for concrete waterproofing and protection.
  1. Exterior/Interior High-Gloss Sealer:

** NOTE TO SPECIFIER ** Do not use for colored concrete applications that utilize reactive acid stain.

  1. Acceptable Product: MAPEI Mapefinish Wet Look, premium high-gloss water-based acrylic sealer and color enhancer; applied in several thin coats as recommended by manufacturer.
  1. Fast-Setting Exterior/Interior Mortar:
  2. Acceptable Product: MAPEI Topcem Premix, ready-to-use, accelerated-cure screed; at thicknesses from 1/4 inch to 4 inches as required.
  1. INTERIOR PRODUCTS
  2. Self-Leveling Exposed Topping: Pre-blended, cementitious, self-curing, abrasion-resistant, suitable as exposed wear layer; MAPEI Ultratop; or Ultraplan M20 plus for over concrete, for use in dry interior applications.

** NOTE TO SPECIFIER ** Delete all but one of the following four paragraphs.

  1. Acceptable Product: MAPEI Ultratop Color: White or Natural Gray. Premium decorative topping suitable for applications 1/8 inch – 2 inches (3 mm – 51 mm), can be integrally colored, stained, or diamond polished.
  2. Acceptable Product: MAPEI Ultratop; Color: White or Natural Gray, stained ______, with acid-based stain.
  3. Acceptable Product: MAPEI Ultraplan M20 Plus; Color Light Gray. Topping suitable for applications 1/8 inch to 2 inches (3 mm – 50 mm), can be integrally colored, stained, or diamond polished.
  4. Acceptable Product: MAPEI Ultraplan M20 Plus; Color: Light Gray, stained ______, with acid-based stain.
  5. Primer: As recommended by topping manufacturer.

** NOTE TO SPECIFIER ** The following toppings are intended as underlayment for a finish floor material such as carpet, ceramic tile, or resilient flooring. They are not suitable for installation over dimensionally unstable substrates such as particleboard, chipboard, hardboard, metal, asbestos cement, or gypsum-based patching compounds. The products are listed in descending order of compressive strength (highest strength listed first).

  1. Self-Leveling Fast Track Underlayment: Pre-blended cementitious, for fast track floor covering installation, for use in dry interior applications.

** NOTE TO SPECIFIER ** Delete products not required.

  1. Acceptable Product: MAPEI Ultraplan 1 Plus, fast setting; for over cured concrete, exterior grade plywood, 1/8 inch to 1 inch (3 mm to 25 mm).
  2. Acceptable Product: MAPEI Ultraplan M20 Plus, fast setting; for over concrete and exterior grade plywood, 1/4 inch (6 mm) to 2 inches (50 mm).
  3. Acceptable Product: MAPEI Ultraplan Easy, fast setting reduced surface preparation self leveling underlayment featheredge to 2 inches (50 mm), over cured concrete, exterior grade plywood, and adhesives residues.
  4. Primer: As recommended by underlayment manufacturer.
  1. Self-Leveling Underlayment: Pre-blended cementitious, for thicknesses from feather edge, for use in dry interior applications.

** NOTE TO SPECIFIER ** Delete any of the following products that would not be suitable for the applications required. The products are listed in descending order of compressive strength; the strongest are listed first.

  1. Acceptable Product: MAPEI Novoplan 2, normal-setting, polymer-modified; for over cured concrete, exterior grade plywood, 1/8 inch to 1 inch (3 mm to 25 mm).
  2. Acceptable Product: MAPEI Novoplan Easy, medium setting reduced surface preparation self-leveling underlayment 1/8 inch to 1 inch (3 mm to 25 mm), over cured concrete, exterior grade plywood, and adhesives residues.
  3. Primer: As recommended by underlayment manufacturer.
  1. Moisture Reduction Barrier: Suitable Moisture Reduction barrier to treat substrate moisture levels that exceed the manufacturers of subsequent flooring recommendations.
  2. Acceptable Product: Planiseal MRB: A two-component, solvent-free fluid-applied breathable epoxy coating specially designed to treat high-moisture vapor transmitting concrete surfaces up to 12 lb /1000 sf/24 hours, and to reduce the moisture vapor transmission of a treated concrete substrate by a minimum of 75 percent.
  3. Testing: Prior to use of Planiseal MRB test for Calcium Chloride per ASTM F-1869.

PART 3 EXECUTION

3.1 EXAMINATION

  1. Do not begin installation until substrates have been properly prepared.
  2. If substrate preparation is the responsibility of another installer, notify Architect of unsatisfactory preparation before proceeding.
  1. PREPARATION
  2. Clean surfaces thoroughly prior to installation.
  3. Prepare surfaces using the methods recommended by the manufacturer for achieving the best result for the substrate under the project conditions.
  4. INSTALLATION
  5. Exterior/Interior High-Gloss Sealer:

** NOTE TO SPECIFIER ** Do not use for colored concrete applications that utilize reactive acid stain.

  1. Acceptable Product: MAPEI Mapefinish Wet Look, premium high-gloss water-based acrylic sealer and color enhancer; applied in several thin coats as recommended by manufacturer.
  1. Fast-Setting Exterior/Interior Mortar:
  2. Acceptable Product: MAPEI Topcem Premix, ready-to-use, accelerated-cure screed; at thicknesses from 1/4 inch to 4 inches as required.
  3. Install in accordance with manufacturer's instructions.
  1. PROTECTION
  2. Protect installed products until completion of project.
  3. Touch-up, repair or replace damaged products after Substantial Completion.

END OF SECTION

03925-1

Top View