DaimlerChryslerPolished Concrete Floor Slab

Revised 7-9-2007

SECTION 03305 - INDUSTRIAL CONCRETE FLOOR SLABS

PART 1 - GENERAL

1.1SUMMARY

  1. This Section specifies concrete floor slab work, which includes, but not limited to:
  2. Steel fiber reinforcing.
  3. Cast-in-place concrete.
  4. Concrete slab poured & finished to be Diamond Ground and Polished
  5. Diamond Grind and Polish i.e. Polished Concrete Process applied to slab surface.
  6. Related Work Specified In Other Sections:
  7. Division 3 Section "Cast-In-Place Concrete" for basic concrete work.

1.2SLAB DESIGN REQUIREMENTS

  1. Engineering Responsibility: Engage a qualified professional engineer to prepare or supervise the preparation of mix designs data for steel fiber reinforced concrete.
  2. Professional Engineer Qualifications: A professional engineer who is legally qualified to practice in the jurisdiction where Project is located and who has not less than ten years experience in providing engineering services for steel fiber reinforced concrete floor slabs, and who is normally engaged in this type of work. Engineering services are defined as those performed for design of industrial floor slabs-on-grade that are similar to those indicated for this Project in material, design, execution and extent.
  3. Performance design of floor slabs shall be prepared by the Contractor's engineer in accordance with the following criteria. Provide dual design criteria; for the first design mix use stipulated fiber quantity and furnish allowable design loads; for the second design mix use stipulated design loads and furnish required fiber quantity for the most economical slab design.
  4. Minimum 28 Days Flexural Strength: 700 psi unless otherwise indicated.
  5. Minimum 28 Days Compressive Strength: 4000 psi unless otherwise indicated.
  6. Minimum Slab Thickness: 8 inches
  7. Minimum 28 Days Compressive Strength: 4000 psi unless otherwise indicated.
  8. Minimum Modulus Of Subgrade Reaction: K= 100 pci
  9. Either Minimum R10,50 Toughness Ratio of 65 percent; or Minimum Re,3 Value of 55 percent
  10. Minimum Uniformly Distributed Loads: 1200 psf
  11. Minimum Concentrated Loads:
  12. Forklift Truck Loads:

Wheel SpacingAxle LoadsCapacity

Single wheel solid tire35”-37”25 kips12 kips

Single pneumatic tire35”-37”25 kips12 kips

Dual wheel pneumatic tire41”/10”28 kips13 kips

  1. Post Loads:

Base Plate 8”x8”Base Plate 12”x12”Spacing

Max point loads-2 loads25 kips25 kips24”

Max point loads-3 loads25 kips 25 kips36”- 36”

Max point loads-4 loads28 kips28 kips36”-24”-36”

1.3POLISHED CONCRETE PERFORMANCE REQUIREMENTS

  1. Slabs to receive Diamond Grind and Polish Process must have a minimum 1/8” of cream & fines @ surface. Proof of cream and fines will be required via core samples taken @ random perimeter locations @ 2’ from edge of any pour by testing agency. Locations of cores will be determined by CM, & Owners Representative. Visual inspection and approval by testing agency, CM and Owners Representative will validate required deliverable.
  2. Definition: Polished Concrete Process is “cracking the cap” by diamond grinding the concrete surface, removing imperfections left by concrete installer, spraying on deep penetrating lithium chemistry densifier per manufactures instructions, grinding off any densifier residue from surface of slab, begin diamond polishing to desired gloss meter reading requirements, spraying on final deep penetrating lithium poly silicate concrete sealer per manufacturers instructions and finish cleaning the polished slab with common scrubber, soft white nylon heads and neutral PH soap specifically designed to clean Polished Concrete surfaces. The result is a polished concrete floor that will not dust, is resistant to penetration from oils, provides an additional 35% or more reflected light and slip coefficients that surpass standard code requirements/ recommendations.
  3. Process may be either a proprietary system from specialty contractor or use specified products with acceptable detailed process in compliance with definition above and approved by CM and Owners Representative.
  4. Acceptable Diamond Grinding Methods: Equipment and techniques defined above that .produce documented results of concrete finishes meeting or exceeding the following: Required FF, FL, Gloss Meter readings, light reflected percentages as measured with a specular gloss measurement device and slip coefficient minimums as defined in this specification. Specifically, a min diamond grind of not less then 1/64 ”; or as required, will be removed from the slab surface to eliminate imperfections left from the concrete finishing process i.e.: float ridges including swirl patterns and black scorch marks from concrete finishing.
  5. Finish Sheen: Gloss Meter reading of min 54 to optimal 68 measured at a 60 deg angle @ floor surface; as achieved with a metal bonded diamond grind up to a 400 dry grit reason bonded polish.
  6. Polished Concrete Process shall be dry diamond method utilizing direct connect HEPA filtration system, Metal bonded diamond heads for grind w/ resin and or epoxy bonded diamond heads for polishing on a multi-orbital planetary action opposing rotational head machine(s) acceptable to CM and Owner’s Representative.
  7. Coordination: Contractor shall coordinate the following:
  8. Concrete placement, floating, vibrating, panning, pure wet curing, location of cores and review of cores providing evidence of 1/8” cream & fines @ slab surface will be coordinated with the polisher, CM & Owners Representative for approval prior to beginning grind and polish procedure.
  9. Schedule of slab poure sequence in conjunction with Polished Concrete Process (grind, densifier,polish, sealer and cleaning) sequence as well as detailed specific grind, polish, application of densifier/sealer & cleaning procedures, means & methods will be placed in writing and provided to CM & Owners Representative for approval prior to beginning work.
  10. Scheduling of joint sealant installation will be provided to CM and Owners Representative for approval. Joints will be places at specified time after polish completion.
  11. Cleaning of concrete surface prior to and after of Polished Concrete Process will be preformed by concrete installer. Cleaning completion procedures and materials pre and post polish will comply with Polishing contractor’s recommendations to maintain finished polish floor surface.
  12. Polishing contractor will clean finished Polished Concrete Floors at min three (3) times as part of Polished Concrete Process prior to requesting final inspection by CM, GC & Owners representative.
  13. Slip Resistance: Static coefficient of friction shall be 0.6 for level floors and 0.8 for ramped surfaces as recommended by the ADA Accessibility Guidelines (ADAAG).
  14. Testing shall be in accordance with ASTM C1028 or use of similar devices recognized by ADAAG.

1.4SUBMITTALS

  1. Source of ready-mixed concrete for approval.
  2. Manufacturer's product data, performance criteria and other documentation for each material specified in this Section that is proposed for use, including:
  3. Admixtures.
  4. Liquid curing/sealing compound.
  5. If products have not been reviewed and accepted by DaimlerChrysler Health or Environmental groups, include MSDS information as a separate submittal directed to the Owner for review.
  6. Premolded joint filler.
  7. Reinforcing fibers.
  8. Bonding agent.
  9. Joint sealants.
  10. Shop drawings including the following:
  11. Locations of drains, trenches, manholes, and other items.
  12. Floor joint layout indicating:
  13. Number and sequence of placements.
  14. Sizes and shapes of placements (shapes shall be square or rectangular only).
  15. Types (construction or control) and spacing of joints.
  16. Include the following:
  17. Proposed method for bulkheads and formwork.
  18. Proposed placement equipment.
  19. Schedule of events and casting plan regarding placement operations, and records of concrete casts.
  20. Mill test certification for steel fiber reinforcement in accordance with ASTM A820.
  21. Identity Chart standardization test for the steel fiber(s) used.
  22. Certification of chloride ion content from admixture suppliers.
  23. Concrete Mix Design: Submit concrete supplier's concrete mix design information based on requirements specified in "Concrete Mix Proportions".
  24. Submit a concrete mix design prepared by either the “laboratory trial batch” or the field experience” method as specified in CSA A 23.1 for approval. Provide proportions of cement, fine aggregate, coarse aggregate, and water.
  25. Submit SFRC design proposal for the floor slab indicating the dosage, type, size and the shape of the steel fiber. Verify the number of fibers per unit volume and provide information on mechanical characteristics of the chosen fiber and its identity chart.
  26. Mix design shall be sealed by a professional engineered registered in the State of Michigan.
  27. Samples of aggregates shall be furnished by the Contractor as required, together with tests for hardness, durability, density, absorption, etc., referenced in ASTM C33.
  28. Certificates: Each load of ready mixed concrete shall be accompanied by triplicate certificates (batch tickets) submitted for approval for each batch discharged indicating project identification name and number, mix type, and listing ingredients, including quantities and types of admixtures, total water, time when water was introduced into the mix, place and date of delivery, amount of concrete in cubic meters, mix time, reading of revolution counter at first addition of water, etc. Identify separately amounts of water added at batch plant and water added on site.
  29. Completed pre-pour sign-off cards.
  30. Qualification Data: For those performing concrete polishing.

1.5QUALITY ASSURANCE

  1. Comply with applicable provisions of Division 3 Section "Cast-In-Place Concrete".
  2. Institute a "Concrete Pour Sign-Off Card" for the placement of concrete floor slabs on grade.
  3. Sign-Off Card shall, at a minimum, consist of a checklist for verification of the following items:
  4. Compaction of sub grade and sub base materials and sub grade elevation.
  5. Installation of underground utilities.
  6. Installation of required reinforcing steel.
  7. Installation of miscellaneous steel embeds.
  8. Locations of shallow utilities have been reviewed by firm placing concrete.
  9. Floor drains, cleanouts, handholds, etc. have been set to required top elevations.
  10. Concrete forms have been set to specified elevation and level tolerances, and have received form release agent application.
  11. Saw cutting equipment, additional lighting (if necessary) and wiring materials are present on site.
  12. Assign a superintendent who is designated to supervise concrete slab-on-grade operations.
  13. Prior to placing each section of concrete slab-on-grade the Contractor's superintendent shall obtain signatures from the various trade subcontractors involved in the checklist items mentioned above. After signatures are obtained, the Contractor's superintendent shall sign the card as well.
  14. Submit the original card to the Owner's Representative with copies to the Architect/Engineer, concrete flooring installer, and other signatories to the cards.
  15. Ready Mix Plant Qualifications: Plant experienced in furnishing ready mixed concrete similar to that indicated for this Project and with a record of successful in-service performance as well as sufficient production capacity to produce required quantity without delaying the Work. Plant shall have adequate storage and handling facilities for material and shall be equipped for accurate weighing, measuring, and control of materials, quantities, mixing, and delivery of concrete meeting specified requirements.
  16. Preinstallation Conference: Prior to start of work, conduct conference at Project site with all parties associated with work of this Section. Notify participants at least 5 working days before conference.
  17. Meet with representatives of the Owner; Architect/Engineer; testing and inspecting agency; concrete producer; concrete slab installer/finisher; steel fiber manufacturer; admixture manufacturer; and others whose work interfaces with or directly affects floor slab placement.
  18. Review methods and procedures related to work of this Section.
  19. Examine subgrade conditions for compliance with requirements, including flatness and modulus of subgrade reaction.
  20. Discuss plans to execute the work, scheduling, equipment, assignments, and storage procedures.
  21. Discuss the following as a minimum:
  22. Concrete mix design and control of same.
  23. Trial batching.
  24. Subgrade and subbase preparation.
  25. Placement procedures for:

1)Form work

2)Reinforcing

3)Concrete placement methods

4)Concrete finishing procedures

5)Sawcut methods and timing

6)Curing procedures

7)Joint sealing

8)Slab protection

  1. Document proceedings, including corrective measures or actions required, and furnish copy of record to each participant.
  1. Concrete Polisher Qualifications: A Polished Concrete Process installer who has documented experience and proven techniques and/or processes of diamond grinding & polishing concrete. When a system is used, installer shall be certified or licensed by the system manufacturer.
  2. Only the following are acceptable; others will not be considered.
  3. Perfect Polish : Contact Mr. Jeff Yates 865-803-4917
  4. Convergent Concrete Technologies: Contact Arn Ottme 979-277-4534
  5. Titan Industrial Flooring: Contact Steve Buchanan 248-433-8178
  6. Concrete Polishing Technologies Inc: Contact Dan Grady 865-803-5041
  7. Concrete Arts: Contact Tom Graf 612-369-1074
  1. Submit the following for review and confirmation prior to contract award by the Construction Manager:
  2. Certificate of training from an Owner acceptable source.
  3. List of Diamond ground and polished concrete projects completed including:

1)Company name, address, phone number, specific description of work procedures, means and methods as preformed including cut sheets of specific grinding and polishing equipment including diamond pad types/grits as well as cut sheets and MSDS sheets of specific densifier and sealer/stain blockes to be used, define existing conditions of concrete pre grind & polish including required FF and FL, define age of slab when diamond grind and polish process was started, total sq ft ground & polished, post polish Gloss Meter readings, slip coefficient measurements, reflected light % data and photos of finished surface from a distance and close up, to show aggregate exposure,

  1. Must prove 3 years minimum experience applying dry polishing system
  2. Must have successfully completed at minimum 500,000 sq.ft cured exposed aggregate dry polished concrete work to date as defined in this specification.
  3. Must provide the maximum sq.ft of Polished Concrete able to complete in one 8 hr shift.
  4. Must provide data on relationships and affiliations with local unions relative to specific Polished Concrete Process and equipment including but not limited to diamond grind, diamond polish and cleaning of slab throughout process.
  1. Polished Concrete Sample Areas: Build a sample slab of minimum 500 square feet by full thickness following all defined concrete requirements for Polished Concrete in this specification in the area directed by the Construction Manager.
  2. Acceptable sample area of concrete; pre grind and polish process, may be incorporated into the Work. However, if the concrete finish is not acceptable to the polisher, the sample shall be removed or incorporated as directed by the Owners representative at no expense to the Owner.
  3. Acceptable sample area of Polished Concrete may be incorporated into the Work. However, if the polished finish is not acceptable to the Owner, the sample shall be removed or incorporated as directed by the Owner at no expense to the Owner.
  4. Sample area will be used to demonstrate & set quality standards for the execution & workmanship of concrete placement, concrete finishing procedures, concrete curing procedures, slab protection, polished Concrete process (diamond grind & polish process) including level of polish achieved, % of reflected light measurements & slip coefficient measurements of the phased work.

1.6PROJECT CONDITIONS

  1. Protection.
  2. Forms and steel shall be entirely free of frost, snow or ice before placing concrete.
  3. Protect concrete work from damage by frost or freezing or from any other cause. Aggregate and mixing water shall be heated before mixing concrete when the outside temperature is 40 degF or lower and falling and shall have a temperature at placing of 50 degF minimum and 85 degF maximum.
  4. Placed concrete shall be fully protected from frost and freezing by approved means in accordance with the applicable requirements of ACI 306. The use of "anti-freeze" additives or admixtures is prohibited. Concrete shall be provided with curing protection for a period of seven days against outside temperatures of 50 degF and lower.
  5. In hot weather concrete shall be placed in accordance with the applicable requirements of ACI305.
  6. Remove protection when directed or no longer required. Damaged concrete shall be removed and replaced at no additional cost to the Owner.
  7. Size, extent, and details of concrete pours shall be reviewed and approved by the Owner’s Representative before concrete is placed.

PART 2 - PRODUCTS

2.1MATERIALS

  1. Forms shall be constructed in accordance with the requirements of ACI347.
  2. Form coating shall be an approved nonstaining type.
  3. Reinforcement
  4. Fibers: Steel fibers conforming to ASTM A820, Type I, deformed, cold drawn steel wire with a minimum tensile strength of 130,000 psi; minimum aspect ratio of 65; minimum length 2 inches, nominal diameter 0.0351 inches.
  5. Basis-of-Design Product: The design is based on Bekaert; Dramix RC65/60BN. Subject to compliance with requirements, provide either the named product or a comparable substitute acceptable to the Owner.
  6. Reinforcing steel and dowels shall be new billet steel conforming to ASTM A615 grade60.
  7. The details of reinforcing steel shall conform to ACI315. Furnish required metal accessories, including spacers, chairs, ties, etc. Cut and bend reinforcement in accordance with the approved shop drawings and bar lists.
  8. Steel Dowels: ASTM A615, Grade 60. Furnish smooth dowels at floor slab construction joints.
  9. Column Isolators: 20 gage sheet metal with Z275 galvanized coating to ASTM A525.
  10. Chairs and Spacers: Rigid type, of sufficient strength to rigidly support weight of reinforcement and construction loads. Use non-corrosive type over metal deck. Use precast concrete chairs with embedded tie wires for support of bottom and top reinforcing steel bar in slabs on grade.
  11. Drummond and Reeves Ltd.
  12. Acrow Richmond
  13. Superior Concrete Accessories Ltd.
  14. Portland Cement: ASTM C150, Type I.
  15. Slag Cement: ASTM C989, Grade 120.
  16. Aggregates shall conform to ASTM C33 and having a petrographic number no greater than 125.
  17. Fine aggregate shall be natural sand, sharp and clean.
  18. Coarse aggregate shall be crushed, hard, dense, durable natural stone or crushed and processed air cooled blast furnace slag, free of any mud, clay, loam, silt or organic matter graded to a balanced mix of 50 percent passing a 1-1/2 inches size sieve and 50% passing 3/4 inches size sieve (50/50 blend).
  19. Water shall be clean and free from injurious amounts of oil, alkali, acids, organic matter and other deleterious substances.
  20. Use admixtures where necessary to achieve acceptable final product regarding Concrete workability; entrained air content; handling; and design strength criteria. Admixtures shall conform to ASTM C494. Admixtures which may cause increased concrete shrinkage shall not be permitted. Additional criteria is as follows:
  21. Superplasticizer: Unless otherwise directed by the Owner, provide one of the following:
  22. Eucon 37; Euclid Chemical Co.
  23. Rheobuild 1000; Master Builders
  24. Sikament; Sika Chemical Corp.
  25. Water Reducing Agents: The type of water reducing agent shall be dependent upon the conditions encountered and shall be in accordance with manufacturer's recommendations. Mid-range water reducers shall not be used. Unless otherwise directed by the Owner, provide one of the following:
  26. Plastocrete; Sika Corp.
  27. Eucon WR or Eucon WR 75; Euclid Chemical Co.
  28. Owner approved substitute.
  29. Admixtures shall be liquid-type premixed by the manufacturer and used directly from containers bearing the label of the Manufacturer. The quantity shall be only that amount required to conform to the approved requirements as shown by the final approved design mix. The addition of admixture shall be made by accurate dispenser for positive control of the quantity as approved.
  30. Fly ash admixtures, chloride-based admixtures, and calcium chloride thiocyanates shall not be used. Admixtures containing more than 0.05 percent chloride ions shall not be used. Products which individually or collectively contribute more than 5 ppm by weight of chloride ions to concrete shall not be used.
  31. Premolded expansion joint fillers at interior joints. Unless otherwise directed by the Owner, provide one of the following:
  32. Ceramar, W.R. Meadows Sealtight.
  33. Approved substitute.
  34. Isolation joint fillers. Material specifically designed and manufactured to provide isolation from ambient and induced shock and vibration. Unless otherwise directed by the Owner, provide one of the following:
  35. FABSORB Foundation Isolation Material, Fabreeka International
  36. Approved substitute.
  37. Floor Sealer/Hardener/Densifier: Clear deep penetrating lithium chemistry solutions specifically designed to penetrate, harden & densify concrete without contributing to or triggering damaging alkali-silica reactions protecting concrete floors against abrasion, dusting, and absorption of liquids may be used. No sodium chemistry sealers/hardners or densifiers may be used. Unless otherwise directed by the Owner, provide one of the following:
  38. CPS Armor Densifiers.
  39. CPS Armor Concrete Sealers
  40. CCT Tentra-si 244 Densifier
  41. CCT Tentra Guard Concrete Sealer
  42. Epoxy bonding agent for bonding freshly mixed concrete to hardened or existing concrete. Unless otherwise directed by the Owner, provide one of the following:
  43. Armatec 110; Sika Chemical Corp.
  44. Powerprep AC; Sto Powercrete
  45. Corr-Bond; Euclid Chemical Co.
  46. Epoxy Floor Fill: Trowel applied epoxy mortar system designed to surface and fill floor slabs up to 2 inches thickness.
  47. Products: Unless otherwise directed by the Owner, provide Euco #456 Mortar, Euclid Chemical Co , or similar product by one of the following:
  48. Euclid Chemical Co.
  49. Master Builders, Inc.
  50. Sika Corp.
  51. Joint Selants: Multicomponent Flexible epoxy joint sealant or polyurea having durometer not less than 70, Shore A. Unless otherwise directed by the Owner, provide one of the following:
  52. Flexible joints at column isolation joints and wall Intersections:
  53. Euco 700 or Euco 700 Special; Euclid Chemical Co.
  54. For all areas not otherwise specified, provide the following in a gray color.
  55. Sonneborn, Division of ChemRex Inc.; Sonolastic TF-100.

2.2MIX DESIGN