MILMAN & ASSOCIATES STRUCTURAL CONSULTING ENGINEERS/ PROJECT MANAGERS

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1 MILMAN & ASSOCIATES STRUCTURAL CONSULTING ENGINEERS/ PROJECT MANAGERS May 29, 2013 Revision B Structural Guideline for Design and Installation Holes in Composite Floor Slab Terminal 3, Departure Level The following summarizes the key guidelines for penetrating through the existing composite floor structure at Departure Level of Terminal 3, in Pier B and Pier C. 1. Proposed holes shall be positioned according to criteria outlined within this guideline. 2. Sketches SK-1, SK-2, and SK-3 provide an illustration of the criteria specified in this guideline. 3. Review all steps in this guideline prior to beginning any Work. 4. Where all criteria within this guideline cannot be satisfied, a structural engineer must be consulted before proceeding with the Work; hence, additional reinforcement may be required. 5. Where loads differ from those specified on the attached sketches, the proposed holes must be reviewed by a structural engineer prior to any Work. 6. Report existing floor penetrations to the structural engineer prior to beginning the Work. 7. Proposed holes near existing composite steel beams that exceed a W610 steel beam size should be reviewed by a structural engineer prior to penetrating the existing floor structure. 8. All holes through the existing composite floor slab shall be drilled holes. The contractor shall not use any other technique to penetrate the existing floor structure. 9. All holes shall be drilled according to GTAA document Terminal 3. Coring Guideline. 10. The existing floor structure shall be scanned prior to any Work to identify the following: a. Existing steel beams b. Existing headed shear connectors (if present) c. High flutes of existing steel deck d. Existing slab reinforcement e. Existing conduits within the concrete slab 11. Site-verify all existing steel beam sizes, spans between existing steel beams, existing steel deck profile, and existing concrete slab thickness. 12. The edge of any hole shall not be less than 305 mm (12 ) from the edge of any existing steel beam flange; however, the effective slab width must not be less than 1200mm (48 ) to protect the composite action between the existing composite slab and steel beams. In other words, the clear distance between any two proposed holes on opposite sides of the same steel beam must not be less than 1200 mm Steeles Ave. West, Suite Tel. (905) Vaughan, Ontario, website: Fax (905) L4K 2L7, Canada

2 MILMAN & ASSOCIATES LIMITED 13. The boundaries of the effective slab width, once the position is determined by the provision of Paragraph 4 above, must be continuous along the full length of the beam. Any holes near the existing steel beam must not intrude upon the (minimum) 1200 mm effective slab width boundaries established. However, the 1200mm provision may be waived if the existing steel beam contains no headed shear connectors (non-composite). 14. Holes shall be drilled through the centreline of the high flutes only (where the thickness of the existing concrete slab is smallest). The low flutes shall not be penetrated. 15. Drilled holes shall be contained completely within the high flute. No vertical ribs in the existing steel deck shall be penetrated. If the desired hole diameter exceeds the upper width of the high flute, the diameter of the hole must be reduced prior to drilling, or the floor deck must be reinforced. 16. All drilled holes must be circular in shape. 17. The diameter of any hole shall not exceed 142mm (5½ ). If the proposed hole diameter exceeds 142 mm (5½ ), a structural engineer must be consulted; the existing deck should be reinforced. 18. A stiff steel pipe sleeve, with a minimum thickness of Schedule 40, shall be installed within each drilled hole that has a diameter in the range of 114 mm (4½ ) to 142 mm (5½ ). The steel sleeve should be secured in place by installing low-viscosity grout, or an equivalent material, around the perimeter of the sleeve, as required. 19. For the purposes of this guideline, the hole diameter refers to the diameter of the drilled hole, which will correspond to the outer diameter of the steel sleeve. The usable diameter of the drilled hole will be the inner diameter of the Schedule 40 steel sleeve. 20. Numerous cracks were observed in the existing concrete slab. For any proposed hole within an existing steel beam s tributary width (one-half the distance to adjacent beams on each side of the steel beam), all cracks within that tributary width must be repaired before conducting any drilling (SK-1, 2, 3). The recommended crack repair product is Sikadur-52 Injection type N (the product data sheet is included as an Appendix to this guideline). 21. For the purposes of this guideline, holes with a diameter of less than 89 mm (3.5 ) are defined as small holes; holes with a diameter of 89 mm (3.5 ) to 142mm (5.5 ) are defined as large holes 22. For large drilled holes: f. No other holes, of any size, shall be drilled through a flute containing a large hole g. Transverse (perpendicular to deck flutes) minimum centre-to-centre distance from a large hole to any neighbouring holes: 23. For small drilled holes: i. 610 mm (24 ) to a large neighbouring hole ii. 305 mm (12 ) to a small neighbouring hole h. Transverse (perpendicular to deck flutes) minimum centre-to-centre distance from a small hole to any neighbouring holes: i. 305 mm (12 ) minimum to a large neighbouring hole ii. 305 mm (12 ) minimum to a small neighbouring hole i. Longitudinal (along same deck flute) centre-to-centre distance between small holes shall not be less than 305 mm (12 ) Structural Guideline for Design and Installation. Holes in Composite Floor Slab. Terminal 3, Departure Level 2

3 MILMAN & ASSOCIATES LIMITED j. In any high flute immediately adjacent to a high flute with a large hole, not more than one (1) small hole, and zero (0) large holes, shall be drilled. k. Where multiple holes are drilled through one flute, all holes in the same flute must be small l. Multiple small holes are permitted in the same flute only where each immediatelyadjacent high flute contains no large holes. 24. Where the span of the composite slab exceeds 2550 mm (8-4½ ) (centre-to-centre distance between existing steel beams), the diameter of any proposed holes shall not exceed 89 mm (3.5 ). 25. Where the span of the composite slab exceeds 2550 mm (8-4 ½ ) (centre-to-centre distance between existing steel beams), not more than one (1) hole is permitted in any flute. The centre-to-centre transverse (perpendicular to deck flutes) distance between holes of any size, shall not be less than 610 mm (24 ). Structural Guideline for Design and Installation. Holes in Composite Floor Slab. Terminal 3, Departure Level 3

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7 Product Data Sheet Edition 24/01/2007 Identification no: Sikadur -52 Injection Type N Low viscosity injection resin Construction Product Description Uses Characteristics / Advantages Product Data Sikadur -52 Injection Type N is a two part, solvent-free, low viscosity injectionliquid, based on high strength epoxy resin. Type N (= Normal Potlife) is used for substrate temperatures between +5 C and +30 C (UK). As an injection resin with good adhesion to concrete, mortar, stone, steel and wood. Sikadur -52 Injection Type N is used to fill and seal voids and cracks in structures such as bridges and other civil engineering buildings, industrial and residential buildings, e.g. columns, beams, foundations, walls, floors and water retaining structures. It not only forms an effective barrier against water infiltration and corrosion promoting media, but it also structurally bonds the concrete sections together. Solvent-free Suitable for both, dry and damp conditions Usable at low temperatures Shrinkage free hardening High mechanical and adhesive strengths Hard but not brittle Low viscosity Injectable with single component pumps Form Colours Part A: Transparent Part B: Brownish Part A+B mixed: Yellowish-brownish Packaging Pre batched: Part A+B: 10 x 1 kg units 1 Sikadur -52 Injection Type N 1/4

8 Storage Storage Conditions/ Shelf-Life 24 months from date of production if stored properly in unopened, undamaged and sealed original packaging, in dry conditions at temperatures between +5 C and +30 C. Technical Data Chemical Base Modified solvent-free two-part epoxy resin. Density Part A: 1.1 kg/l (at +20 C) Part B: 1.0 kg/l (at +20 C) Part A+B mixed (2 : 1): 1.1 kg/l (at +20 C) Viscosity Temperature +10 C +20 C +30 C Type Normal part A+B mixed (2 : 1) ~ 1200 mpas ~ 430 mpas ~ 220 mpas +40 C - Thermal Expansion Coefficient 89 x 10-6 per C (from -20 C to +40 C) (According to EN ISO 1770) Mechanical / Physical Properties Compressive Strength 52 N/mm 2 (after 7 days at +23 C) (According to ASTM D695-96) Flexural Strength 61 N/mm 2 (after 7 days at +23 C) (According to DIN 53452) Tensile Strength 37 N/mm 2 (after 7 days at +23 C) (According to ISO 527) Bond Strength To concrete: (According to DafStb-Richtlinie, part 3) > 4 N/mm 2 (failure in concrete) (after 7 days at +23 C) E-Modulus Flexural Strength: 1800 N/mm 2 (after 7 days at +23 C) (According to DIN ) 2 2/4 Sikadur -52 Injection Type N

9 System Information Application Details Consumption / Yield Substrate Preparation 1 kg of Sikadur -52 Injection Type N is ~ equal to 1 l injection resin. Requirements: Sound, clean, free from oil and grease, old coatings and surface treatments etc. Pre-treatment for good bond: Concrete, mortar, stone should be thoroughly prepared by high pressure water jetting or mechanical means such as grinding, chiselling etc. Cracks must be cleaned to remove dust with compressed air. Application Conditions / Limitations Substrate Temperature +5 C min. / +30 C max. Substrate Humidity Dry or damp (SSD - Saturated Surface Dry: no standing water) Application Instructions Mixing Mixing Time Application Method / Tools Cleaning of Tools Mixing ratio A : B = 2 : 1 parts by weight and by volume Prebatched packaging: Add all of part B to part A. Mix with an electric mixer at slow speed (max. 250 rpm) for at least 3 minutes. Avoid entraining air. Bulk packaging: Add both parts in the correct proportion into a suitable clean, dry container and mix in the same way as for the prebatched units. Cracks in horizontal slabs: Saturate a few times using a brush or gravity fill them by pouring mixed Sikadur -52 Injection Type N between two dams e.g. made from Sikaflex sealant. Cracks penetrating slabs to their soffit should first be sealed on the underside, e.g. with Sikadur -31 epoxy mortar or a suitable cementitious Sika mortar. Cracks in vertical structures: Mixed Sikadur -52 Injection Type N can be injected under pressure into the cracks using a single component injection pump, such as the Aliva AL-1200, AL-1250 or the Sika Hand Pump. Injection ports (packers) are set at approx. 25 cm intervals beside the crack and the crack between the injection ports (packers) sealed e.g. with Sikadur -31 to prevent injection resin to escape during the injection process. Vertical cracks should always be injected from the bottom upwards. As soon as injection resin oozes out of the next packer / injection port, the first one is sealed and the injection process continued from the next one. After completion of the injection process, the injection ports (packers) as well as the sealing material between the ports are removed. Clean all tools and application equipment with Sika Colma-Cleaner/Thinner C immediately after use. Hardened / cured material can only be mechanically removed. 3 3/4 Sikadur -52 Injection Type N

10 Potlife Temperature +5 C +10 C +23 C +30 C Normal Type (1 kg mixture) ~ 120 minutes ~ 80 minutes ~ 25 minutes ~ 10 minutes +40 C - Notes on Application / Limitations Maximum width of cracks to be injected: 5 mm. Sikadur -52 Injection Type N is suitable for dry and damp, but not for wet injection conditions. Construction Value Base All technical data stated in this Product Data Sheet are based on laboratory tests. Actual measured data may vary due to circumstances beyond our control. Local Restrictions Please note that as a result of specific local regulations the performance of this product may vary from country to country. Please consult the local Product Data Sheet for the exact description of the application fields. Health and Safety Information Legal Notes For information and advice on the safe handling, storage and disposal of chemical products, users should refer to the most recent Material Safety Data Sheet containing physical, ecological, toxicological and other safety-related data. The information, and, in particular, the recommendations relating to the application and end-use of Sika products, are given in good faith based on Sika's current knowledge and experience of the products when properly stored, handled and applied under normal conditions in accordance with Sika s recommendations. In practice, the differences in materials, substrates and actual site conditions are such that no warranty in respect of merchantability or of fitness for a particular purpose, nor any liability arising out of any legal relationship whatsoever, can be inferred either from this information, or from any written recommendations, or from any other advice offered. The user of the product must test the product s suitability for the intended application and purpose. Sika reserves the right to change the properties of its products. The proprietary rights of third parties must be observed. All orders are accepted subject to our current terms of sale and delivery. Users must always refer to the most recent issue of the local Product Data Sheet for the product concerned, copies of which will be supplied on request. Sika Limited Watchmead Welwyn Garden City Hertfordshire AL7 1BQ United Kingdom Phone Telefax ISO ISO /4 Sikadur -52 Injection Type N

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