1.1 This section is to be utilized for polishing both integral colored or natural gray concrete floors.

Transcription

1 SECTION CONCRETE POLISHING - NEW STORES PART 1 - GENERAL 1.1 This section is to be utilized for polishing both integral colored or natural gray concrete floors. A. Refer to concrete polishing plan for extents of type of polishing, hand grinding and polishing and areas to receive applied surface treatments. 1.2 SUMMARY A. Section includes: 1. KROGER DIRECT BUY PROGRAM: Owner supplied/owner installed. a. The Kroger Company will provide the polishing concrete system. b. Scope of work to include the following items: 1) Surface preparation. 2) Application of liquid concrete densifier. 3) Grinding and polishing of concrete floor. 4) Hand grinding and polishing. 5) Application of Slip Resistant treatment. 6) Application of salt guard treatment. 7) Application of stain protection treatment. B. Refer to Division 03 Section "Polished Gray Cast-In-Place Concrete Slabs" for non-colored concrete slabs to receive a polished finish. C. Refer to Division 03 Section "Polished Integral Colored Cast-In-Place Concrete Slabs" for integral colored concrete slabs to receive a polished finish. D. Requirements 1. Installation of joint filler by contractor prior to polishing and finishing. 2. Contractor will make available approximately 7,000 to 10,000 sq. ft. (650 to 930 sq. m) of contiguous floor area per day for polishing operations unless otherwise indicated. 3. Utilities: Power for polishing equipment, water, heat, and light will be provided by the General Contractor. 1.3 ADMINISTRATIVE REQUIREMENTS A. Pre-installation Conference: Two weeks prior application of polished concrete floor finish system, conduct conference at Project site with concrete polishing installer to comply with requirements in Division 00 Section "General Conditions." The Contractor will be in charge of the meeting. The Contractor shall take minutes of the meeting. 1. Attendees:

2 a. Contractor. b. Polished concrete installer. c. Owner representative. d. Joint filler installer. 2. Agenda a. Review of Owner provided Floor Finish Plan, Final Fixture Plan, Floor Finish Schedule. b. Environmental requirements and dust control. c. Surface preparation. d. Repair. e. Field quality control. f. Cleaning. g. Protection of systems. h. Coordination with other work. i. Safety procedures. 1.4 SUBMITTALS A. Product Data: For each type of product indicated. Include manufacturer s recommended installation procedures. B. Procedure Submittals: Include surface preparation and installation procedures specific to Project. C. Protection Plan: For surrounding areas and non-work surfaces. D. Pre-Polish Inspection Report. E. Minutes of pre-polishing meeting. F. Closeout Submittals 1. Kroger Job Completion Checklist. 2. Slip Coefficient of Friction and Gloss Reading Form. 3. Warranty: Installer s standard warranty. 4. Operation and Maintenance Data: Installer's maintenance manual, including maintenance and cleaning instructions for polished concrete floor system. 1.5 APPROVED EQUALS A. For an equal product to be considered for approval by the Owner the installer must submit product information of the proposed product along with the product information of the specified product and shall furnish the product data sheets, MSDS sheets and certificates of performance of both for comparison. B. No other products shall be used other than those which have been approved in writing by the Owner and incorporated into the Agreement. Requests for approved equal items must be

3 submitted in writing to the Owner, together with all necessary supporting data for both the specified and equal item. The Owner shall be the sole judge in accepting the equal item or may reject the same. No material, not accepted by the Owner in writing, may be used in lieu of specified material. If the approved equal material or equipment increases costs in any way, these costs shall be borne by the installer. 1.6 QUALITY ASSURANCE A. Installer Qualifications: An experienced certified CPAA installer with adequate number of skilled personnel who are thoroughly trained and experienced in concrete slab polishing with 2-3 years of experience and a minimum of 10 projects performed within three years of similar type, size and complexity as this Work. B. Testing procedures: 1. ASTM C Standard Test Method for Determining the Static Coefficient of Friction (SCOF) of Ceramic Tile and Other Like Surfaces by the Horizontal Dynamometer Pull- Meter Method. 2. NFSI 101-A-2009 National Floor Safety Institute using a tribometer for testing. 3. ANSI B C. Mockups: Provide two (2) mockups to verify selections made under Sample submittals and to demonstrate aesthetic effects and set quality standards for materials and execution. 1. Provide mockups for polished concrete floor finish system including all steps to achieve required finish. a. Size: Minimum 20 ft. x 20 ft. (6.09 m x 6.09 m) of typical poured-in-place flooring condition for each color and pattern in locations directed by Owner. b. One mockup is to demonstrate the need for an additional grind prior to polish. c. Include concrete joint filling process, coordinate with contractor. 2. Provide an additional mockup only when the concrete is extremely hard to demonstrate that an additional metal grind is needed. 3. Do not proceed with concrete polishing until mockup is approved by Owner. 4. Approval of mockups does not constitute approval of deviations from the Contract Documents contained in mockups unless Owner specifically approves such deviations in writing. 5. Maintain mock-up during construction in an undisturbed condition as a standard for judging the work. 1.7 SITE CONDITIONS A. Do not install polished concrete floor system until concrete substrate is properly cured for a minimum of 28 days prior to installation of polished concrete floor system unless high early strength concrete or other concrete mix additive products have been utilized for faster cure times

4 B. Do not install polished concrete floor system until air temperature s between 55 degrees F. (13 degrees C.) and 85 degrees F. (29 degrees C.) C. Work area shall have no uncovered openings through doors, windows, skylights or any other open penetrations in walls and roof. D. Do not install polished concrete floor system until finished lighting levels are present. E. Do not install polished concrete floor system until work area is broom swept and free of work from other trades. F. Limit and control damage from excessive dust caused by grinding/polishing procedure. G. Temporary electric power provided by Contractor will be available at time of polishing. Refer to Division 00 Section "General Conditions." 1.8 WARRANTY A. Warranty: Installer s dustproof warranty covering the polished concrete floor system. 1. Warranty Period: Ten years from date of Substantial Completion. PART 2 - PRODUCTS 2.1 SYSTEM DESCRIPTION A. Installation of polished concrete floor system for new interior concrete floors by grinding and polishing with various size grit metal-bonded and resin-bonded diamonds and application of concrete densifier. 2.2 PERFORMANCE CRITERIA - POLISHED A. Performance Requirements: The final result of the concrete floor polishing is required to meet or exceed the criteria described below: 1. Specular Gloss/Reflectance, ASTM D523. Minimum gloss reading of 50 before treatments described in 2.4 are applied. a. CPAA Sheen Level 2 Honed Finish. 2. Aggregate Exposure: 1/8 to 3/8 inch (3 to 9.5 mm) maximum to present a mottled saltand-pepper, course aggregate appearance 3. Static Coefficient of Friction, NFSI 101-A-2009 and ASTM C1028. a. Dry Surface: SCOF b. Wet Surface: SCOF

5 4. Floor Surface Profile, ASTM E a. Refer to Division 03 Section Cast-In-Place Concrete Slabs for floor flatness criteria. 2.3 PERFORMANCE CRITERIA SLIP RESISTANT FINISH A. Performance Requirements: Provide slip resistance of floor by installation of slip resistant finish: 1. Pre-COF Dry: Pre COF Wet: Post COF Dry: Post COF Dry: POLISHED CONCRETE FINISHING PRODUCTS A. Concrete Densifier: Clear, odorless liquid form of a lithium silicate to permanently seal, densify, dustproof and harden concrete surfaces and provide abrasion resistance by penetrating into concrete pores and chemically reacting. On projects scheduled to receive concrete dye, use compatible densifier product as recommended by concrete dye manufacturer. 1. Products: a. AmeriPolish, Inc.; 3D HSL; (479) b. Dayton Superior Corporation; Pentra Hard; (888) c. PROSOCO, Inc.; Consolideck LS; (800) B. Dye Densifier: Lithium based densifier plus added dye color. 1. Products: a. SureLock ; Color: Dark Saddle Brown by AmeriPolish ; (800) b. Consolideck GemTone Stain; Color: Dark Saddle Brown by PROSOCO, Inc.; (800) c. For natural gray polished slabs use clear concrete densifier. C. Slip Resistant Treatment: Manufacturer s proprietary acidic compound to provide slip resistance to floor. 1. Products: a. InvisaTread by Surface Solutions, LLC; (888) No substitutions allowed. D. Salt Guard Treatment. 1. Products: a. Saltguard by PROSOCO, Inc.; (800) or approved equal. E. Stain Protection Treatment

6 1. Products: a. PROtec Stain Guard by Surface Solutions, LLC; (888) No substitutions allowed. F. Cleaning Solution: Mild, highly concentrated liquid concrete cleaner and conditioner; biodegradable, and environmentally safe. Cleaner must be ph neutral. G. Water: Potable. 2.5 GRINDING AND POLISHING A. Floor Grinder: Polishing shall be a diamond method, utilizing metal bonded diamond/resin bonded diamond multi orbital planetary action opposing rotational diamond headed machine with approximate grinding pressure of 675 pounds using only HTC, Diamatic, Sase, CPS, or Husqvarna machines. B. Vacuum System: Vacuum system shall be directly connected to floor grinder to reduce amount of dust exposure and to provide a dust free environment. HEPA 3-stage filtration system is required. 1. Minimum 350 CFM 2. Water Lift: 8.5 Mercury 3. 3 Inch Hose Sq. ft. of Primary Filter Area PART 3 - EXECUTION 3.1 EXAMINATION A. Pre-Polish Inspection: Prior to concrete polishing, clean the floor with an auto scrubber equipped with soft nylon brushes and neutral cleaner to provide a clean floor for inspection. Conduct an inspection the concrete floors that are to be polished and photo document the location of any substantial imperfection and the overall appearance of the floor. Include the Owner, concrete installer, and floor polishing installer in the inspection. Submit written report to the Contractor and Owner. B. Examine surfaces to receive treatment. Notify Contractor if surfaces are not acceptable. Do not begin application until unacceptable conditions have been corrected. 1. Final sheen shall be equivalent to that as accepted on the mock-up. 3.2 EQUIPMENT SAFETY A. When Liquid Petroleum (LPG) powered equipment is employed the following safety precautions are to be enacted. 1. A catalytic converter is to be attached to the equipment

7 2. The LP tanks are to be filled only to 80% to prevent overfilling. 3. Fuel tanks are to be stored in accordance will all applicable laws, codes, and ordinances. 4. Provide proof of a safety certification program for all operators of the equipment. 5. The carburetor CO setting is to be maintained at 0.5% CO or 5,000 ppm per OSHA at idle and at full load. 6. Equipment is to be equipped with a carbon monoxide detector that will shut the equipment off when the levels exceed those stated above. 7. The levels of carbon monoxide in a room or space shall not exceed0.005% or 50 ppm as an eight hour average. 8. When equipment is not in use it is to be turned off and not idled. 9. Provide complete building ventilation when operating equipment. 10. All personnel operating the equipment must wear a carbon monoxide badge detector. 3.3 PREPARATION A. Mark-off active work areas with caution tape. B. All construction joints must be filled prior to commencement of polishing. 3.4 INSTALLATION, GENERAL A. Provide a dust free environment during the grinding process and prior to the application of all other products listed. B. Coordinate polishing operations with other associated work and trades. C. Clean dust from adjacent areas daily. D. Provide maximum dust protection during the grinding process. 3.5 CONCRETE POLISHING INSTALLATION A. Polished Concrete Floor Finish System: Apply polished concrete finish system to cured and prepared slabs to match accepted mockup. B. Basis of design: CPAA Sheen Level 2 Honed Finish C. Perform grinding and polishing process as described below to achieve smoothly polished concrete finish with an appearance and sheen level as described in section Machine grind floor surfaces with hybrid metal bonded tooling. 2. Thoroughly clean floor with auto scrubber 3. Apply clear concrete densifier undiluted in sufficient amounts to point of rejection, remove excess liquid, and allow to cure according to manufacturer s instructions. 4. Continue grinding process with #100 resin bonded tooling. 5. Thoroughly clean floor with auto scrubber 6. Perform hand grinding and polishing within ½ of walls. 7. Apply dye concrete densifier undiluted in sufficient amounts to point of rejection, remove excess liquid, and allow to cure according to manufacturer s instructions

8 8. Continue grinding process with #200 resin bonded tooling. 9. Perform hand grinding detailed within ½ of all perimeter walls. Hand grinding quality to match the same texture and gloss level as the main sales floor area. 10. Start polishing process utilizing #400, #800 and #1500 grit resin bonded tooling. 11. Thoroughly clean floor with auto scrubber 12. Apply clear concrete densifier undiluted in sufficient amounts to point of rejection, remove excess liquid, and allow to cure according to manufacturer s instructions. Delete this appliacation of densifier in those areas which is to receive Stain Protection Treatment. 13. Conduct final polishing process utilizing #3000 grit diamond impregnated polishing pad on high speed propane burnisher to enhance shine. 14. Maintain maximum dust control throughout entire polishing process and properly dispose of waste products produced by grinding in accordance with all regulations. 15. Neutralize and clean polished floor surfaces. 16. Perform slip coefficient testing. 17. Perform initial gloss readings where directed by Owner. 18. Grinding waste is to be disposed of offsite in accordance with all applicable laws and regulations and with authorities having jurisdiction. D. No topical materials are allowed to achieve the required gloss readings. 3.6 MODIFIED CONCRETE POLISHING INSTALLATION FOR OFFICES, BREAKROOMS AND ASSOCIATE SECURED STORAGE AREAS A. Perform this modified polishing process with topical treatment for the low traffic gray concrete in office area. Machine polish floor surfaces with high speed propane burnisher equipped with diamond embedded pads as described below to achieve a smoothly polished concrete finish with an appearance and sheen level as described in section 2.2. B. Maintain maximum dust control throughout entire polishing process and properly dispose of grinding waste is to be disposed of offsite in accordance with all applicable laws and regulations and with authorities having jurisdiction. 1. Begin grinding process with #50 grit diamond impregnated pads. 2. Thoroughly clean floor with auto scrubber 3. Apply clear concrete densifier undiluted in sufficient amounts to point of rejection, remove excess liquid, and allow to cure according to manufacturer s instructions. 4. Continue grinding process with #100 grit diamond impregnated pads. 5. Thoroughly clean floor with auto scrubber 6. Apply clear concrete densifier undiluted in sufficient amounts to point of rejection, remove excess liquid, and allow to cure according to manufacturer s instructions. 7. Continue grinding process with #200 grit diamond impregnated pads. 8. Start polishing process utilizing #400 grit diamond impregnated pads. 9. Thoroughly clean floor with auto scrubber 10. Apply two thin coats of stain protector versus one thick coat and burnish in with a High speed propane burnisher. 11. Conduct final polishing process utilizing #3000 grit diamond impregnated polishing pad on high speed propane burnisher to enhance shine

9 3.7 SLIP RESISTANT TREATMENT A. Install in front of cases a minimum of 4-0 (1.22 m) or further out to terminate at the first control joint. B. Application: The application of this treatment must be incorporated into the overall polished concrete finishing process as follows. 1. Begin application upon reaching 400 grit honing process. 2. Spray apply the InvisaTread, allow to dwell until itself neutralizes (turns cloudy), agitate if needing more etch. 3. Once neutral, scrub off floor with several passes using floor scrubber to get all residual removed. 4. Add dye and finish polishing process. 3.8 SALT PROTECTION TREATMENT A. Apply product on polished concrete floors of approximately 1,500 S.F ( sq. m) of the inside store entry area of each set of entry doors. Treatment should extend 12-0 (3.66 m) to 15 0 (4.572 m) on each side of the entry door. 1. Refer to reference drawing for exact locations and area. B. Test area prior to application. C. Thoroughly clean floor surface with an auto scrubber and clean water and allow to dry before applying Clean area to remove all oil, dirt laitance and other contaminants. D. Application: Apply evenly with microfiber mop or in accordance with the manufacturers written instructions and burnish in with a High speed propane burnisher. 3.9 STAIN PROTECTION TREATMENT A. Apply stain protector in designated areas such as wine and floral departments in addition to 3 to 4 shopping aisles containing pickles, salad dressings and laundry products as stipulated in the individual project proposal. 1. Refer to reference drawing for exact locations and area. B. Thoroughly clean floor surface with an auto scrubber and clean water and allow to dry before applying stain protector. C. Test area prior to application. D. Application: Apply two thin coats of stain protector versus one thick coat and burnish in with a high speed propane burnisher. For these specific areas, this will replace the 3rd treatment of densifier specified in section

10 3.10 FIELD QUALITY CONTROL A. Testing and Inspecting: Perform the following tests and inspections and submit Owner provided Slip Coefficient of Friction and Gloss Readings form. B. Static Coefficent of Friction (SCOF): 1. Perform tests prior to and after application of slip resistant treatment. 2. Perform testing in center of all aisles identified by Owner. C. Gloss Testing. 1. ASTM D utilizing a gloss meter based on level of gloss required. 2. Reading to be taken in the center of all aisles in locations identified by Owner. D. Kroger Job Completion Checklist: Owners representative to walk the store with applicator to complete and submit to the Owner the completed checklist 3.11 PROTECTION A. Until Project is turned over to Owner, building contractor to clean polished concrete floor as required to prevent surface residue from forming on the concrete surface. B. Building contractor to install protective covering where construction activities could soil or damage floor FINAL SCRUB AND BURNISH A. Within 48 hours prior to Store grand opening polishing contractor to perform a final scrub and burnish of the floor to a minimum gloss reading of 50. Perform all final gloss readings at this time. END OF SECTION