SECTION 033543 - PART 1 - GENERAL 1.01 SUMMARY A. Section Includes: Products and procedures for placement, finishing, and polishing new cast-inplace concrete floors. 1.02 RELATED REQUIREMENTS A. Section 03 3000 - Cast-In-Place Concrete. 1.03 SUBMITTALS A. Product Data: Manufacturer s technical literature for each product indicated, specified, or required. Include manufacturer's technical data, application instructions, and recommendations. B. Samples for Verification: 1. Aggregates: Labeled, sealed plastic bags with one pound of each aggregate in concrete mix. C. Pre-Installation Conference Agenda: Submit as supplied by the polishing contractor. D. Safety Certification: Submit product certification from National Floor Safety Institute evidencing floor passes Phase 1 as high traction. E. Samples for Verification: From the concrete producer using the approved mix design and same batch plant to be used on slab, submit 12 inch square samples of polished finish in each color, texture, and pattern specified. Samples shall be from the concrete producer using the approved mix design, same materials, and same batch plant to be used in the Work. Hand polish to the specified sheen and level of aggregate exposure. F. Maintenance Data: For inclusion in operation and maintenance manual required by Division 01. Include manufacturer s instructions for maintenance of installed work, including methods and frequency recommended for maintaining optimum condition under anticipated use. Include precautions against cleaning products and methods which may be detrimental to polished finishes and performance. 1.04 QUALITY ASSURANCE A. Concrete Producer Qualifications: Firm experienced in manufacturing ready-mixed concrete products and that complies with following requirements for production facilities and equipment: 1. ASTM C 94. 2. NRMCA's Certification of Ready Mixed Concrete Production Facilities. B. Polisher Qualifications: 1. Experience: Company with not less than 5 years experience in performing specified work similar in design, products, and extent to scope of this Project; with a record of successful in-service performance; and with sufficient production capability, facilities, and personnel to produce required Work. 2. Supervision: Maintain competent supervisor who is at Project during times specified Work is in progress, and, who is experienced in installing systems similar to type and scope required for Project. 3. Trade Association: Member in good standing of CPAA. C. Static Coefficient of Friction: Products and polishing operations shall achieve following as determined by quality control testing according to NFSI 101-A: 1. Level Floor Surfaces: Minimum 0.6. 2. Sloping Floor Surfaces: Minimum 0.8. D. Field Mock-up for Aesthetic Purposes: Before performing work of this Section, provide 10 foot x 10 foot (minimum) as many field samples as required to verify selections made under submittals and to demonstrate aesthetic effects of polished finish. Approval does not PSP 111039 CONSTRUCTION DOCUMENTS 10/25/12 033543-1
constitute approval of deviations from Contract Documents, unless such deviations are specifically approved by Architect in writing. 1. Mock-up shall be from concrete producer using the approved mix design, same materials and same batch plant to be used in the Work. 2. Reinforcement placement shall be same as will be in the work. 3. Polish 6 ft square floor area for each polished finish type. 4. Use same personnel, including supervisors, who will perform work. 5. Install products and materials according to specified requirements. 6. Work shall be representative of those to be expected for work. 7. Show maximum variation that will exist in work. 8. Approval is for following aesthetic qualities: a. Proper placement and finishing techniques. b. Floor flatness. c. Compliance with approved submittals. d. Uniformity of depth of aggregate. e. Uniformity of exposure of aggregate. f. Uniformity and level of sheen. g. Joint sealant installation. 9. Obtain Architect s approval before starting work on Project. 10. Protect approved field mock-ups from elements with weather resistant covering. 11. Maintain field mock-ups during construction in an undisturbed condition as a standard for judging completed Work. 12. Do not demolish, alter, or remove field mock-ups until acceptable to Owner and Architect. 13. When directed, demolish and remove field mock-ups from Project. E. Pre-Installation Conference: Prior to placing concrete for areas scheduled for polished concrete floor finish, conduct conference at Project to comply with requirements of applicable Division 01 Sections. 1. Required Attendees: a. Owner or owner s representative. b. Architect. c. Contractor, including project manager and superintendent. d. Polishing contractor supervisor. e. Concrete producer. f. Concrete finisher, including supervisor. 2. Minimum Agenda: Attendees are to establish the expectations of the polished concrete and determine what needs to be done before beginning the process to insure the best possible outcome: a. Review the specifications to discuss and evaluate for compliance with Contract Documents, including substrate conditions, substrate preparations, sequence of installation and other preparatory work performed by other installers. b. Review the chemicals, level of grinding, level of sheen, edges, and patching. c. Review concrete mix design, placement procedures, finishing, and flatness requirements. d. Review possible problems and how to mitigate. e. Review approved submittals. f. Review installation procedures, including, but not limited to: 1) Concrete placement, finishing, and preparation for polished finish. 2) Concrete curing. 3) Application of polishing products. 4) Grinding and polishing operations. 3. Reports: Record discussions, including decisions and agreements reached, and furnish copy of record to each party attending. PSP 111039 CONSTRUCTION DOCUMENTS 10/25/12 033543-2
1.05 PROJECT CONDITIONS A. Damage and Stain Prevention: Take precautions to prevent damage and staining of concrete surfaces to be polished. 1. Prohibit following over concrete surfaces to be polished: a. Vehicle parking. b. Pipe cutting operations. c. Ferrous metals storage. d. Products that rust. 2. Protect concrete surfaces to be polished from following: a. Petroleum, oil, hydraulic fluid, or other liquid dripping from equipment. b. Acids and acidic detergents. c. Painting activities. B. Environmental Limitations: Comply with manufacturer's written instructions for substrate temperature, ambient temperature, moisture, ventilation, and other conditions affecting polishing operations. PART 2 - PRODUCTS 2.01 MANUFACTURER A. Basis of Design: Contract Documents are based on products by Amerete, Inc., Fort Worth, Texas to establish a standard of quality. Other available products having equivalent characteristics may be considered, provided deviations are minor and do not change concept expressed in Contract Documents as judged by Architect. 2.02 CONCRETE MATERIALS A. Cementitious Materials: As specified in appropriate Division 03 Section. B. Normal-Weight Aggregates: 1. Description: a. ASTM C 33, Class [2N]. b. Selected, hard, and durable gravel free of material that reacts with cement or causes staining. c. Uniformly or gap graded to match approved sample. d. From single source with documented service record data of at least 10 years' satisfactory service in similar applications and service conditions using similar aggregates and cementitious materials. 2. Large Aggregate: 1 inch nominal river rock, no limestone. 3. Pea Gravel Aggregate: 3/8 inch nominal. 4. Fine Aggregate: a. Type: Fine sand. C. Water: ASTM C 94 and potable. D. Admixtures: As specified in appropriate Division 03 Section. 2.03 CURING OPTIONS A. Curing Compounds: ASTM C 309, Type 1, Class B, all resin, dissipating cure. B. Wet Cure: Seven day cure. C. Absorptive Cover: AASHTO M 182, Class 2, burlap cloth made from jute or kenaf, weighing approximately 9 oz. per sq. yd. 2.04 APPLIED PRODUCTS A. Liquid Densifier: 1. Description: Odorless, non-hazardous, potassium silicate that penetrates concrete to react with free lime and calcium hydroxide to produce permanent chemical reaction that hardens, densifies and tightens concrete surface. 2. Basis of Design: Amerete, Inc.; Everhard. B. Patching Compound: PSP 111039 CONSTRUCTION DOCUMENTS 10/25/12 033543-3
1. Description: Compound composed of 40 percent portland cement, 45 percent limestone, and 15 percent vinyl acetate copolymer, color matched to Sherwin Williams color fan by Architect. 2. Basis of Design: Amerete, Inc.; Durafil. C. Grout Material: 1. Description: Clear modified silicate sealant, containing no pore clogging latex, when mixed with dust salvaged from grinding process forms a paste that reacts with calcium hydroxide in concrete that hardens when surface imperfections are filled. 2. Basis of Design: Amerete, Inc.; Filzit Surfacing System. D. Polish Guard: 1. Description: Non-film forming, stain resistant, food resistant, chemical stain resistant, impregnating sealant designed to be used on concrete surfaces previously densified. 2. Basis of Design: Amerete, Inc.; Resistall. E. Hone Guard: 1. Non-film forming, stain resistant, food resistant, chemical stain resistant, impregnating sealant designed to be used on concrete surfaces previously densified. 2. Basis of Design: Amerete, Inc.; Scotchall. F. Protective Cover: 1. Description: Non-woven, puncture and tear resistant, polypropylene fibers laminated with a multi-ply, textured membrane, not less than 42 mils in thickness. 2. Basis of Design: Amerete, Inc.; CreteClad. G. Sealant: Hi-Tech Structural Systems Polyurea Joint Filler HT-PE85. 2.05 POLISHING EQUIPMENT A. Field Grinding and Polishing Equipment: 1. Variable speed, 3 or 4 head counter-rotating, walk-behind machine with not less than 600 lbs of down pressure on grinding or polishing pads. 2. Dust extraction equipment with flow rate suitable for dust generated, with pre-separator and squeegee attachments. B. Edge Grinding and Polishing Equipment: Hand-held or single head walk-behind machines which produces same results, without noticeable differences, as field grinding and polishing equipment. C. Burnishing Equipment: Single head high speed walk-behind machines. D. Grinding Pads: Metal bonded pads with embedded industrial grade diamonds of varying grits fabricated for mounting on equipment. E. Polishing Pads: Resin bonded pads with embedded industrial grade diamonds of varying grits fabricated for mounting on equipment. F. Burnishing Pads: Maintenance pads coated with embedded industrial grade diamonds for use with burnishing equipment. 2.06 CONCRETE MIX DESIGN A. Material Quality Standards: Concrete mix designs for each type and strength of concrete used for floors will be prepared as specified in appropriate Division 03 Section, with following qualifications: 1. Slump Limit: 3 inches, plus or minus 1 inch. 2. Maximum Water-Cement Ratio: 0.45. 3. Air Content: None permitted. 4. Admixtures: Calcium chloride based compounds not permitted. PART 3 - EXECUTION 3.01 ACCEPTABLE POLISHERS A. Basis of Design: Contract Documents are based on polishing operations by Amerete, Inc., Fort Worth, Texas to establish a standard of quality. Other polishers with products and polishing capabilities having equivalent characteristics may be considered, provided deviations PSP 111039 CONSTRUCTION DOCUMENTS 10/25/12 033543-4
are minor and do not change concept expressed in Contract Documents as judged by Architect. Substitutions must be approved by Architect before bidding. 3.02 EXAMINATION A. Acceptance of Surfaces and Conditions: Examine substrates to be polished for compliance with requirements and other conditions affecting performance. Proceed only when unsatisfactory conditions have been corrected in a manner complying with Contract Documents. B. Examine floor to determine if placement and finishing complies with mock-up. C. Examine floor flatness to determine if the F(F) is 50 or greater. Measuring with a 10 foot metal straight end to determine if within 1/8 inch flatness is acceptable. D. After the initial grind, examine surface to determine if aggregate exposure matches sample and mock-up. Grind until approved. 3.03 PREPARATION A. Cleaning New Concrete Surfaces: Prepare and clean concrete surfaces. Provide sound concrete surfaces free of laitance, glaze, efflorescence, curing compounds, form-release agents, dust, dirt, grease, oil, paint splatter, and other contaminants incompatible with polished concrete floor finish. 3.04 PLACING AND FINISHING CONCRETE FOR FLOORS A. General: Comply with appropriate Division 03 Section. B. Hot and Cold Weather Placement: As specified in appropriate Division 03 Section. C. As concrete is being placed, do not push aggregate down and locate aggregate so that it will be exposed in 3 passes with 40 grit tooling. D. Do not over trowel as to burn in. E. Plumbing and electrical outlets are to be troweled to be flat and properly finished. F. Edges are to be flat and level. G. Place concrete to avoid visible rebar lines after slab is polished. H. Make decorative saw cuts after polishing. I. Pour backs are to be of the same concrete mix design, same materials and same batch plant as previous placements; pour backs must be level with adjoining concrete. J. Placement: Deposit and consolidate concrete in continuous operation, within limits of construction joints, until placement of a panel or section is complete. 1. Consolidate concrete during placement operations so concrete is thoroughly worked around reinforcement and other embedded items and into corners. 2. Screed slab surfaces with a straightedge and strike off to correct elevations. 3. After screeding, consolidating and leveling, do not work surface until ready for floating. K. Floor Flatness: F(F) 50 according to ASTM E 1155. L. Curing Method: 1. Wet Curing: a. Immediately begin after floating. b. Keep concrete surface continuously wet by covering with absorptive cover or by continuous water-fog spray. c. Cover concrete surface with absorptive cover with 4 inch lap over adjacent covers. d. Thoroughly saturate cover with water and keep continuously wet. 3.05 CONCRETE POLISHING A. Joint Treatment: 1. Saw cut "decorative" joints with router type device to eliminate typical round saw blade "over run" at end of joint. 2. Fill construction joints, decorative joints and cracks with joint sealant. Shave sealant flush with top of adjacent concrete surface. PSP 111039 CONSTRUCTION DOCUMENTS 10/25/12 033543-5
B. Initial Grinding: 1. Use grinding equipment and low grit grinding pads. 2. Grind concrete to specified aggregate exposure imparting uniform scratch pattern in concrete. C. Level of Grinding: 1. Description: Large aggregate and/or pea gravel aggregate intentionally exposed up to 90% aggregate exposure. 2. Basis of Design: Amerete, Inc.; Luxcrete Ultra 3000 Grit. Architect s sample shown below (actual size): D. Treating Surface Imperfections: 1. Mix patching compound for larger imperfections and color match. Use grout material for small cracks and voids. 2. Fill surface imperfections including, but not limited to, holes, surface damage, small and micro cracks, air holes, pop-outs, and voids. 3. Work compound and treatment until color differences between concrete surface and filled surface imperfections are not noticeable. E. Applying Liquid Densifier: Apply undiluted to point of rejection, remove excess liquid, and allow to cure. F. Grout Grinding: 1. Use grinding equipment and appropriate grit grinding pads. 2. While applying fresh grout material prior to, grind concrete in direction perpendicular to initial grinding to remove scratches. G. Additional Grinding: 1. Use grinding equipment with increasingly finer grit grinding pads. 2. Grind concrete in as many passes necessary with each pass perpendicular to previous pass to remove scratches. H. Polishing: PSP 111039 CONSTRUCTION DOCUMENTS 10/25/12 033543-6
1. Use polishing equipment with increasingly finer grit polishing pads. 2. Polish concrete in as many passes necessary with each pass perpendicular to previous pass to remove scratches. I. Applying Polish Guard: Uniformly apply and remove excessive liquid. J. Applying Final Polish: Using burnishing equipment and finest grit burnishing pads, burnish to uniform sheen matching approved mock-up. K. Final Polished Sheen: Uniform semi-gloss sheen using 800 grit polishing heads. 3.06 PROTECTION A. Covering: Protect polished finish work from subsequent construction with protective covering. 3.07 FINISH TYPES A. Refer to Drawings for locations: 1. DPC-1 - interior 6-pass polish. END OF SECTION PSP 111039 CONSTRUCTION DOCUMENTS 10/25/12 033543-7