USACE / NAVFAC / AFCESA / NASA UFGS-04 01 21 (October 2007)
----------------------------
Preparing Activity: USACE Superseding
UFGS-04 01 21 (April 2006)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2009
SECTION 04 01 21
REHABILITATION OF REINFORCED AND UNREINFORCED MASONRY WALLS USING SURFACE APPLIED FRP COMPOSITES
10/07
NOTE: This guide specification covers the requirements for rehabilitation of
masonry walls and is intended for use in defining those requirements for procurement
of structural strengthening using fiber reinforced polymer (FRP) composite systems.
Edit this guide specification for project specific requirements by adding, deleting,
or revising text. For bracketed items, choose applicable items(s) or insert
appropriate information.
Remove information and requirements not required in respective project, whether
or not brackets are present.
Comments and suggestions on this guide specification are welcome and should
be directed to the technical proponent of the specification. A listing of technical
proponents, including their organization designation and telephone number, is
on the Internet.
Recommended changes to a UFGS should be submitted as a Criteria Change Request
(CCR).
PART 1 GENERAL
NOTE: In general, reinforced masonry is defined as masonry construction containing
vertical bar reinforcement, horizontal bar or joint reinforcement, mortar, and
grout combined so that the component materials will act together to resist the
design loading conditions.
Masonry not meeting the above definition but bonded together with mortar and
containing, if necessary, the minimum amount of reinforcement for crack control
and vertical stiffeners, is classified as non-reinforced or unreinforced masonry (URM).
The project drawings should show all necessary details, architectural and structural,
including wall sections, masonry bond and pattern, control joint locations,
joint dimensions, reinforcement locations, anchors, bond beam and special units,
masonry dimensions, and FRP composite details to complement this section.
Work covered by this specification will include the installation of near surface
embedded fiber reinforced polymer (FRP) composite systems as structural repointing
applied to masonry members. The work shall include:
a. Inspection of the structural members specified on the contract drawings to
be reinforced with FRP. The inspection shall check the location for cracks
and existing conditions of the masonry substrate.
b. Furnishing of materials, labor, equipment and all items necessary for rehabilitation
of existing masonry members by application of externally bonded FRP composite
systems as specified on the contract drawings and specifications.
c. Cooperation and coordination with all other trades in executing the work
described in the overall contract.
1.1 REFERENCES
NOTE: This paragraph is used to list the publications cited in the text of
the guide specification. The publications are referred to in the text by basic
designation only and listed in this paragraph by organization, designation,
date, and title.
Use the Reference Wizard's Check Reference feature when you add a RID outside
of the Section's Reference Article to automatically place the reference in the
Reference Article. Also use the Reference Wizard's Check Reference feature
to update the issue dates.
References not used in the text will automatically be deleted from this section
of the project specification when you choose to reconcile references in the
publish print process.
The publications listed below form a part of this specification to the extent referenced. The publications are
referred to within the text by the basic designation only.
[ACI INTERNATIONAL (ACI)ACI 440.2R(2008) Guide for the Design and Construction of Externally Bonded FRP Systems for Strengthening Concrete StructuresACI 440.3R(2004) Guide Test Methods for Fiber Reinforced Polymer (FRP) for Reinforcing or Strengthening Concrete StructuresACI 503.1-503.4(1992, R2003) Standard Specification for Repairing Concrete with Epoxy Mortars][AMERICAN CONFERENCE OF GOVERNMENTAL INDUSTRIAL HYGIENISTS (ACGIH)ACGIH Publication 0028(2006) TLVs and BEIs][ASTM INTERNATIONAL (ASTM)ASTM C 581(2003; R 2008e1) Standard Practice for Determining Chemical Resistance of Thermosetting Resins Used in Glass-Fiber-Reinforced Structures, Intended for Liquid ServiceASTM D 2240(2005) Standard Test Method for Rubber Property - Durometer HardnessASTM D 2563(2008) Classifying Visual Defects in Glass-Reinforced Plastic Laminate PartsASTM D 3039/D 3039M(2008) Tensile Properties of Polymer Matrix Composite MaterialsASTM D 3045(1992; R 2003) Practice for Heat Aging of Plastics Without LoadASTM D 3171(2006) Standard Test Method for Constituent Content of Composite MaterialsASTM D 4541(2002) Pull-Off Strength of Coatings Using Portable Adhesion TestersASTM G 154(2006) Operating Fluorescent Light Apparatus for UV Exposure of Nonmetallic Materials][INTERNATIONAL CODE COUNCIL (ICC)ICC ES AC125(2003) Interim Criteria for Concrete and Reinforced and Unreinforced Masonry Strengthening Using Fiber-Reinforced Polymer (FRP) Composite SystemsICC ES AC178(2003) Interim Criteria for Inspection and Verification of Concrete and Reinforced and Unreinforced Masonry Strengthening Using Fiber-Reinforced Polymer (FRP) Composite Systems][NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)NFPA 255(2005; Errata 2006) Standard Method of Test of Surface Burning Characteristics of Building Materials][U.S. DEPARTMENT OF DEFENSE (DOD)EI 042XX(200X) Design of Fiber Reinforced Polymer Composites Systems for Rehabilitation of Unreinforced and Lightly Reinforced Masonry Walls][U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)29 CFR 1910.1200Hazard Communication]1.2 SUBMITTALS
NOTE: Review submittal description (SD) definitions in Section 01 33 00 SUBMITTAL
PROCEDURES and edit the following list to reflect only the submittals required
for the project. Submittals should be kept to the minimum required for adequate
quality control.
A “G” following a submittal item indicates that the submittal requires Government
approval. Some submittals are already marked with a “G”. Only delete an existing
“G” if the submittal item is not complex and can be reviewed through the Contractor’s
Quality Control system. Only add a “G” if the submittal is sufficiently important
or complex in context of the project.
For submittals requiring Government approval on Army projects, a code of up
to three characters within the submittal tags may be used following the "G"
designation to indicate the approving authority. Codes for Army projects using
the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO"
for District Office (Engineering Division or other organization in the District
Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project
Office. Codes following the "G" typically are not used for Navy, Air Force,
and NASA projects.
Choose the first bracketed item for Navy, Air Force and NASA projects, or choose
the second bracketed item for Army projects.
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation
are for [Contractor Quality Control approval.] [information only. When used, a designation following the "G"
designation identifies the office that will review the submittal for the Government.] The following shall be
submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-01 Preconstruction Submittals
Quality Control[; G][; G, [_____]]
A quality assurance plan for installation and curing of all FRP materials to include personnel
safety issues, installer certification, application and inspection of the FRP system, location
and placement of splices, curing provisions, means to assure dry surfaces, quality assurance
samples and cleanup. The plan will indicate the testing that will be performed and identify
the party or parties responsible for this testing.
SD-02 Shop Drawings
Composite System[; G][; G, [_____]]
Complete shop drawings for each installation of the composite system showing details of fiber
architecture, fiber type, dimensions, number and thickness of layers, direction of fiber layers,
sequence of layer applications, lap splices, joint and end details, anchorage of the FRP composite
system, proposed connections to diaphragms and adjacent walls, and locations to be applied as
specified. Include any calculations prepared by or on behalf of the Contractor to determine
the layout of the FRP materials to be installed.
SD-03 Product Data
Materials
Manufacturer's product data sheets indicating physical, mechanical, and chemical characteristics
of all materials used in the FRP system application.
Tensile Properties
Values as determined by tensile testing in accordance with ASTM D 3039/D 3039M, elastic modulus
determined by the strength and rupture strain values and ultimate tensile strength and rupture
strain values determined by subtracting three (3) standard deviations from the average values
of twenty (20) or more tensile tests.
Material Safety Data Sheets (MSDS)
Data sheets for all materials to be used at the job site in accordance with OSHA and 29 CFR 1910.1200
.
SD-04 Samples
Materials[; G][; G, [_____]]
FRP plate 300 x 300 mm 12 x 12 inches or plate of equivalent area when one of the fiber reinforcing
dimensions is less than 300 mm 12 inches.
Anchors
Provide two of each type of anchor to be used.
SD-05 Design Data
Design Calculations[; G][; G, [_____]]
Design calculations for the FRP composite system shall be submitted for approval to the Contracting
Officer, and shall be stamped by a registered professional civil or structural engineer. Calculations
shall conform to requirements set forth in EI 042XX and in the ICC ES AC125 Acceptance Criteria
and are based on tension force and strain limits.
SD-06 Test Reports
Field Testing
Laboratory Testing
System environmental durability test results conducted and reported by an independent testing
facility; the report shall provide the following information:
a. FRP System nomenclature
b. Testing facility name
c. Testing facility address
d. Testing facility telephone number
e. Testing facility point of contact
f. Freeze-thaw test results
g. UV test results
h. Fire resistance test results
Wall Tests[; G][; G, [_____]]
Test results by an independent testing facility on walls which are representative of the actual
configuration and loading conditions for this contract, showing the following information:
a. FRP System nomenclature
b. Primer/filler system nomenclature
c. Coating/finishing system nomenclature
d. Testing facility name
e. Testing facility address
f. Testing facility telephone number
g. Testing facility point of contact
h. Test wall substrate material
i. Test wall aspect ratio
j. FRP fiber orientation and fiber density
k. FRP composite application process
l. Cyclic in-plane test results in accordance with EI 042XX and ICC ES AC125 to include the
following:
(1) Description of test setup.
(2) Rate and method of loading.
(3) Deformation and strain measurements.
(4) Modes of failure.
Hardness Test
Minimum Shore hardness values at 24 and at 48 hours in ten-degree intervals between 4 and
38 degrees C 40 and 100 degrees F for both neat resin and for FRP laminate on masonry substrate.
Provide minimum Shore hardness values for fully cured resin and fully cured FRP laminate on
masonry substrate.
SD-07 Certificates
Materials[; G][; G, [_____]]
Certification from the system manufacturer of the guaranteed material and section properties
for the supplied material.
Regulatory Requirements
Certification that resins proposed for use meet Federal VOC regulations and those of the local
Air Pollution Control Districts having jurisdiction over the geographical area in which the
project is located.
System Manufacturer[; G][; G, [_____]]
A list of a minimum ten (10) FRP composite strengthening projects completed with the manufacturer's
composite system. The list shall include: the dates of work, type, description and amount
of work performed, as well as a point of contact for the Contractor doing the work, and an owner
representative to include name, address and telephone number.
Contractor[; G][; G, [_____]]
A list of a minimum five (5) completed FRP composite strengthening projects performed by the
Contractor to include a minimum of three (3) with the manufacturer's composite system. Include
the dates of work, type, description and amount of work performed, the FRP system installed
for each project, and the name and telephone number of a contact person or owner for which the
work was completed.
Field Representative[; G][; G, [_____]]
The name of the Contractor's field representative who will perform the actual work supervision,
the date certification course completed, and a list of a minimum of ten (10) completed FRP composite
strengthening projects of similar applications using the manufacturer's composite system. Include
the dates of work, type, description and amount of work performed, and the name and telephone
number of a contact person or owner for which the work was completed.
Applicators[; G][; G, [_____]]
Certificates of training by the FRP system manufacturer for all FRP applicators, a syllabus
of the certification course, as well as listing of past application projects completed by the
applicators. Include the dates of work, type, description and amount of work performed, and
the name and telephone number of a contact person or owner for which the work was completed.
SD-08 Manufacturer's Instructions
Composite System; G, [____]
Submit the manufacturer's printed installation instructions to include the following:
a. Brand name
b. Catalog numbers
c. Names of manufacturers for each material to be used. Include with instructions the estimated
quantity of each material to be used on the job.
d. Detailed mixing and application instructions to include:
(1) Mixing instructions
(2) Curing times between coats or layers
(3) Application procedures for surface coatings
(4) Cold weather installation to include the minimum application temperature recommended
by the FRP system manufacturer or 4 degrees C 40 degrees F whichever is higher. Application
at temperatures below 4 degrees C 40 degrees F shall be approved by the Contracting Officer
and the minimum Shore hardness for the lower temperatures shall be provided.
(5) Hot weather installation to include the maximum application temperature recommended
by the FRP system manufacturer or 38 degrees C 100 degrees F whichever is lower. Application
at temperatures above 38 degrees C 100 degrees F shall be approved by the Contracting Officer
and the minimum Shore hardness for the higher temperatures shall be provided.
(6) Inclement weather installations
(7) Application procedures of top coating material
SD-10 Operation and Maintenance Data
Record Retention; G, [____]
Procedures to properly maintain the installed FRP system as well as written manufacturer recommended
repair procedures for damage to the in-place FRP system.
1.3 COMPOSITE SYSTEM
1.3.1 Design Requirements
NOTE: The resin system used in the FRP composite system seals up the surface
of the wall where it is applied and can impede air and moisture migration through
a wall. If the wall should not be sealed tight, full coverage of the wall with
the FRP system should be avoided thus allowing normal air and water vapor transmission.
The design of the FRP composite system shall conform to ACI 440.2R and shall provide [seismic] [wind] [and] [blast]
strengthening for [clay] [and] [concrete] masonry walls. The strengthening design requires that walls with the
FRP system applied fail by cracking through the masonry units and mortar prior to any delamination or rupture
of the FRP composite system. The Contractor shall submit Design Calculations as specified in the Submittals
paragraph. Provide an FRP system that does not adversely affect air and moisture permeation through the masonry
walls.
1.3.2 Performance Requirements
NOTE: Provide the parameters of strength or force that must be provided by
the rehab. The following variables must be considered in determining the enhanced
performance requirements: the load on the wall, the size of the wall, the wall
aspect ratio, wall openings, etc.
The FRP composite system shall provide [seismic] [wind] [and] [blast] strengthening for [clay] [concrete] masonry
walls by [[_____]%] [the quantity indicated on the shop drawings]. The system shall transfer [seismic] [wind]
[and] [blast] loading in concert with the existing masonry to the building foundation.
1.4 QUALIFICATIONS
1.4.1 System Manufacturer
The FRP composite system manufacturer shall have used the proposed materials system on a minimum of ten (10)
completed strengthening projects.
1.4.2 Contractor
The Contractor shall have completed a minimum of five (5) FRP composite strengthening projects on vertical flat
surfaces and a minimum of three (3) of those jobs using the manufacturer's composite system. The Contractor
shall provide the qualifications for its Field Representative as specified in the Submittals paragraph.
1.4.3 Applicators
1.4.3.1 Training
The FRP composite applicators shall have completed, as a minimum, a certification course provided by the FRP
manufacturer, which includes hands-on application of FRP systems to masonry substrates. A field representative
who has completed the course of instruction and has completed a minimum of ten (10) FRP composite strengthening
projects, three (3) using the manufacturer's composite system, shall be present onsite during all installation
of the FRP system.
1.4.3.2 Experience
Only qualified applicators meeting these requirements and those having prior experience in the specified surface
preparation and coating applications shall be assigned to perform the work described herein.
1.5 WORK SITE SAFETY
Workers having access to the work area shall be informed of the contents of the applicable material safety data
sheets (MSDS) and of potential health and safety hazards and protective controls associated with materials used
on the project. The work area is one that may receive mists and odors from the rehab application and curing
operations. Train workers in the safe handling and application of FRP materials and the exposure limit for each
material that the worker will use or otherwise be exposed to during the course of the project. Instruct personnel
having a need to use respirators and masks in the use and maintenance of such equipment.
1.6 REGULATORY REQUIREMENTS
Insure that the composite system used does not release volatile organic compounds (VOC) into the air in excess
of the most restrictive of NIOSH RELs, OSHA PELs or ACGIH TLVs for worker or occupant exposure during installation
and/or over the useful life of the structure. If VOCs exceed any of these exposure limits during installation
or use, provide additional ventilation for the duration of the excess outgassing. Insure that at no time will
they exceed STEL, even if additional ventilation or air supply is provided. Provide the necessary equipment
to comply with these requirements. Once cured, insure the FRP composite system does not exhibit any detectable
odor at a distance of 300 mm one foot from the FRP surface.
1.7 PREINSTALLATION CONFERENCE
Prior to commencement of any work, the Contractor shall arrange and conduct a meeting between the Contracting
Officer, Contractor, and the independent special inspector to discuss the project requirements. The Contractor
shall review the requirements of the Specification and overall project requirements. Review and discuss all
aspects of the project including containment, environmental control, surface preparation, strengthening system
application, quality assurance, schedule requirements, and safety shall be reviewed and discussed. Request clarification
of any ambiguities, and advise the Contracting Officer of any potential conflicts and/or any technical requirements
that appear improper or inappropriate.
1.8 DELIVERY AND STORAGE
1.8.1 Labeling
Deliver polymer resin materials in original factory-sealed containers with the manufacturer's labels intact and
legible with verification of product nomenclature, manufacturer's name, product identification and batch number,
date of manufacture and shelf life or expiration date. Do not use polymer resin materials that have exceeded
the shelf life.
1.8.2 Storage
Store materials in a covered, well-ventilated area protected from exposure to any detrimental conditions including:
airborne contaminants, dirt, dust, sunlight, temperatures lower than 4 or greater than 38 degrees C 40 or greater
than 100 degrees F, rainfall, sparks or flame and in accordance with the manufacturer's requirements. Store
polymer resins separate from their hardeners.
1.9 PROJECT/SITE CONDITIONS
1.9.1 Environmental Requirements
1.9.1.1 Application Temperature
a. Do not apply primers, saturating resins and adhesives to cold or frozen surfaces. When the surface
temperature of the masonry surface falls below a minimum level, as specified by the FRP system manufacturer,
the work will cease until both the air and masonry temperature rise above the specified minimum. Supplemental
sources of heat shall not be used to raise the air or masonry surface temperature unless approved by
the FRP composite system manufacturer.
b. When the surface temperature of the masonry and/or the air temperature rise above the maximum level
as specified by the FRP system manufacturer, the work will cease until both the air temperature masonry
temperature cool below the specified maximum.
1.9.1.2 Wet or Damp Surfaces
Unless they have been formulated for such applications, do not apply resins and adhesives to damp or wet surfaces.
1.9.1.3 Breathable Wall Surfaces
Do not completely cover masonry surfaces that are designed to allow air and vapor transmission with FRP systems.
1.9.2 Existing Conditions
As-built drawings of the structure [are attached] [can be accessed at [_____]]..
1.9.3 Work Coordination
Coordinate work to minimize exposure of building occupants, other Contractor personnel, and visitors to dust,
mists, and odors from preparation, FRP system application and clean-up operations.
1.10 WARRANTY
Furnish a warranty (either by the manufacturer or Contractor) for FRP composite system installation. Insure
the warranty covers the FRP composite system [design,] installation, bond to the substrate, and interlaminar
bond, as well as mechanical property retention, and fabric-resin compatibility. The warranty shall run directly
to the Government and shall cover a period of not less than 5 years from the date of Government's acceptance.
PART 2 PRODUCTS
NOTE: FRP system forms can be categorized based on how they are delivered to
the work site and installed. Externally applied FRP composite systems come
in a variety of forms including wet lay-up systems, prepreg systems, and precured systems.
Wet lay-up FRP systems consist of dry unidirectional or multi-directional fiber
sheets or fabrics that are impregnated onsite with a saturating resin. The
saturating resin is used to bond the sheets to the masonry surface. Wet lay-up
systems are saturated with resin and cured in place and in this sense are analogous
to cast-in-place concrete. For dry lay-up systems, the fabric is placed on
the wall and then saturated in-place with resin and cured in place.
Prepreg FRP systems consist of unidirectional or multidirectional fiber sheets
or fabrics that are preimpregnated with a saturating resin in the supplier's
facility. Prepreg systems are bonded to the concrete surface with or without
an additional resin application, depending upon specific system requirements.
Prepreg systems are saturated offsite and, like wet lay-up systems, are cured
in place. Prepreg systems usually require heat for cure.
Precured FRP systems consist of composite shapes (plates, strips, ribbons, and
bars configured as an open mesh grid or solid laminate) manufactured in the
system supplier's facility and shipped to the job site. Typically, an adhesive
is used to bond the precured shapes to the masonry surface.
It is important that only one system manufacturer supply all materials system
components (reinforcements, resins and adhesives) for a specific job. The arbitrary
selection of a fiber reinforcement and a resin/matrix material can lead to failure
of the FRP composites system due to matrix-reinforcement incompatibilities and
are, therefore, not allowed.
2.1 MATERIALS
Do no substitute the submitted reinforced FRP composite system or any its components during the course of the
project.
2.2 MANUFACTURED PRODUCTS
NOTE: The values listed in the following table should be provided by the design
engineer and be based on the values and assumptions that were used in developing
the rehab design. The items in Table 1 below will be the minimum acceptable
property values for the FRP system to be installed and potential FRP systems
submitted which do not meet these minimums should be rejected.
Submittals must demonstrate that the proposed materials will match the intent
of the engineering design using the properties listed above. Proposed FRP systems
must utilize the same primary fiber reinforcement type (e.g., carbon fiber,
aramid fiber, or E-glass fiber) as the system listed above.
Proposals for material systems must include, at a minimum, documented evidence
that the Manufacturer of the proposed system meets the requirements of Table
1, and demonstrate the structural equivalency of the proposed system to the
system(s) specified.
Table 1 lists the minimum allowable gross laminate properties for the cured [glass] [carbon] [aramid] [hybrid]
reinforced FRP composite system. The Contractor shall provide values for the Tensile Properties of the composite
material as specified in the Submittals paragraph.
TABLE 1
FRP
COMPOSITE TEST
REQUIREMENT METHOD
Elongation:
max. [_____]% ASTM D 3039/D 3039M
Guaranteed Tensile
Strength, min., in [_____] kPa (psi) ASTM D 3039/D 3039M
primary fiber
direction.
Ult. Breaking Load,
min., in primary [_____] kg/mm (lb/in) ASTM D 3039/D 3039M
fiber direction
width
Modulus of Elasticity,
min. based on cross [_____] kPa (psi) ASTM D 3039/D 3039M
sectional area of
primary fibers
Percent Tensile
Strength
Retained after:
[7 days exposure
at 100% humidity [_____]% ASTM G 154]
[2,000 hours
exposure to UV [_____]% ASTM G 154]
[3,000 hours
exposure to ozone [_____]% ASTM C 581]
[3,000 hours
exposure to alkali [_____]% ASTM C 581]
[3,000 hours
exposure to salt water [_____]% ASTM C 581]
[3,000 hours exposure
at 60 C (140 F). [_____]% ASTM D 3045]
[Guaranteed Tensile
Strength at 90 degrees [_____] kPa (psi) ASTM D 3039/D 3039M
to primary fibers, min.]
[Ultimate Tensile
Strength of Lap [_____] kPa (psi) ASTM D 3039/D 3039M
Splices in Primary
Fiber Direction]
[Ply Thickness [_____] mm (in) ASTM D 3039/D 3039M]
[Fiber Volume Fraction [_____]% ASTM D 3171]
[Visual Defects Acceptance ASTM D 2563
Level [_____]]
2.3 COMPONENTS
2.3.1 FRP Composite System
NOTE: Select the appropriate system from the three choices below and delete
the others.
2.3.1.1 Wet Lay-up System
A wet lay-up FRP system consists of [glass] [carbon] [aramid] fiber in [an epoxy] [a polyester] [a polyurethane]
resin.
2.3.1.2 Prepreg System
A prepreg FRP system consists of [glass] [carbon] [aramid] fiber in an uncured polymer resin.
2.3.1.3 Precured System
A precured FRP system consists of [glass] [carbon] [aramid] fiber, fabricated as [strips] [plates] [ribbons]
[bars] in [an open mesh grid] [a solid laminate] configuration with a resin matrix of [vinyl ester] [polyester]
[epoxy] [polyurethane] [specialty resin] applied to the surface of the masonry wall using [a polyurethane] [an
epoxy] structural adhesive.
2.3.2 Use of Primer/Filler
The primer/filler used for the protective seal coat and for filling voids consists of a thickened [epoxy] [polyester].
2.3.3 Finish and Coating
Perform final finish and apply architectural coatings as prescribed in architectural specifications and drawings
[_____].
2.4 ACCESSORIES
2.4.1 Anchors
Install anchors for the FRP system as prescribed by the FRP system manufacturer and designated in the Shop Drawings.
2.4.2 Miscellaneous
Provide other materials as needed for the proper installation of the complete composite system as specified.
2.5 MIXES
Mix [Resins] [Adhesive] in accordance with the FRP system manufacturer's recommended procedure. Assure that
all [resin] [adhesive] components are at a proper temperature and are mixed in the correct ratio until there
is a complete mixing of components and a uniform color. Mix each batch of [resin] [adhesive] in quantities sufficiently
small to ensure that all mixed [resin] [adhesive] can be used within the [resin] [adhesive] pot life. Do not
use mixed [resin] [adhesive] that exceeds its pot life as defined by the system manufacturer.
2.6 [FLAME SPREAD/FIRE PROTECTION
NOTE: Unless stated otherwise by the local fire building code, this paragraph
may be deleted if the FRP materials are installed on the exterior of a structure
or if a flame barrier is installed between living space and the FRP materials
system.
Meet requirements for Class 1 fire rating in accordance with NFPA 255 and meet or exceed local building code
requirements for flame spread and smoke generation.]
PART 3 EXECUTION
3.1 SUBSTRATE, TEMPERATURE, AND ENVIRONMENT
3.1.1 Examination
Examine existing conditions to assess the quality of the masonry substrate, identify potential obstructions,
and verify dimensions/geometries shown on shop drawings.
3.1.2 Environmental Temperature
Should the potential for adverse temperatures occur during installation, the application of FRP shall cease until
temperatures return to within the range specified in the Manufacturer's Instructions. Obtain approval from the
FRP manufacturer and the Contracting Officer before using supplemental heating or cooling sources.
3.1.3 Other Environmental Factors
Should the potential for direct contact by rain, dust or dirt, excessive sunlight, high humidity, or vandalism
occur during installation, temporary protection may be required until the resins have cured. Provide and install
tents and/or plastic screens as required to protect the FRP system as it cures. Assure resins are cured before
removal of temporary shoring or allowing the structure to be exposed to new loads. In the event of suspected
damage to the FRP system during installation, notify the Contracting Officer. Repair any damage caused by installer
negligence at no additional cost to the Government.
3.2 PREPARATION
3.2.1 Materials Testing
Assure that delivered FRP materials meet the specified requirements prior to starting the project. This may
require laboratory testing. Reject all materials that do not meet the minimum requirements, as specified in
Table 1 and by the Contracting Officer. In addition, determine the gel time, pot life, and curing hardness of
the resins.
3.2.2 Worksite Ventilation
Ventilate work areas during FRP application so that worker exposure to chemical substances do not exceed limits
established by ACGIH Publication 0028, or required by a more stringent applicable local regulation. Ventilate
interior work zones having a volume of 280 cubic m 10,000 cubic ft or less at a minimum of 2 air exchanges per
hour. Maintain ventilation in larger work zones by means of mechanical exhaust. Exhaust solvent vapors outdoors,
away from air intakes and workers. Temporarily seal return air inlets in the work zone before start of work
until the polymer resin has cured.
3.2.3 Substrate Repair
3.2.3.1 Surface
[The area to receive FRP composite is relatively sound structurally.] [There are known problems associated with
the condition of the original masonry and the masonry substrate that can compromise the integrity of the FRP
system.] [Surface cracks greater than 1.6 mm 1/16-inch shall be filled to a minimum depth of 25 mm 1 inch.] [Remove
areas of loose or spalling masonry material.]
3.2.3.2 Sub-Surface
Do not apply externally bonded FRP systems to masonry substrates containing corroding reinforcing-steel. Note
and report evidence of localized cracking and/or spalling at grouted cells or of rust stains to the Contracting
Officer. Do not proceed with work until the cause(s) of the corrosion is addressed and the corrosion-related
deterioration repaired.
3.2.4 Surface Preparation
3.2.4.1 Surface Cleaning
Remove all loose or unsound materials and other conditions that would inhibit bond such as laitance, dust, dirt,
oil, curing compound, existing paint or coatings, efflorescence, and any other matter that could interfere with
the bond of the FRP system from the masonry or repaired surfaces to which the FRP system is to be applied.
3.2.4.2 New Masonry Preparation
Unspoiled new masonry only requires wire brushing to remove loose surface particles.
3.2.4.3 Old Clay Masonry Preparation
Prepare surface of older clay masonry using hand tools, power tools or water blasting techniques. Do not use
abrasive blasting.
3.2.4.4 Old Concrete Masonry Preparation
Concrete masonry may be blasted using a light blast abrasive or cleaned using hand tools, power tools or water
blasting techniques.
3.2.4.5 Cleaned Surface Protection
After the cleaning operations are complete protect the surface prior to FRP installation so that no materials
that may interfere with bond are redeposited on the surface. Apply the FRP composite system to the prepared
wall within 72 hours of performing the surface preparation.
3.2.5 Surface Plane Variation Tolerance
3.2.5.1 Tooled Mortar Joints
Fill all tooled mortar joints with putty or another epoxy-based paste with adequate bonding properties to the
masonry substrate to make them flush with the adjacent clay masonry unit or concrete block. Assure localized
out-of-plane variations between masonry units do not exceed 1.6 mm 1/16-inch or the tolerances recommended by
the FRP system manufacturer, whichever is less. Smooth localized out-of-plane variations in the masonry units
using putty as needed. It is not necessary to screed filler onto the surface to fill all bug holes. Fill larger
holes greater than 6 mm 1/4 inch in diameter and other voids with putty.
3.2.5.2 Untooled Mortar Joints
Grind or chisel untooled mortar joints that protrude beyond the masonry surface or other protuberances or irregularities
flush with the surface.
3.2.6 Obstructions, Corners and Non-Planar Surfaces
Obstructions, re-entrant corners, concave surfaces and embedded objects can affect the performance of the FRP
system. Modify as necessary. Movable obstructions and embedded objects may need to be removed prior to installing
the FRP system. [Give special care to re-entrant corner detailing and concave surface detailing to ensure that
the bond of the FRP system to the substrate is maintained.]
3.2.7 Surface Moisture
Assure all surfaces to receive the strengthening system are as dry as recommended by the FRP system manufacturer.
Evaluate moisture content in accordance with the requirements of Section 2.3.2.5 of ACI 503.1-503.4.
3.3 FRP INSTALLATION
Do not install the FRP composite if the ambient air temperature or substrate surface temperature exceeds that
recommended by the system manufacturer. Do not install the FRP composite when surface moisture is present on
the substrate or when rainfall or condensation is anticipated in the work areas.
3.3.1 Primer
NOTE: Wet lay-up systems typically require a primer to saturate and penetrate
the masonry surface and enhance the bond strength of the FRP system. Adhesives
used with pre-cured systems, depending upon its chemistry, may not require use
of a primer.
Delete this paragraph if not required in the project.
a. Mix primers according to the FRP system manufacturer's installation instructions. Assure resin components
are at a proper temperature and mixed in the Manufacturer's prescribed mix ratio for its prescribed mixing
time until there is a uniform and complete mixing of components.
b. Apply primers to areas on the masonry surface where the FRP system is to be placed. Place primer
uniformly on the prepared surface at the manufacturer's specified rate of coverage. Allow primer to
cure to the degree specified by the FRP manufacturer before applying subsequent materials.
3.3.2 Putty/Filler
Assure putty/filler used is compatible with the FRP strengthening system and complies with the FRP system manufacturer's
specifications. Use putty or another epoxy-based paste with adequate bonding properties to masonry only to fill
voids and smooth surface discontinuities prior to application of other materials. Allow putty to cure to the
degree specified by the FRP manufacturer before applying subsequent materials. Grind rough edges or trowel lines
of cured putty smooth prior to continuing the installation.
3.3.3 Wet Lay-Up and Prepreg Systems
Install the FRP system in strict accordance with the FRP system manufacturer's recommendations. Apply sufficient
saturating resin to achieve full saturation of the fibers in accordance with the manufacturer's specifications.
Release or roll out entrapped air between layers before the resin sets. Place successive layers of saturating
resin and fiber materials before complete cure of the previous layer of resin. Handle sheet and fabric materials
in a manner to maintain the fiber straightness and orientat Remove and repair fabric kinks, folds, or other
forms of severe waviness.
3.3.4 Precured Systems
Install the FRP system in strict accordance with the FRP system manufacturer's recommendations. Uniformly apply
adhesives shall be to the prepared surfaces where pre-cured systems are to be placed. Apply adhesives at a rate
recommended by the FRP manufacturer to ensure full bonding of successive layers. Release or roll out entrapped
air between layers before the adhesive sets.
3.3.5 Lap Splices
[Stagger lap splices unless noted otherwise in the Shop Drawings and by the Contracting Officer.] [Lap splices
are not permitted except as shown in the Shop Drawings.]
3.3.6 Curing of Resins
Inspect the primer and FRP resin to assure proper cure according to the manufacturer's recommendation. Field
modification of resin chemistry is not permitted.
3.3.7 Surface Finish - Coating Application
NOTE: Only those surfaces exposed to direct sunlight and weather require surface
finish coating. There may also be applications where it is desired for architectural
reasons or aesthetics.
3.3.7.1 Preparation
Apply paints and coatings prior to final resin cure for best results. After the FRP resin has cured, the coating
can be applied by performing a light dust blast of 30-mesh silica sand (or equivalent method) to break the gloss
finish in preparation of a finish coating. Remove dust and residue from all surfaces by flushing with clean
water before applying the coating. Assure all surfaces are dry before applying the surface finish coating.
3.3.7.2 Multiple Coats
Use coatings compatible with the FRP strengthening system and applied in accordance with the manufacturer's recommendations.
Apply two finish layers of coating according to the coating manufacturer's instructions prior to full cure of
the FRP system.
3.3.8 Installation Procedure Modification
Installation procedures may be modified to achieve maximum results, subject to approval by the Contracting Officer.
Procedural modifications approved by the Contracting Officer and Contracting Officer's Representative prior to
implementation are allowed.
3.3.9 System Placement Tolerances
Follow FRP ply orientation and ply stacking sequence in accordance with that shown in the Shop Drawings. Assure
variations in angle from the intended direction of fiber alignment prescribed in the Shop Drawings are less than
5 degrees.
3.4 WALL FEATURE COMPATIBILITY
3.4.1 Weep Holes
Maintain all weep holes. Assure that no resin enters existing weep holes. Do not cover existing weep holes
with the FRP composite.
3.4.2 Construction Joints
3.4.2.1 [Control Joints
Maintain all CMU control joints. Insure that the FRP composite does not bridge existing control joints.]
3.4.2.2 [Expansion Joints
NOTE: Design loads must be evaluated to determine whether or not to maintain
existing expansion joints.
[Maintain all clay masonry expansion joints.] [Those expansion joints indicated on the shop drawings shall be
maintained.] Insure that the FRP composite does not bridge existing expansion joints.]
3.4.3 [Diaphragms
Anchor the FRP system into the floor and ceiling diaphragms in accordance with the Shop Drawings. Assure anchorage
does not create local stresses that may locally fracture the walls when deflection occurs due to out-of-plane
loading.]
3.5 QUALITY CONTROL
Maintain quality assurance and quality control (QA/QC) programs and criteria. Provide full inspection of the
surface preparation and composite systems applications to ensure full compliance with the specified requirements.
3.5.1 Independent Special Inspector
Provide a special inspector, trained and certified by the FRP system manufacturer and approved by the Contracting
Officer. The special inspector shall not be an employee of the Contractor or be financially associated with
the Contractor beyond the inspection contract. The special inspector shall perform inspections in accordance
with this specification and ICC ES AC178.
3.5.2 Laboratory Qualification
The testing laboratory shall be one approved by the Engineer of Record, the Contracting Officer and the Contractor.
The laboratory shall have experience in testing FRP materials and have performed ASTM D 3039/D 3039M wall tests
for at least three (3) different Contractors prior to this contract.
3.6 LABORATORY TESTING
3.6.1 Witness Panels
3.6.1.1 Wet Lay-up and Prepreg
Fabricate witness panels onsite using installation procedures identical to the method used to install the FRP
system to the masonry surfaces. Fabricate two witness panels for each day of production or one for each 46 square
m 500 square ft of production whichever is more. From a standard polymer resin mix, saturate a 300 x 300 mm
12 x 12 inch piece of fabric according to specified fiber-resin ratio. On a smooth, flat, level surface covered
with polyethylene sheeting or 0.4 mm 16-mil plastic film, prime the surface with polymer resin and then prepare
the witness panel by placing two layers of saturated fabric oriented in the same direction on the flat surface.
Apply an additional topping of polymer resin and cover the completed sample with plastic film and squeegee out
all bubbles. Store samples in a sample box at the work site and do not move them for a minimum 48 hours after
casting. Mark the panels with the date of fabrication, location of application, number of plies and primary
fiber direction. Ship the samples within two weeks of fabrication to the pre-approved testing laboratory for
evaluation.
3.6.1.2 Precured
Witness panel samples for precured sheet and strip material are the width of the procured sheet and a length
sufficient to achieve 92,900 square mm 144 square inches in total area taken randomly from the material received
at the job site.
3.6.2 Panel Testing
NOTE: Due to the sensitivity of ASTM D 3039/D 3039M, not all testing laboratories
are capable of performing this test. The testing laboratory used shall have
a history of performing ASTM D 3039/D 3039M tests prior to the contract.
Determine lap splice strength, tension strength, and elastic modulus of FRP materials. Test not fewer than two
(2) coupons from each witness panel in the laboratory in accordance with ASTM D 3039/D 3039M. If one coupon
from a witness panel fails to meet the minimum strength specified in Table 1, test five (5) additional coupons
from the witness panel with the failed coupon. If a second one fails, test five (5) coupons from all panels
for that day of production. Take appropriate remedial measures to ensure integrity of the FRP system applied
for the day the failed witness panels were prepared. In addition, test a minimum of five (5) coupons from each
witness panel for the remainder of the job or until ten successive witness panels are tested with no coupon failures.
Then two (2) coupon tests per witness panel may be resumed. The Contracting Officer may waive or alter the frequency
of testing.
3.6.3 Report
The laboratory shall report the mechanical properties of the witness panels in accordance with ASTM D 3039/D 3039M
. Provide a copy of the report to the Contracting Officer and Special Inspector for review.
3.7 FIELD TESTING
3.7.1 Mixed Resin Hardness
NOTE: The term "resins" include primers, saturating resins, binders, and adhesive components.
The required resin samples are a minimum of 1/4-inch (6.4 mm) in thickness,
whereas FRP placed on a wall is much thinner, typically 1/8-inch (3.2 mm) or
less. During initial stages of curing, thicker cross sections tend to be softer
than thin ones. There is, therefore a variation in the required hardness to
account for this phenomenon.
Prepare two samples of each mixed resin, primers, binders, saturants, and adhesives, per day from two, separate,
nonconsecutive batches of each. The resin samples should be a minimum of 3.2 mm 1/8-inch thick and 50 mm 2 inches
in diameter. Retain the mixed resin samples for testing to evaluate curing progress.
3.7.1.1 Testing
Evaluate relative curing progress of the resin on the job site by measuring the hardness of the resin sample
at 24 hours and 48 hours of cure in accordance with provisions of ASTM D 2240. Insure the polymer resin exceeds
the Shore hardness reported by the manufacturer evaluated at the lowest air temperature for the curing time period.
Take measurements at a minimum of three different points distributed over the resin specimen's surface at least
6.4 mm 1/4-inch apart from each other.
3.7.1.2 Report
Report the mean hardness value obtained, resin identification and manufacturer, resin batch number, resin mixing
date and time, test date and time, air temperature when the resin was mixed, air temperature when the testing
was performed, the minimum air temperature for the curing period, and the type and serial number of durometer
used.
3.7.1.3 Remedial Measures
In the event that measured hardness is less than the manufacturer's reported hardness for the temperature range,
take remedial measures as specified.
3.7.2 In-Place FRP Hardness
3.7.2.1 Testing
Evaluate relative curing progress of the in-place FRP resin at 24 hours and at 48 hours using the Shore Durometer
hardness test described in ASTM D 2240. Perform a minimum of five tests on each 9.3 square m 100 square ft of
wall or portion thereof with FRP composite applied to it. Insure the Shore hardness exceeds the manufacturer's
values for the time period measured and the lowest air temperature during that time period.
3.7.2.2 Report
Report both the individual and mean hardness values obtained, the locations where each hardness test was performed,
the FRP application date, test date and time, air temperature when the FRP was applied, air temperature when
testing performed, and the type and serial number of durometer used.
3.7.2.3 Remedial Measures
In the event that hardness is less than the manufacturer's reported hardness for the temperature range, take
remedial measures as specified. For any structural member where testing indicates that the installed composite
system does not meet the minimum specified hardness values, immediately halt the FRP installation and notify
the Contracting Officer. Remove the affected, installed FRP composite at no expense to the Government and replaced
with FRP composite meeting or exceeding the minimum hardness values.
3.7.3 Adhesion Strength
3.7.3.1 Testing
a. Using the method described by ACI 440.3R or ASTM D 4541 conduct direct tension adhesion testing of
cored samples. Perform a minimum of three tests for each day of production or for each 46 square m 500
square ft of FRP application, whichever is less. Perform pull-off tests on each area of fiber sheet
installed on a single day. Perform tests on each type of masonry substrate or for each surface preparation
technique used.
b. Allow the FRP system to cure a minimum of 24 hours before execution of the direct tension pull-off
test. The locations of the pull-off tests shall be representative and on flat surfaces. If possible,
conduct the tests on areas of the FRP system subjected to relatively low stress during service. The
minimum acceptable value for any single tension test is 1.2 MPa 175 psi. The average adhesion strength
of the three tests at each location shall not be less than 1.38 MPa 200 psi. The tension adhesion tests
shall exhibit failure of the masonry substrate indicated by a layer of masonry on at least 80 percent
of the underside of the test puck following the test.
3.7.3.2 Report
Report the adhesive strength values for each test and the average strength for each day's production. Report
the type of failure for each. Report No adhesion of the masonry to the FRP surface adhered to the test puck
to the Contracting Officer.
3.7.3.3 Remedial Measures
In the event that the adhesive strength does not meet the minimum allowable strength, take remedial measures.
Halt FRP installation and notify the Contracting Officer. Remove affected, installed FRP composite at no expense
to the Government. Clean the substrate surface and apply FRP composite that meets or exceeds the minimum specified
values.
3.7.3.4 Test Repair
After testing, fill the hole in the FRP composite with putty and smooth it. Apply a 4-inch (100 mm) or more
overlapping sheet patch of equivalent plies over the location where the sample was taken.
3.7.4 Laminate Thickness and Number of Plies
Measure the cured laminate thickness and count the number of plies. Avoid taking samples from high stress areas
or splice areas. Where laminate is too thin or not having sufficient plies, add additional plies to meet design
specifications.
3.8 QC/QA INSPECTION
3.8.1 Special Inspector Duties
Inspect the FRP composite overlay during and immediately following application of the composite. Inspect FRP
systems and all associated work as required by the applicable codes and as described in the QA/QC plan. Observe
all aspects of onsite preparation and material application including surface preparation, resin component mixing,
application of primer, application of resin and fiber sheet, curing of composite, and the application of protective
coatings. The special inspector shall require compliance with the design drawings and specifications.
3.8.2 Daily Inspection Records
Include in daily inspection records:
a. Date and time of installation;
b. Ambient temperature, relative humidity, and general weather observations;
c. Surface temperature of the masonry receiving the FRP composite system;
d. Surface dryness;
e. Surface preparation methods;
f. Surface cleanliness;
g. Type of auxiliary heat source, if applicable;
h. Fiber or pre-cured laminate batch number(s) and location in structure;
i. Batch numbers, mix ratios, mixing times, and mixed color of all resins, including primers, putties,
saturants, adhesives, and coatings mixed for the day;
j. Observations of progress of cure of resins;
k. Conformance with installation procedures;
l. Pull-off test results: bond strength, failure mode, and location;
m. FRP system properties from witness panel tests, if required;
n. Location and size of any delaminations or air voids;
o. General progress of work.
Inspection and progress reports shall be submitted daily to the Contracting Officer.
3.8.3 Void Detection
After allowing at least 24 hours for initial resin cure to occur, perform a visual and acoustic tap test inspection
of the layered surface. Other methods for detecting voids may be employed; all parties concerned shall agree
upon these methods prior to the submission of bids or proposals. Mark voids requiring corrective action in accordance
with the specified FRP maintenance and repair procedure.
3.8.4 Delaminations
Evaluate the cured FRP system for delaminations or air voids between multiple plies or between the FRP system
and the masonry. Use inspection methods capable of detecting delaminations of 1300 square mm 2 square inches
or greater. Submit all delaminations or other anomalies to the Engineer of Record for evaluation.
3.8.4.1 Wet lay-up and Prepreg Systems
NOTE: The cause of delamination shall be determined and corrected prior to
application of the patch.
a. Small delaminations or air voids less than 1300 square mm 2 square inches each are permissible, so
long as the delaminated area is less than 5 percent of the total laminate area and there are no more
than 10 such delaminations or air voids per 0.93 square m 10 square ft.
b. Repair large delaminations or air voids, greater than 16,000 square mm 25 square inches by selectively
cutting away the affected sheet and applying a sheet patch of equivalent plies overlapping the undisturbed
FRP sheet by a minimum of 100 mm 4 inches on all sides. Use anchors in reticent corners where overlapping
is not possible. The number and locations of the anchors require approval by the engineer of record.
c. Delaminations or air voids less than 16,000 square mm 25 square inches may be repaired by resin injection
or ply replacement, depending upon the size and number of delaminations and their locations. Consult
the Contracting Officer on which repair method will be used.
3.8.4.2 Pre-cured Systems
For pre-cured FRP systems, evaluate each delamination or air void and repair in accordance with the Contracting
Officer's direction.
3.8.5 Fiber Orientation
Evaluate fiber or pre-cured laminate orientation by visual inspection. Evaluate for fiber waviness, a localized
appearance of fibers that deviate from the general straight-fiber line in the form of kinks or waves. Report
fiber or pre-cured laminate misalignment of more than 5 degrees from that specified on the design drawings (approximately
80 mm/m 1 in/ft) to the Contracting Officer for evaluation and acceptance.
3.8.6 Record Retention
Retain the records of inspection and witness panels throughout the warranty period. Retain samples of mixed
resin and maintain a record of the placement of each batch. Upon completion of repairs, re-inspect the laminate
to verify that the repair was properly accomplished. Evaluate the FRP systems and accept/reject based on conformance
or nonconformance with the design drawings and specifications. Include FRP system material properties, as-built
fiber orientation, presence of delaminations, cure of resins, and adhesion to substrate in the evaluation.
3.9 REPAIRS
3.9.1 Application Defects
Repair all defects spanning more than 5% of the surface area according to the FRP maintenance and repair procedure.
There are two types of repairs: resin injection or removal and reapplication of the FRP system.
3.9.2 Tears in the Reinforcing Fibers
Repair tears in the reinforcing fibers that cross fiber tows greater than 50 mm 2 inches in length by adding
additional plies of FRP material.
3.9.3 Remedial Measures for Defects
In locations where the FRP adhesion does not meet the minimum adhesion requirements, remove the laminate from
the wall surface and apply new laminate. Review and get approval of the revised anchor details by the Contracting
Officer prior to installation. Should the Contracting Officer determine that anchors are inappropriate, remove
the FRP composite and replace with new composite meeting the minimum adhesion requirements.
3.10 WORK AREA CLEAN UP
Upon completion of the work, remove staging, scaffolding, and containers from the work site or destroy in an
approved manner. Remove FRP composite, resin, and other deposits on adjacent surfaces and leave the entire job
cleaned to equal or better condition to that prior to the start of the job. Place cloths, cotton waste and other
debris that might constitute a fire hazard in closed metal containers and remove at the end of each day. Dispose
of all resins and adhesives properly as indicated on the MSDS sheets. Store and transport all resins and adhesives
as indicated in MSDS directions. Contain and dispose of spent abrasive blast media properly as required by local
authorities. Contain all material to be discarded at the site until properly disposed.