SECTION 03732

CONCRETE REPAIR

PART 1 GENERAL

SECTION INCLUDES

Preparation of concrete and application of repair materials.

[Rehabilitation] [Restoration] of concrete surfaces.

Repair of concrete internal reinforcement.

RELATED SECTIONS

Section 03300 - Cast-In-Place Concrete.

Section 04500 - Masonry Restoration and Cleaning.

Section [_____ - __________:] Applied finish to [repaired] concrete surface.

REFERENCES

ANSI/ASTM C404 - Aggregates for Masonry Grouts.

ANSI/ASTM C882 - Bond Strength of Epoxy-Resin Systems Used with Concrete.

ANSI/AWS D1.4 - Structural Welding Code for Reinforcing Steel.

ASTM A82 - Cold-Drawn Steel Wire for Concrete Reinforcement.

ASTM A615 - Deformed and Plain Billet-Steel Bars for Concrete Reinforcement.

ASTM A616 - Rail-Steel Deformed and Plain Bars for Concrete Reinforcement.

ASTM A617 - Axle-Steel Deformed and Plain Bars for Concrete Reinforcement.

ASTM C33 - Concrete Aggregates.

ASTM C150 - Portland Cement.

ASTM D638 - Tensile Properties of Plastics.

ASTM D695 - Compressive Properties of Rigid Plastics.

ASTM D790 - Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials.

SUBMITTALS

Submit product data under provisions of Section [01300.] [01340.]

Submit product data indicating product standards, physical and chemical characteristics, technical specifications, limitations, maintenance instructions, and general recommendations regarding each material.

Submit manufacturer's installation instructions under provisions of Section [01300.] [01340.]

Submit manufacturer's certificate under provisions of Section [01400] [01405] that specified [products] [__________] meet or exceed [specified requirements.] [____________________.]

PROJECT RECORD DOCUMENTS

Submit documents under provisions of Section [01700.] [01720.]

Accurately record actual locations of structural reinforcement

repairs, type of repair[,] [.] [and] [_______________.]

QUALITY ASSURANCE

Materials Manufacturer: Company specializing in manufacturing the products specified in this Section with minimum [three] [_____] years [documented] experience.

Applicator: Company specializing in concrete repair [with minimum [_____] years [documented] experience.] [approved by materials manufacturer.]

[Design reinforcement splices under direct supervision of a Professional Structural Engineer experienced in design of this work and licensed [at the place where the Project is located.] [in the State of [_______________.]]]

Welding: ANSI/AWS D1.4.

MOCKUP

Provide mockup of typical patch and repair under provisions of Section [01400.] [01405.]

Provide [analysis] [and] [testing] of mockup under provisions of Section [01400.] [01410.]

Provide panel, [_____] feet ([_____] m) long by [_____] feet ([_____] m) wide, illustrating patching method, color, and texture of repair surface [and] [__________.]

Prepare [one] [_____] sample under provisions of Section [01300] [01340] of each type of injection and patching procedure.

Locate [where directed.] [_____________________________.]

When accepted, mockup will demonstrate minimum standard for the Work. Mockup may [not] remain as part of the Work.

DELIVERY, STORAGE, AND HANDLING

Deliver products to site under provisions of Section [01600.] [01610.]

Store and protect products under provisions of Section [01600.] [01620.]

Comply with instructions for storage, shelf life limitations, and handling.

PART 2 PRODUCTS

APPLICATORS

[___________________________________________.]

[___________________________________________.]

[___________________________________________.]

Substitutions: Under provisions of Section [01600.] [01630.]

MANUFACTURERS

[____________________________] Product [_______________.]

[____________________________] Product [_______________.]

[____________________________] Product [_______________.]

Substitutions: Under provisions of Section [01600.] [01630.]

PATCHING MATERIALS

Epoxy Resin: Two-part epoxy adhesive containing [100] [_____] percent solids, meeting the following minimum characteristics:

Characteristic	Test_Method	Results

Bond Strength	ANSI/ASTM C882	[2,700] [____] psi

([18.6] [____] MPa)

Tensile Strength	ASTM D638	[6,600] [____] psi

([45] [____] MPa)

Elongation	ASTM D638	[2] [____] percent

at 7 days at 70 degrees F (21 degrees C)

Flexural Strength	ASTM D790	[8,000] [____] psi

([55] [____] MPa)

Compressive Strength	ASTM D695	[6,500] [_____] psi

([45] [____] MPa)

Bonding Agent: [Polyvinyl acetate] [__________] emulsion, dispersed in water while mixing, non-coagulant in mix, water resistant when cured.

Portland Cement: ASTM C150, Type [_____;] [gray] [white] color[.] [as selected.]

Sand: [ASTM C33;] [ANSI/ASTM C404;] uniformly graded, clean.

Water: Clean and potable.

Cleaning Agent: Commercial muriatic acid[.] [of [_____] percent strength.]

REINFORCEMENT MATERIALS

Reinforcing Steel: ASTM A615, [40] [60] [75] ksi ([276] [414] [517] MPa) yield grade billet-steel [plain] [deformed] bars, [uncoated] [galvanized] finish.

****** [OR] ******

Reinforcing Steel: ASTM A617, [40] [60] ksi ([276] [414] MPa) yield grade axle-steel [plain] [deformed] bars, [uncoated] [galvanized] finish.

****** [OR] ******

Reinforcing Steel: ASTM A616, [50] [60] ksi ([345] [414] MPa) yield grade rail-steel [plain] [deformed] bars, [uncoated] [galvanized] finish.

Stirrup Steel: [ASTM A82.] [_______________.]

Splicing Sleeves: [_____] type; [_______________] manufactured by [____________________.]

MIXING EPOXY MORTARS

Mix epoxy mortars in accordance with manufacturer's instructions for purpose intended.

Mix components in clean equipment or containers.	Conform to pot life and workability limits.

MIXING CEMENTITIOUS MATERIALS

Mix cementitious [mortar] [grout] in accordance with manufacturer's instructions for purpose intended.

[Include] [Exclude] bonding agent as additive to mix.

PART 3 EXECUTION

EXAMINATION

Verify that surfaces are ready to receive work.

Beginning of installation means installer accepts existing [surfaces.] [substrate.]

PREPARATION

Clean concrete surfaces of dirt, laitance, corrosion, or other contamination; wire brush using [water.] [acid.] Rinse surface and allow to dry.

Flush out cracks and voids with [chemical solvent] [muriatic acid] [water] to remove laitance and dirt. [Chemically neutralize by rinsing with water.]

Provide temporary entry ports spaced to accomplish movement of fluids between ports, no deeper than the depth of the crack to be filled. Limit port size diameter to be no greater than the thickness of the crack. Provide temporary seal at concrete surface to prevent leakage of adhesive.

For areas patched with epoxy mortar, remove broken and soft concrete [1/4] [_____] inch ([6] [_____] mm) deep. Remove corrosion from steel. Clean surfaces mechanically; wash with [acid] [__________] and rinse with water.

[Sandblast] [_________] clean the exposed reinforcement steel surfaces. Mechanically cut away damaged portions of bar.

REPAIR WORK

Repair exposed structural, shrinkage, and settlement cracks of concrete [as indicated on Drawings] by the [epoxy injection] [bonding agent and cementitious paste] method.

[Repair spalling.] [Fill voids flush with surface.] [Apply surface finish.]

Repair reinforcement by welding [new bar reinforcement to existing reinforcement] [____________________] with [sleeve splices.] [_______________.] Strength of welded [splices] [and] [reinforcement] to exceed original stress values.

INJECTION - EPOXY RESIN ADHESIVE

Inject adhesive into prepared ports under pressure using equipment appropriate for particular application.

Begin injection at lower entry port and continue until adhesive appears in adjacent entry port. Continue from port to port until entire crack is filled.

Remove temporary seal and excessive adhesive.

Clean surfaces adjacent to repair and blend finish.

APPLICATION - EPOXY MORTAR

Trowel apply mortar mix to an average thickness of [_____] inches ([_____] mm). Tamp into place filling voids at spalled areas.

For patching honeycomb, trowel mortar onto surface, working into honeycomb to bring surface flush with surrounding area. Finish trowel surface to match surrounding area.

Cover exposed steel reinforcement with epoxy mortar; feather edges to flush surface.

APPLICATION - CEMENTITIOUS [MORTAR] [GROUT]

Apply [spray] [brush] [roller] coating of bonding agent to [dry] [damp] concrete surfaces. Provide full surface coverage.

Apply cementitious [mortar] [grout] by steel trowel to an average thickness of [_____] inches ([_____] mm). Tamp into place filling voids at spalled areas. Work mix into honeycomb.

Damp cure cementitious [mortar] [grout] for [four] [_____] days.

FIELD QUALITY CONTROL

Field [inspection and] testing will be performed under provisions of Section [01400.] [01410.]

Test concrete for [calcium chloride] [__________] content during the execution of the Work.

SCHEDULE

North End of Existing Retaining Wall: Epoxy mortar with

smooth trowel finish.

Cracked East Basement Wall: Epoxy resin injection, roughened surface finish to match adjacent work.

END OF SECTION