USACE / NAVFAC / AFCESA / NASA UFGS-04 01 20 (October 2007)
----------------------------
Preparing Activity: USACE Superseding
UFGS-04 01 20 (April 2006)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2009
SECTION 04 01 20
REHABILITATION OF REINFORCED AND UNREINFORCED MASONRY WALLS USING FRP COMPOSITE STRUCTURAL REPOINTING
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 that
contains 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 structural repointing using 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 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 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 3171(2006) Standard Test Method for Constituent Content of Composite MaterialsASTM D 3916(2008) Tensile Properties of Pultruded Glass-Fiber-Reinforced Plastic RodASTM D 4501(2001e1) Adhesive Bonds Between Rigid Substrates by the Block-Shear MethodASTM D 638(2008) Standard Test Method for Tensile Properties of PlasticsASTM D 882(2002) Tensile Properties of Thin Plastic Sheeting][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][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.
For non-Design-Build type contracts, Shop Drawings and Design Data should be
provided by the Government.
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 the installation and curing of all application materials to include
personnel safety issues, installer certification, application and inspection of the FRP system,
structural paste/adhesive curing provisions, means to assure clean, dry masonry 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
FRP Composite System[; G][; G, [_____]]
Complete shop drawings for each installation of the composite system. The shop drawings shall
contain details of the fiber reinforcement type, dimensions, and end details, proposed connections
to the 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
Delivery Inspections
Values as determined by tensile testing in accordance with ASTM D 3916, for FRP rods or ASTM D 3039/D 3039M
, for flat or rectangular shaped FRP reinforcement. Design elastic modulus shall be determined
by the strength and rupture strain values. Ultimate tensile strength and rupture strain values
shall be 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, [____]
FRP bar 300 mm 12 inches long. Plate of cured structural paste/adhesive 75 x 75 mm 3 x 3
inches.
SD-05 Design Data
Design Calculations; G, [_____)
Design calculations for the FRP composite system 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 be based on tension force and strain limits.
SD-06 Test Reports
Field Testing
Laboratory Testing
Reults of Shore hardness tests at 3 and at 24 hours in ten degree intervals between 4 and
38 degrees C 40 and 100 degrees F for structural pastes/adhesives used. System environmental
durability test results conducted and reported by an independent testing facility; the report
shall show 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. 2000 hour UV exposure test results
h. Fire resistance test results
i. Seven day exposure at 100% humidity test results
j. 3000 hour test results for ozone exposure, for alkali exposure, for salt water immersion,
and for 60 degrees C 140 degrees F exposure
Wall Tests; G, [____]
Test results by an independent testing facility on walls which are representative of the actual
configuration and loading conditions for this contract. Currently, no standard tests exist;
therefore, the submitted testing shall be approved by the Contracting Officer. The report shall
show 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. Test wall substrate material
g. Test wall aspect ratio
h. FRP orientation and frequency/location
i. FRP composite shape and cross-sectional area
j. 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.
SD-07 Certificates
Materials; G, [____]
Certification from the system manufacturer of the guaranteed material and section properties
for the supplied material.
Regulatory Requirements; G, [____]]
Certification that structural pastes/adhesives 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 five (5) successfully completed FRP composite strengthening projects completed
with the manufacturer's composite system. The list shall include at a minimum:
a. The dates of work
b. Type, description and amount of work performed
c. A point of contact for an owner representative to include:
(1) Name
(2) Address
(3) Company/Agency name
(4) Telephone number
Contractor; G, [____]
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 list shall include at a minimum:
a. The dates of work
b. Type, description and amount of work performed
c. A point of contact for an owner representative to include:
(1) Name
(2) Address
(3) Company/Agency name
(4) Telephone number
Field Representative; 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 five (5) FRP composite strengthening
projects, three (3) using the manufacturer's composite system. The field representative shall
be present on site during installation of the FRP system. The list shall include at a minimum:
a. The dates of work
b. Type, description and amount of work performed
c. A point of contact for an owner representative to include:
(1) Name
(2) Address
(3) Company/Agency name
(4) Telephone number
Applicators[; G][; G, [_____]]
Certificates of training by the FRP system manufacturer for all FRP applicators as well as
listing of past application projects completed by the applicators. A course syllabus for the
certification course completed by the FRP composite applicators.
SD-08 Manufacturer's Instructions
FRP Composite System[; G][; 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 Maintenance; 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 FRP COMPOSITE SYSTEM
1.3.1 Design Requirements
The design of the FRP composite system shall conform to ACI 440.2R and shall provide [seismic] [wind] [and] [blast]
strengthening for clay brick and concrete masonry walls; the Contractor shall provide design calculations as
specified in the Submittals paragraph. Walls with the FRP system shall fail by cracking through the masonry
units and mortar prior to any debonding or rupture of the FRP composite system.
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 brick] [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 five (5)
completed 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 five (5) 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 application
preparation 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 hazard and protective controls associated with materials used
on the project. Workers shall be trained in the safe handling and application, and the exposure limit, for each
material that the worker will use or otherwise be exposed to during the course of the project. Personnel having
a need to use respirators and masks shall be instructed in the use and maintenance of such equipment.
1.6 REGULATORY REQUIREMENTS
The bonding materials used shall 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,
additional ventilation shall be provided for the duration of the excess outgassing. At no time will they exceed
STEL, even if additional ventilation or air supply is provided. The Contractor is responsible for providing
the necessary equipment to comply with these requirements. Once cured, the FRP composite system shall 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. 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. The Contractor shall 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, STORAGE, AND HANDLING
1.8.1 FRP Reinforcing Bars and Shapes
FRP reinforcing bars are susceptible to surface damage. Puncturing their surface can significantly reduce the
strength capacity of the FRP reinforcements. In the case of glass FRP rods, the surface damage can cause a loss
of durability due to infiltration of alkalis. The following handling guidelines are recommended to minimize
damage to both the FRP bars and workers handling them:
a. FRP reinforcing bars should be handled with work gloves to avoid personal injuries from either exposed
fibers or sharp edges;
b. Do not store the FRP bars on the ground. Pallets should be placed under the bars to keep them clean
and to provide easy handling;
c. High temperatures, ultraviolet rays, and chemical substances should be avoided because they can damage
FRP bars;
d. Occasionally, bars become contaminated with form releasing agents or other substances. Substances
that decrease bond should be removed by wiping the bars with solvents before placing them in the masonry;
e. It may be necessary to use a spreader bar so that the FRP bars can be hoisted without excessive bending.
1.8.2 Structural Pastes/Adhesives
1.8.2.1 Labeling
Structural pastes/adhesives shall be delivered 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. Adhesive materials that have exceeded
the shelf life shall not be used.
1.8.2.2 Storage
All structural paste/adhesive materials shall be stored in a covered, well-ventilated area and protected from
exposure to any detrimental conditions including: airborne contaminants, dirt, dust, sunlight, temperatures
lower than 4 degrees C 40 degrees F or greater than 38 degrees C 100 degrees F, rainfall, sparks or flame and
in accordance with the manufacturer's requirements.
1.9 PROJECT/SITE CONDITIONS
1.9.1 Environmental Requirements
1.9.1.1 Application Temperature
a. Structural pastes/adhesives shall not be applied 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 rises 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, structural pastes/adhesives shall not be applied to damp
or wet surfaces.
1.9.2 Existing Conditions
As-built drawings of the structure [are attached] [can be accessed at [_____]].
1.9.3 Work Coordination
Work shall be coordinated 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
Manufacturer's standard warranty for FRP composite system installation shall be furnished. The warranty shall
include the FRP composite system [design,] installation, bond to the substrate, and interlaminar bond, as well
as mechanical property retention, and bar-adhesive 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: Structural repointing, using precured FRP systems, consists of embedding
composite rods and shapes, manufactured in the system supplier's facility and
shipped to the job site, and a structural adhesive required to bond the precured
rods and shapes into grooves cut in the masonry surface.
All materials (reinforcements and structural Pastes/adhesives) for a specific
job shall be supplied by one system manufacturer only.
Substitution of FRP rods or shapes or substitution of structural pastes/adhesives
from those which comprise the manufacturer's FRP system are not allowed. The
arbitrary selection of a fiber reinforcement and an adhesive material can lead
to failure of the FRP composites system due to possible matrix-reinforcement
incompatibilities.
2.1 MATERIALS
NOTE: The values listed in the following tables should be those values and
assumptions that were used in developing the rehab/strengthening design. Those
items in Table 1 below will be the minimum acceptable property values for the
FRP bars and shapes to be installed. Those items in Table 2 will be the minimum
acceptable properties for the structural paste/adhesive.
For test methods with two methods listed, the first refers to round shapes like
FRP bars and the second pertains to rectangular cross sectional shapes.
Submittals must demonstrate that the proposed materials will match the intent
of the engineering design using the properties listed below.
Submittals for material systems must include, at a minimum, documented evidence
that the manufacturer of the proposed system meets the requirements of the Tables
below, and demonstrate the structural equivalency of the proposed system to
the system(s) properties specified.
The FRP [rods] [shapes] shall conform to the material properties listed in Table 1. The structural paste/adhesive
shall conform to the material properties listed in Table 2. No substitution of the submitted reinforced FRP
composite system or its components will be allowed for the project. The Contractor shall provide values for
the Tensile Properties of the composite material as specified in the Submittals paragraph.
TABLE 1: Properties of Pre-formed FRP Rods and Shapes
FRP
COMPOSITE TEST
PROPERTY REQUIREMENT METHOD
Elongation:
max. [_____]% ASTM D 3916/ASTM D 3039/D 3039M
Visual Defects Acceptance ASTM D 2563
Level [_____]
Guaranteed Tensile
Strength, min., [_____] kPa (psi) ASTM D 3916/ASTM D 3039/D 3039M
Tensile Modulus of
Elasticity, min. [_____] kPa (psi) ASTM D 3916/ASTM D 3039/D 3039M
Cross-sectional Area [_____] mm2 (in2) ASTM D 3916/ASTM D 3039/D 3039M
Fiber Volume Fraction [______]% ASTM D 3171
TABLE 2 Structural pastes/adhesives/Polymer Adhesives
FRP
COMPOSITE TEST
PROPERTY REQUIREMENT METHOD
Elongation: [_____]% ASTM D 882
Ultimate Tensile
Strength, min., [_____] kPa (psi) ASTM D 638
Modulus of Elasticity,
min. [_____] kPa (psi) ASTM D 638
Bond Strength [_____] kPa (psi) ASTM D 4501
2.2 COMPONENTS
The FRP system shall consist of [glass] [carbon] [aramid] [rods] [rectangles] [grids] with a resin matrix of
[vinyl ester] [polyester] [epoxy] [urethane] [specialty resin] binder and an [epoxy] [urethane] [_____] structural
adhesive. The structural paste/adhesive used as an embedding material shall be formulated to bond masonry and
FRP materials and, once cured, protect the FRP shapes from the environment. The structural paste/adhesive shall
be suitable for use in both non-load bearing and load bearing applications.
2.3 ACCESSORIES
The Contractor shall provide all other materials as needed for the proper installation of the complete composite
system as specified.
2.4 MIXES
Mixing of structural paste/adhesive materials shall be done in accordance with the FRP system manufacturer's
recommended procedure. All adhesive components shall be at a proper temperature and shall be mixed in the correct
ratio until there is a complete mixing of components and a uniform color. The amount of each batch of adhesive
materials mixed shall be in quantities sufficiently small to ensure that all mixed structural paste/adhesive
can be used within its pot life. Mixed structural paste/adhesive that exceeds its pot life as defined by the
system manufacturer shall not be used.
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 and 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. Any supplemental heating
or cooling sources shall be approved by the FRP manufacturer and the Contracting Officer before use.
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 construction pastes/adhesives have
cured. The Contractor shall provide and install tents and/or plastic screens as required to protect the paste/adhesive
as it cures. The structural paste/adhesive shall be cured before removal of temporary protection or allowing
the structure to be exposed to new loads. In the event of suspected damage to the FRP system during installation,
the Contracting Officer shall be notified. Should the damage be caused by the Contractor's negligence, the resulting
repairs shall be done at no additional cost to the Government.
3.2 PREPARATION
3.2.1 Delivery Inspections
Prior to starting the project, the Contractor and Independent Special Inspector shall assure that delivered FRP
materials meet the specified requirements. This will require laboratory testing. The tensile strength, and
modulus of elasticity for each batch of FRP bars used shall be determined. Materials that do not meet the minimum
requirements, as specified in Tables 1 and 2 and by the Contracting Officer, shall be rejected. In addition,
the gel time, pot life, and cured hardness of the structural paste/adhesive shall be determined.
3.2.2 Substrate repair
3.2.2.1 Surface
[The mortar joints to receive FRP composite are 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.] [Remove areas of loose or spalling mortar material.]
3.2.2.2 Sub-Surface
FRP systems shall not be applied to masonry substrates containing corroded reinforcing steel. Evidence of localized
cracking and/or spalling at grouted cells or rust stains shall be noted and reported to the Contracting Officer.
Work shall not proceed until the cause(s) of the corrosion is addressed and the corrosion-related deterioration
repaired.
3.2.3 Work Preparation
3.2.3.1 Substrate Inspection
The applicator shall insure that all other scheduled masonry repairs are complete and cured. The mortar surfaces
to which the FRP system is to be applied shall be free of loose or unsound materials and other conditions that
would inhibit bond such as oil, efflorescence or moisture.
3.2.3.2 Worksite Ventilation
Depending on the type of structural paste/adhesive used, work areas shall be ventilated during structural paste/adhesive
application so that worker exposure to chemical substances shall not exceed limits as established by ACGIH Publication 0028
, or as required by a more stringent applicable local regulation. Interior work zones having a volume of 280
cubic meters 10,000 cubic feet or less shall be ventilated at a minimum of 2 air exchanges per hour. Ventilation
in larger work zones shall be maintained by means of mechanical exhaust. Solvent vapors shall be exhausted outdoors,
away from air intakes and workers. Return air inlets in the work zone shall be temporarily sealed before start
of work until the structural paste/adhesive has cured.
3.2.3.3 Obstructions
Obstructions and embedded objects can affect the performance of the FRP system and shall be modified as necessary.
If possible, obstructions may need to be removed prior to installing the FRP system.
3.3 FRP INSTALLATION
3.3.1 Temperature and Moisture
3.3.1.1 Substrate
The FRP composite shall not be installed if the ambient air temperature or substrate surface temperature exceeds
that recommended by the system manufacturer. The FRP composite shall not be installed when surface moisture
is present on the substrate or when rainfall or condensation is anticipated in the work areas.
3.3.1.2 Structural Paste/Adhesive
The temperature of the polymeric structural paste/adhesive components at the time of mixing shall be as specified
by the manufacturer. When the air or substrate temperature is outside the prescribed range, work shall not proceed
unless other measures approved by the Contracting Officer are employed.
3.3.2 Embedment Slot Cutting
Lay out embedment slot locations on the wall surface at the specified locations. Prepare containment to catch
dust and masonry chips generated during the embedment slot cutting/grinding.
3.3.2.1 Slot Cutting
Using a grinder or saw with a suitable blade, cut slots in the masonry to the width and depth specified in the
shop drawings. Special care shall be taken to avoid local fracture of the masonry.
3.3.2.2 Slot Finishing
The masonry slot surfaces to receive FRP composite shall be free from fins, and protrusions that may prevent
the FRP [bars] [shapes] from being embedded to the specified depth in the wall. The contact surfaces shall be
dried as recommended by the FRP system manufacturer. Moisture content shall be evaluated in accordance with
the requirements of Section 2.3.2.5 of ACI 503.1-503.4. The contact surfaces shall have no loose particles,
paint, oil, dirt, dust, efflorescence, mildew or free moisture on them at the time of application. Solvent or
chemical cleaning methods shall not be used to clean surfaces. All contact surfaces shall be cleaned by hand
using wire brushes or by using compressed air. [Using masking tape or other suitable adhesive tape, fix a strip
at each edge of the slots].
3.3.3 FRP Reinforcing Bar Preparation
3.3.3.1 Handling
The construction activities shall be conducted in such a way that potential damage to the FRP bars and shapes
is minimized.
3.3.3.2 Cutting
Cutting of the FRP bars shall be performed with a high-speed grinding cutter or a fine blade saw. FRP bars should
never be sheared. The use of a dust mask is recommended when cutting.
3.3.4 FRP Installation
3.3.4.1 Application of Structural Paste/Adhesive
The structural paste/adhesive shall be mixed according to the specifications prescribed by the manufacturer.
A layer of structural paste/adhesive shall be placed uniformly in the slots cut in the masonry substrate.
3.3.4.2 FRP Reinforcing Bar Application
Press the FRP reinforcing bar into the slot so that the surface of the [bar] [shape] is below the surface of
the wall. Completely fill the slot with the structural paste/adhesive to encapsulate the bar and strike the
surface even with the surface of the masonry.
3.3.5 Curing
Structural paste/adhesive curing temperatures shall be maintained within the required temperature range designated
by the manufacturer for the formulation used for the manufacturer specified time. The composite system shall
be protected from contact by moisture for a minimum period of 24 hours.
3.3.6 Finish
Once cure is complete, remove any masking tape applied around the edges of the slots taking care not to damage
the structural paste/adhesive. [The structural paste/adhesive shall be [stained] [painted] according to the
shop drawings in accordance with the manufacturer's instructions.]
3.3.7 Construction Joints
3.3.7.1 Control Joints
All control joints shall be maintained. The FRP composite shall not bridge existing control joints.
3.3.7.2 Expansion Joints
All expansion joints shall be maintained. The FRP composite shall not bridge existing expansion joints.
3.3.8 Installation Procedure Modifications
Modifications of the manufacturers installation procedures and to the design and shop drawings shall not be made
without the written approval of the Contracting Officer and Engineer of Record. The Contracting Officer and
Engineer of Record shall approve procedural modifications prior to implementation.
3.4 QUALITY CONTROL
3.4.1 General Requirements
Quality assurance and quality control (QA/QC) programs and criteria provided in the pre-construction submittals
shall be maintained by the FRP installation Contractor, and others associated with the project. The Contractor
shall provide full inspection of the surface preparation and composite systems applications to ensure the requirements
of this specification are fully complied with.
3.4.2 Independent Special Inspector
A special inspector, trained and certified by the FRP system manufacturer, shall be provided by the Contractor
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 FIELD TESTING
3.5.1 Mixed Structural paste/adhesive Hardness
During installation, two samples of mixed structural paste/adhesive shall be prepared per shift from two, separate,
[nonconsecutive batches] [separate tube sets] of structural paste/adhesive. The structural paste/adhesive samples
shall be a minimum of 3 mm 1/8-inch thick and 50 mm 2-inches in diameter. The mixed structural paste/adhesive
samples shall be retained for testing to evaluate curing progress.
3.5.1.1 Curing Evaluation
Relative curing progress of the resin shall be evaluated on the job site by measuring the hardness of the resin
sample at 3 hours and 24 hours of cure in accordance with provisions of ASTM D 2240. The shore hardness measurements
shall exceed the minimum hardness values submitted by the materials manufacturer based on the lowest air temperature
during the curing period evaluated. Measurements shall be at a minimum of three different points distributed
over the surface of the structural paste/adhesive at least 6 mm 0.25 inch apart from each other.
3.5.1.2 Report
The special inspector shall report the mean hardness value obtained, structural paste/adhesive identification,
manufacturer, and batch number, structural paste/adhesive mixing date and time, test date and time minimum air
temperature during the curing evaluation time, and the type and serial number of the durometer used.
3.5.1.3 Remedial Measures
In the event that curing does not meet the above criteria, remedial measures shall be taken as specified.
3.5.2 In-Place Structural paste/adhesive Hardness
During installation, a minimum of one test shall be performed on each 152 m 500 linear feet or portion thereof
of FRP bar installed at 3 hours after installation and at 24 hours after installation.
3.5.2.1 Curing Evaluation
Relative curing progress of the in-place FRP resin shall be evaluated using the Shore hardness test described
in ASTM D 2240. The shore hardness measurements shall exceed the minimum hardness values submitted by the materials
manufacturer based on the minimum substrate temperature observed during the evaluation period.
3.5.2.2 Report
The special inspector shall 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 and substrate temperature
when the FRP was applied, air and substrate temperature when testing was performed, and the type and serial number
of durometer used.
3.5.2.3 Remedial Measures
In the event that curing does not meet the above criteria, remedial measures shall be taken specificied.
3.6 LABORATORY TESTING
3.6.1 Witness Panels
NOTE: There are two FRP configurations the witness panels need to emulate:
1) masonry walls where grooves are cut in the outer surface or shell of the
unit with the FRP bars laid in the grooves, and 2) structural repointing where
grooves are cut only in the mortar joints.
The witness panels consist of two blocks of masonry/mortar joined by the FRP
bars to roughly approximate a dog bone. For thin masonry units, those less
than 150 mm (six inches) high, i.e. clay masonry, a short prism is required
at each end. For larger masonry units such as standard concrete masonry units,
only a single masonry unit is required at each end. For structural repointing
witness panels, 150 mm (six-inch) high blocks of mortar similar to that in the
wall are required.
During installation, witness panels shall be fabricated onsite using installation procedures identical to the
method used to install the FRP system into the masonry surfaces. The panels shall be marked with the date of
fabrication, and location of application. Two witness panels shall be fabricated for each day of production
or one for each 152 m 500 linear feet of production, whichever is more. The witness panels shall be submitted
to an approved laboratory within two weeks of fabrication. The Contracting Officer may waive or alter the frequency
of testing.
3.6.1.1 Witness Panel Construction
[The witness panel shall consist of two brick prisms, two bricks high, with full mortar bed joints.] [The witness
panel shall consist of two standard CMU units, two units high with a face shell mortar bed joints.] A groove
shall be cut in opposite surfaces of the prisms centered on each other and FRP bars installed in the same manner
as those in the wall allowing sufficient separation between prisms to insert a hydraulic actuator and steel plates
to spread the applied loads.
3.6.1.2 Witness Panel Testing
Not fewer than one witness panel from each day's production shall be tested in the laboratory. If one panel
fails to meet the minimum strength specified in Table 1, all the witness panels for the day's production shall
be tested. If a second one fails, all panels for the project shall be tested until the job is completed. Appropriate
remedial measures shall be taken to ensure integrity of the FRP system. The witness panel test is designed to
directly measure the shear capacity of the bond between the embedded FRP bars and the masonry units. The test
involves pushing apart the two prisms to which the FRP bar is applied.
a. Insert the steel plates between the masonry prisms to provide a means to distribute the load from
the hydraulic actuator. A hydraulic actuator is placed between the steel plates, and a load applied
at a constant rate until failure. Measure the load applied to the prisms using a pressure transducer
or analog pressure gauge.
b. For failures within the cut slot, calculate the bond strength by dividing the maximum load at failure
by the slot surface area.
c. For tensile failures of the FRP bars, the bond strength shall be noted as the tensile strength of
the bar, the maximum load divided by the bar cross-sectional area.
3.6.1.3 Report
Report the bond strength and the mode of failure. An acceptable failure mode is characterized by either the
removal of a layer of masonry bonded to structural paste/adhesive or the tensile rupture of the FRP bar. If
the FRP bar fails by shear at the prism edge, the test shall be repeated and the data discarded. If failure
is due to loss of bond between the FRP bar and the structural paste/adhesive or within the structural paste/adhesive,
remedial measures shall be taken, as specified.
3.6.2 Laboratory Qualification
NOTE: If rectangular FRP shapes are specified to be used, the laboratory should
have experience using test method ASTM D 3039/D 3039M. If FRP bars are specified,
ASTM D 3916 should be cited.
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] [ASTM D 3916
] wall tests for at least three (3) different Contractors prior to this contract.
3.7 REMEDIAL MEASURES
For all strengthened sections where testing indicates that the installed composite system has material properties
below the minimum specified values, the installed FRP composite shall be removed and replaced with FRP composite
meeting or exceeding the minimum specified values. None of the cost to remove unacceptable FRP composite, repair
damaged masonry as a result of the FRP removal, and install replacement FRP composite shall not be accrued to
the government but shall be the responsibility of the Contractor.
3.8 FIELD QUALITY ASSURANCE
3.8.1 Inspection
FRP systems and all associated work shall be inspected as required by the applicable codes and described in this
specification. The FRP composite installation shall be completely inspected by the special inspector during
and immediately following installation of the FRP composite system. The FRP systems shall be evaluated and accepted
or rejected based on conformance or nonconformance with the design drawings and specifications. The special
inspector shall require compliance with the design drawings and specifications. The independent special inspector
shall observe all aspects of onsite preparation and material application including the following:
a. Material container labels
b. Surface Preparation (cutting and/or grinding slots in the wall surface)
c. Mixing of polymer structural paste/adhesive
d. Application of structural paste/adhesive to the slots
e. Placement of bars in the slots
f. Curing of structural paste/adhesive
g. Adhesion to substrate
h. Application of coatings
3.8.2 Daily Inspection Records
Daily inspection records shall include:
a. Date and installation start and finish times;
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. FRP [bar] [shape] batch number(s), linear footage, and locations installed in structure;
i. Batch numbers, mix ratios, mixing times, total volumes, and mixed color of all polymer resins, including
primers, putties, pastes, adhesives, and coatings mixed for the day;
j. Observations on progress of structural paste/adhesive cure to include measured Shore hardness values;
k. Conformance with installation procedures;
l. General progress of work.
3.8.3 Record Maintenance
The independent special inspector shall retain the records of inspection and witness panels throughout the warranty
period. The Contractor shall retain samples of mixed structural paste/adhesive and maintain a record of the
placement of each batch. Inspection and progress reports shall be submitted daily to the Contracting Officer.
3.9 REPAIRS
All defects shall be repaired according to the FRP maintenance and repair procedure provided by the system manufacturer.
3.10 WORK AREA CLEAN UP
Upon completion of the work, staging, scaffolding, and containers shall be removed from the site or destroyed
in an approved manner. FRP composite, structural paste/adhesive, and other deposits on adjacent surfaces shall
be removed and the entire job left cleaned to equal or better condition to that prior to the start of the job.
Cloths, cotton waste and other debris that might constitute a fire hazard shall be placed in closed metal containers
and removed at the end of each day. All adhesives shall be stored, transported, and disposed of properly as
indicated on the MSDS sheets. Masonry dust and chips shall be contained and disposed of properly as required
by local authorities. All material to be disposed of shall be contained at the site until properly disposed
of.