USACE / NAVFAC / AFCESA / NASA UFGS-09 67 23.13 (April 2008)
----------------------------------
Preparing Activity: NASA Superseding
UFGS-09 67 00.00 40 (January 2008)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2009
SECTION 09 67 23.13
STANDARD RESINOUS FLOORING
04/08
NOTE: This specification covers the requirements for thin-set, troweled, heavy-duty,
epoxy floor toppings.
Thin-set, heavy-duty, troweled floor topping is a mixture of a two-component
epoxy-resin binder and a blend of several sizes of pregraded walnut-shell aggregate.
Drawings must show areas of application.
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.
Submit recommended changes to a UFGS as a Criteria Change Request (CCR).
PART 1 GENERAL
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 are automatically 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.
[ASTM INTERNATIONAL (ASTM)ASTM A 990(2008) Standard Specification for Castings, Iron-Nickel-Chromium and Nickel Alloys, Specially Controlled for Pressure Retaining Parts for Corrosive ServiceASTM C 881/C 881M(2002) Standard Specification for Epoxy-Resin-Base Bonding Systems for ConcreteASTM D 1475(1998; R 2008) Standard Test Method for Density of Liquid Coatings, Inks, and Related ProductsASTM D 1544(2004) Standard Test Method for Color of Transparent Liquids (Gardner Color Scale)ASTM D 1652(2004) Standard Test Method for Epoxy Content of Epoxy ResinsASTM D 2240(2005) Standard Test Method for Rubber Property - Durometer HardnessASTM D 2471(1999) Standard Test Method for Gel Time and Peak Exothermic Temperature of Reacting Thermosetting ResinsASTM D 445(2006) Standard Test Method for Kinematic Viscosity of Transparent and Opaque Liquids (and the Calculation of Dynamic Viscosity)ASTM D 523(2008) Standard Test Method for Specular GlossASTM D 570(1998; R 2005) Standard Test Method for Water Absorption of PlasticsASTM D 638(2008) Standard Test Method for Tensile Properties of PlasticsASTM D 696(2008) Standard Test Method for Coefficient of Linear Thermal Expansion of Plastics Between -30 degrees C and 30 degrees C With a Vitreous Silica Dilatometer][THE SOCIETY FOR PROTECTIVE COATINGS (SSPC)SSPC SP 6(7) Commercial Blast Cleaning]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. Keep submittals 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, use a code of
up to three characters within the submittal tags 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.][for information only. When used, a designation following the
"G" designation identifies the office that reviews the submittal for the Government.] Submit the following in
accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Submit Fabrication Drawings in accordance with the paragraph entitled, "Drawings," of this section.
Submit installation drawings for heavy duty epoxy flooring systems in accordance with the paragraph
entitled, "Application of Floor Topping," of this section.
SD-03 Product Data
Submit manufacturer's catalog data for the following items:
Epoxy-Resin Binder/Matrix
Cured Epoxy Binder
Walnut Shell Aggregate
Surface Sealing Coat
SD-04 Samples
Submit samples on Hardboard in accordance with paragraph entitled, "Sampling," of this section.
SD-05 Design Data
Submit mix designs (Contractor and job) for the following items including a complete list of
ingredients and admixtures. Applicable test reports must verify that the mix has been successfully
tested and meets design requirements.
Epoxy-Resin Binder/Matrix
Cured Epoxy Binder
Surface Sealing Coat
SD-06 Test Reports
A copy of the Records of Inspection after completion of the contract in accordance with paragraph
entitled, "Quality Assurance," of this section.
SD-07 Certificates
Submit Listing of Product Installations in accordance with paragraph entitled, "Qualifications,"
of this section.
Submit certificates for the following showing conformance with the referenced standards contained
in this section.
Epoxy-Resin Binder/Matrix
Cured Epoxy Binder
Walnut Shell Aggregate
Surface Sealing Coat
1.3 DELIVERY, HANDLING, AND STORAGE
Protect materials from weather, soil, and damage during delivery, storage, and construction.
Deliver materials in original packages, containers, or bundles bearing brand name and name of material.
Maintain materials used in the installation of floor topping at a temperature between 18 and 30 degrees C 65
and 85 degrees F.
1.4 QUALITY ASSURANCE
Submit a copy of the Records of Inspection, as well as the records of corrective action taken.
1.4.1 Qualifications
A Listing of Product Installations for heavy duty epoxy flooring must include identification of at least 5 units,
similar to those proposed for use, that have been in successful service for a minimum period of 5 years. List
must include purchaser, address of installation, service organization, and date of installation.
Applicators installing the floor topping must have had experience in the application of troweled walnut-shell
aggregate thin-set floor topping.
1.4.2 Sampling
Provide three samples on Hardboard not less than 300 millimeter 12 inch square for each required color.
Panels must show nominal thickness of finished toppings and color and texture of finished surfaces. Finished
floor toppings must match the approved samples in color and texture.
1.4.3 Drawings
Submit Fabrication Drawings for heavy duty epoxy flooring Systems consisting of fabrication and assembly details
to be performed in the factory.
PART 2 PRODUCTS
2.1 MIXES
2.1.1 Epoxy-Resin Binder/Matrix
Epoxy-resin binder to be a clear two-component compatible system consisting of: (1) a liquid blend of a biphenol-based
epoxy resin and an aliphatic polyglyceridyl ether, and (2) a liquid blend of two modified amine curing agents,
which individually cures the epoxy resin at room temperature to a glossy smooth film. Two components and the
cured epoxy binder must have the following physical properties:
PROPERTY TEST METHOD REQUIREMENT
COMPONENT A (EPOXY RESIN)
Viscosity (kinematic), at ASTM D 445 3000 to 5000
25 degrees C, millipascal-
second
Weight per epoxide, grams ASTM D 1652 205 to 225
Color (Gardner Color Scale), ASTM D 1544 5
maximum
Weight per milliliter, grams ASTM D 1475 1.13 - 1.15
COMPONENT B (CURING AGENT)
Viscosity (kinematic), at 25 ASTM D 445 75 to 125
degrees C, square milliliter
per second
Weight per milliliter, grams ASTM D 1475 0.90 to 0.91
Color (Gardner Color Scale), ASTM D 1544 8
maximum
PROPERTY TEST METHOD REQUIREMENT
COMPONENT A (EPOXY RESIN)
Viscosity (kinematic), at ASTM D 445 3000 to 5000
77 degrees F, centipoises
Weight per epoxide, grams ASTM D 1652 205 to 225
Color (Gardner Color Scale), ASTM D 1544 5
maximum
Weight per gallon, pounds ASTM D 1475 9.46 - 9.56
COMPONENT B (CURING AGENT)
Viscosity (kinematic), at 77 ASTM D 445 75 to 125
degrees F, centistokes
Weight per gallon, pounds ASTM D 1475 7.50 to 7.60
Color (Gardner Color Scale), ASTM D 1544 8
maximum
2.1.2 Cured-Epoxy Binder
Combine components A and B in the proportions specified by the manufacturer to form a clear compatible system
immediately on mixing. Cure combined components to a clear film possessing a glossy, nongreasy surface at relative
humidities less than 80 percent, and have the following properties after curing 24 hours at 25 degrees C 77 degrees
F, followed by 24 hours at 52 degrees C 125 degrees F:
PROPERTY TEST METHOD REQUIREMENT
Water absorption, percent ASTM D 570 0.40
24 hours at 25 degrees C,
maximum
Hardness, Shore D ASTM D 2240 74 to 82
Linear shrinkage, millimeter/ ASTM C 881/C 881M 0.15
millimeter, maximum
Shrinkage, glass bow, milli- ASTM A 990 0.40
meter divergence, maximum
Coefficient of linear thermal ASTM D 696 200 X 10-6
expansion, mm/mm/degrees C, 0 degrees C
maximum to 40 degrees C
Gel time/peak exotherm at ASTM D 2471 20 to 40
25 degrees C, 100 gm mass in minutes at 150
120 millimeter metal container degrees C, maximum
*3 millimeter thick castings
**3 by 25 by 80 millimeter castings, aged in forced draft oven
PROPERTY TEST METHOD REQUIREMENT
Tensile strength, psi* at ASTM D 638 4500 to 6500
test temperature:
77 degrees F
Tensile elongation, percent* ASTM D 638 20 to 40
at test temperature:
77 degrees F
Water absorption, percent ASTM D 570 0.40
24 hours at 77 degrees F,
maximum
Hardness, Shore D ASTM D 2240 74 to 82
Linear shrinkage, ASTM C 881/C 881M 0.006
inch/inch maximum
Shrinkage, glass bow, inch ASTM A 990 0.016
divergence, maximum
Coefficient of linear thermal ASTM D 696 200 X 10-6
expansion, inch/inch/degree 0 degrees C
C, maximum to 40 degrees C
Gel time/peak exotherm at ASTM D 2471 20 to 40
77 degrees F, 100 gm mass in minutes at 300
4-ounce metal container degrees F, maximum
*1/8 inch thick castings
**1/8 by 1 by 3 inch castings, aged in forced draft oven
2.1.3 Walnut Shell Aggregate
Walnut shell aggregate must be delivered to the site in three separate package gradations for blending. Gradations
to be furnished to be:
PERCENT
SIEVE SIZE MAXIMUM MINIMUM
GRADATION NO. 1
Retained on 3.35 millimeter 0.0 -
Passing 3.35 millimeter, retained on 5.0 0.0
2.36 millimeter
Passing 2.36 millimeter, retained on 100.0 74.0
1.7 millimeter
Passing 850 micrometer 1.0 -
GRADATION NO. 2
Retained on 1.18 millimeter 0.0 -
Passing 1.18 millimeter, retained on 5.0 0.0
1.0 millimeter
Passing 1.0 millimeter, retained on 100.0 85.0
425 micrometer
Passing 425 micrometer, retained on 9.0 0.0
250 micrometer
Passing 250 micrometer 1.0 -
GRADATION NO. 3
Retained on 850 micrometer 0.0 -
Passing 850 micrometer, retained on 5.0 0.0
500 micrometer
Passing 500 micrometer, retained on 100.0 80.0
250 micrometer
Passing 250 micrometer, retained on 13.0 0.0
150 micrometer
Passing 150 micrometer 2.0 -
PERCENT
SIEVE SIZE MAXIMUM MINIMUM
GRADATION NO. 1
Retained on No. 6 0.0 -
Passing No. 6, retained on No. 8 5.0 0.0
Passing No. 8, retained on No. 12 100.0 74.0
Passing No. 20 1.0 -
GRADATION NO. 2
Retained on No. 16 0.0 -
Passing No. 16, retained on No. 18 5.0 0.0
Passing No. 18, retained on No. 40 100.0 85.0
Passing No. 40, retained on No. 60 9.0 0.0
Passing No. 60 1.0 -
GRADATION NO. 3
Retained on No. 20 0.0 -
Passing No. 20, retained on No. 35 5.0 0.0
Passing No. 35, retained on No. 60 100.0 80.0
Passing No. 60, retained on No. 100 13.0 0.0
Passing No. 100 2.0 -
2.1.4 Surface Sealing Coat
Surface sealer must be nonambering aliphatic or aromatic moisture-curing polyurethane into which has been incorporated
a suitable flatting agent. Add flatting agent not more than 24 hours prior to actual application of the coating.
Cured coating with flatting agent must give 60-degree specular gloss of 10 to 20 when tested in accordance with
ASTM D 523.
PART 3 EXECUTION
3.1 INSTALLATION
3.1.1 Safety Precautions
Prior to application in confined spaces of toppings and coatings containing flammable or toxic properties, provide
forced ventilation to ensure that vapor concentration is kept at acceptable limits recommended by the manufacturer
of the product.
Erect "NO SMOKING" signs, and prohibit smoking or use of spark- or flame-producing devices within 15 meter 50
feet of any mixing or placing operation involving flammable materials.
Personnel required to handle, mix, or apply toppings containing toxic or flammable properties must be provided
with, and required to wear, such items of personal protective equipment and apparel for eye, skin, and respiratory
protection as are recommended by the manufacturer of the product.
Accomplish sand blasting under approved controlled conditions with respect to sand and dust control to prevent
damage to personnel and facility.
3.2 PREPARATION
3.2.1 Concrete Subfloor
Installation of floor topping must not commence until concrete has cured a minimum of 28 calendar days. Concrete
to have rough or broom type finish. Prior to applying the prime coat, clean concrete surface by an approved
method.
3.2.2 Steel Subfloor
Clean surfaces of grease, rust, and mill scale by dry sand blasting in accordance with SSPC SP 6 for commercial
sand blasting. Using other means of surface preparation is optional, as approved, provided the degree of cleanliness
and profile obtained by sand blasting is equaled. Power brushing is not permitted.
3.2.3 Mixing Of Materials
Job mix proportions are based on the trial batch proportions used to prepare the floor topping samples submitted
and approved. Binder aggregate ratio normally range from 1:2 to 1:2.3 (by weight), since mixtures providing
satisfactory density, trowelability, and surface texture are affected by variations in particle shapes, sizes,
and size distribution. Blend three different walnut shell aggregate gradations (by weight) as follows: 1 part
No. 1; 1.15 parts No. 2; and 1.15 parts No. 3. Minor adjustments of the mix proportions of the approved floor
topping samples are permitted, subject to approval.
Use mechanical equipment for mixing of materials. Use rotating replaceable 20 to 60 liter 5- to 16-gallon pail
mixers for blending components A (epoxy resin) and B (curing agent) of epoxy binder.
Use rotating paddle-type masonry mortar mixers for preblending the three sizes and color pigment, if any, of
the walnut shell aggregate and addition of the mixed epoxy resin binder. Mixing times to be as recommended by
the materials supplier(s), provided mixing times result in homogeneous mixtures. In case the equipment used
does not provide uniform mixtures in the times recommended, with approval, adjust the mixing times. Limit quantity
of material mixed at one time to that which can be applied and finished within the working life of the mixtures.
Temperature of materials at the time of mixing must be between 18 and 30 degrees C 65 and 85 degrees F.
3.2.4 Protection
In addition to the protection of adjacent surfaces during installation, areas used to store and mix materials
must have a protective covering under the materials. After application of the sealer coats, protect finished
flooring during the remainder of the construction period. In areas of expected minimum or moderate traffic,
cover floors with 12300 newton per meter (70 pounds) 70-pound kraft paper, a 30-30-30 waterproof kraft paper,
or an approved substitute, with strips taped together and edges secured to prevent roll-up. Vegetable fiberboard,
plywood, or other suitable material that does not mar the flooring must be placed over the paper to protect areas
used as passages by workmen and areas subject to floor damage because of subsequent building operations. Upon
completion of construction, remove the protection, clean flooring and, where necessary, repair, reseal, or both,
at no additional cost to the Government.
3.3 APPLICATION OF FLOOR TOPPING
Anchor plates set with the top surface at or above the finished epoxy floor level do not require coverage with
this flooring material. Extend flooring under equipment, except when the equipment base is indicated to be flush
against the structural floor. Cover and/or mask surfaces not to receive the epoxy floor topping, such as equipment
or cabinets installed prior to surface-preparation efforts and adjacent to the flooring installation.
Prepared subfloor surface must be dry and at a temperature of not less than16 degrees C 60 degrees F when application
of the floor topping is initiated. Immediately prior to application of the prime/scratch coat on the prepared
surface, remove dust or other loose particles by blowing with compressed air or vacuum cleaned. Air compressor
used must be equipped with an efficient oil-water trap to prevent oil contamination or wetting of surface.
Apply a thin roller coat of the epoxy binder specified to the prepared subfloor as a prime coat. As an aid to
placing, compacting, and finishing the floor topping, the forming of a scratch coat by sprinkling a minimum quantity
of the walnut shell aggregate on the prime coat surface immediately following the prime coat application is allowed.
Prime coat application rate must be approximately 3.7 square meter per liter 150 square feet per gallon. Prior
to application of the prime/scratch coat, fill cracks in the concrete, and make provisions to keep control or
expansion joints open.
Place the floor topping prior to final gelling of the prime/scratch coat. Immediately after the materials are
mixed as specified, dump the mixture in the placement area and spread to prolong troweling life. Screed or rough
trowel placed materials to the specified thickness and then compact by the use of a smooth roller prior to finish
troweling to a nominal thickness of 4.7 millimeter plus or minus 1.58 millimeter 3/16 inch plus or minus 1/16
inch. Finished surface must be free of ridges, hollows (bird-baths), and trowel marks, and smoothness must vary
not more than 3 millimeter 1/8 inch when tested with an 2500 millimeter 8-foot straightedge. Make provisions
to maintain the work areas in a relatively dust-free environment during curing of the topping.
After the floor topping has set firmly (approximately 6 to 16 hours depending on subfloor temperature) in a relatively
dust-free environment, apply two thin coats of the sealer coat, by means of brush, roller, squeegee, or notched
trowel to provide a pore-free, easy-to-clean surface. At the time of sealer application, the surface must be
dust-free. Depending on relative humidity, the applied sealer must cure to a tack-free condition in 2 to 4 hours.
Second coat must not be applied until after the initial coat has cured to a tack-free, hard film. Maintain topping
areas in a relatively dust-free environment during curing of the sealer coats.
3.4 FIELD QUALITY CONTROL
3.4.1 Repairing
Damaged and unacceptable portions of completed work must be removed and replaced with new work to match adjacent
surfaces at no additional cost to the Government.
3.5 CLEANING
Clean surfaces of the new work, and adjacent surfaces soiled as a result of the work. Equipment, surplus materials,
and rubbish from the work must be removed from the site.