USACE / NAVFAC / AFCESA / NASA UFGS-09 67 23.16 (August 2008)
-------------------------------
Preparing Activity: NAVFAC Superseding
UFGS-09 62 50.12 (April 2006)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2009
SECTION 09 67 23.16
FUEL RESISTIVE RESINOUS FLOORING, 5-COAT SYSTEM
08/08
NOTE: This guide specification covers the requirements for a five-coat, epoxy
mortar flooring system with reflective urethane topcoats, slip resistance, and
joint work.
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).
NOTE: The epoxy mortar flooring system is appropriate for use in: aircraft
maintenance hangars, equipment maintenance shops, jet engine test cells, and
all other industrial floors where resistance to impact, abrasion, and fuel is
required. Installation costs: $5.00 - $10.00 per 0.1 square meters square foot
. Nominal thickness: 6.25 mm 1/4 inch. Benefits: Tolerates high Moisture Vapor
Emission (MVE) rates, produces a level surface over coarse concrete, high impact
resistance, good chemical resistance, and may provide a suitable topcoat base
for more than 10 years service. Can be rejuvenated by replacing urethane topcoats,
and non-skid, only. Approximate service life: Urethane topcoating with non-skid
grit at three or more years. The flooring system is neither conductive nor
Electro-Static Dissipative (ESD), however, either formulation is easily designed
upon request. This specification is not for use in overcoating existing sound
coating systems.
NOTE: Prior to the flooring systems installation, a concrete condition assessment
in accordance with the Naval Facilities Engineering Service Center's (NFESC)
Users Guide (UG)-2036-SHR is highly recommended. The condition assessment is
designed to identify problem floors and eliminate premature flooring failures
produced by: 1) Coating concrete with low surface strength, 2) coating concrete
with high surface contamination levels (oils, fuels, fats, waxes, etc.), and
3) coating concrete with a high Moisture Vapor Emission (MVE) rate. The thin
film flooring system is suitable for application to: A) "Smooth" or "Coarse"
concrete surface textures, B) concrete with a MVE rate no more than 254 micrograms
moisture per second, square meter 4.5 pounds moisture per 24 hours, 1000 square
feet (ASTM F 1869), C) concrete with surface strength greater than 1.34 MPa
200 psi (ASTM D 4541), and D) concrete with fuel/oil contamination to a depth
no more than 6.25 mm 1/4 inch.
NOTE: If a concrete floor has a Moisture Vapor Emission (MVE) rate more than
254 micrograms moisture per second, square meter 4.5 pounds moisture per 24
hours, 1000 square feet (ASTM F 1869), apply a layered Moisture Reducing System
(MRS) prior to the epoxy mortar flooring system application. Use MRS compatible
with the submitted flooring system and approved / warranted by the epoxy mortar
flooring system manufacturer. Apply the MRS to shot blasted concrete and reduce
the MVE rate to less than 254 micrograms moisture per second, square meter 4.5
pounds moisture per 24 hours, 1000 square feet. MRSs can employ combinations
of concrete sealers, specific epoxies, and moisture insensitive grouts, with
or without mesh. MRSs are available from the following partial list of epoxy
mortar flooring system vendors: Tennant (800) 553-8033, Stonhard (856) 779-7500,
General Polymers (800) 543-7694, Crawford Labs (800) 356-7625, Floor Seal (800)
295-0221. Moisture Vapor Emission Test Kits (MVETK) are available from the
following partial list of vendors: Crawford Labs (800) 356-7625, Floor Seal
(800) 295-0221, Sinak (619)231-1771, General Polymers (800)534-7694.
NOTE: Include Section 03 01 30.71 CONCRETE REHABILITATION for minor spalls and
surface deterioration repair to depths less than three inches. Specify epoxy
mortar for repairs to depths no more than 50 mm 2 inches. Specify epoxy concrete
for repairs to depths from 25 to 75 mm 1 to 3 inches. Saw cut repairs to depths
greater than 25 mm 1 inch to a rectangular geometry. Finish repairs to resemble
surrounding concrete using a stainless steel trowel.
Include Section 32 01 19.61 RESEALING OF JOINTDS IN RIGID PAVEMENT for large
spalls and severe deterioration repair to depths from 75 to 150 mm 3 to 6 inches
. Specify Portland Cement Concrete (PCC) with less than 0.45 water-cement ratio,
light steel trowel finish, and cure using plastic coated burlap. Use rectangular
geometry for repairs with saw cut edges to a nominal repair depth of 150 mm
6 inches. Cure PCC repair for approximately 30 days prior to the application
of the flooring system. Do not cure repairs using liquid membrane-forming compounds.
For repairs to spalls and severely distressed concrete to depths greater than
150 mm 6 inches, seek material guidance from Section 03300N CAST-IN-PLACE CONCRETE
and procedural guidance from the American Concrete and Pavement Association
(ACPA) Guideline TB-002.02P "Concrete Paving Technology - Guidelines for Full
Depth Repair." Fill repair base with a minimum of 50 mm 2 inches of clean,
non-reactive concrete sand over a suitable vapor retarder (0.25 mm 10 mils polyethylene
sheeting). Finish repairs by light steel trowel and cured using plastic coated
burlap. Cure repairs for approximately 30 days, or more, prior to the the flooring
system application. Do not cure repairs using liquid membrane-forming compounds.
Scarify level any curled and/or settled slab ends with joint surfaces displaying
more than 3.2 mm 1/8 inch difference in vertical height. Resulting surfaces
shall contain a height difference no more than 1.5 mm 1/16 inch and a surface
texture equal to ICRI-CSP 4.
NOTE: Include Section 03300N CAST-IN-PLACE CONCRETE for new concrete slab construction.
Emply measures to control the base, subbase, and subgrade moisture Moisture
Vapor Emission (MVE) rates to total no more than 169.0 micrograms moisture per
second, square meter 3.0 pounds moisture per 24 hours, 1000 square feet when
measured on the slab's surface (ASTM F 1869). Improper MVE controls have produced
numerous premature coating failures. In addition to appropriate subbase drainage,
specify a minimum of 50 mm 2 inches of clean, non-reactive concrete sand over
no less than 0.25 mm 10 mils of polyethylene sheeting (ASTM D 4397) with sealed
lap joints. Specify concrete mix to be free of accelerators containing calcium
chloride and other sources of chloride ion contamination. Specify two passes
of a light power troweled finish and cure using plastic coated burlap or equal
method. Do not cure concrete using liquid membrane-forming compounds. Do not
specify surface hardeners or dry shake finish (Section 09 97 23). Approximately
60 days following the concrete pour and prior to the flooring system installation,
test concrete for the MVE rate and confirm rate is no more than 254 micrograms
moisture per second, square meter 4.5 pounds moisture per 24 hours, 1000 square
feet (ASTM F 1869). Consult ACI 224.3R "Joints in Concrete Construction," ACI
302.1R "Guide for Concrete Floor and Slab Construction," ACI 360R "Design of
Slabs on Grade," and other appropriate construction guidance.
NOTE: Where tile is to be removed prior to the flooring system application,
test both tile and mastic for the presence of asbestos. If asbestos is detected,
include Section 02 82 16.00 20 ENGINEERING CONTROL OF ASBESTOS CONTAINING MATERIALS
for removal and disposal.
NOTE: If flooring system is to be applied to warehouse floors with heavy forklift
traffic, a semi-flexible joint sealant is required in lieu of the specified
flexible sealant. Use a semi-flexible epoxy sealant with approximately 90 percent
elongation. Do not use semi-flexible sealants in areas exposed to exterior
temperatures.
NOTE: Include Section 01 45 02 NAVFAC QUALITY CONTROL.
NOTE: Include Section 01 57 19.00 20 TEMPORARY ENVIRONMENTAL CONTROLS. This
section defines fugitive dust, generated waste, hazardous materials, hazardous
substance, hazardous waste, solid waste, construction and demolition (CD) debris,
and liquid waste, and contains documentation for dangerous waste profile, waste
information sheet, waste identification document, waste generation record, landfill
disposal form, and hazardous material reporting.
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 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.
[ASTM INTERNATIONAL (ASTM)ASTM C 307(2003; R 2008) Tensile Strength of Chemical-Resistant Mortar, Grouts, and Monolithic SurfacingsASTM C 531(2000; R 2005) Linear Shrinkage and Coefficient of Thermal Expansion of Chemical-Resistant Mortars, Grouts, and Monolithic Surfacings, and Polymer ConcretesASTM C 579(2001; R 2006) Compressive Strength of Chemical-Resistant Mortars, Grouts, Monolithic Surfacings, and Polymer ConcretesASTM C 679(2003) Tack-Free Time of Elastomeric SealantsASTM C 884/C 884M(1998; R 2005) Thermal Compatibility between Concrete and Epoxy-Resin OverlayASTM D 1308(2002; R 2007) Effect of Household Chemicals on Clear and Pigmented Organic FinishesASTM D 2240(2005) Standard Test Method for Rubber Property - Durometer HardnessASTM D 2621(1987; R 2005) Infrared Identification of Vehicle Solids from Solvent-Reducible PaintsASTM D 2697(2003; R 2008) Volume Nonvolatile Matter in Clear or Pigmented CoatingsASTM D 3335(1985a; R 2005) Low Concentrations of Lead, Cadmium, and Cobalt in Paint by Atomic Absorption SpectroscopyASTM D 3718(1985a; R 2005) Low Concentrations of Chromium in Paint by Atomic Absorption SpectroscopyASTM D 3925(2002) Sampling Liquid Paints and Related Pigmented CoatingsASTM D 412(2006ae1e2) Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers - TensionASTM D 4541(2002) Pull-Off Strength of Coatings Using Portable Adhesion TestersASTM D 6237(2003) Painting Inspectors (Concrete and Masonry Substrates)ASTM D 638(2008) Standard Test Method for Tensile Properties of PlasticsASTM E 11(2004) Wire Cloth and Sieves for Testing PurposesASTM F 1869(2004) Measuring Moisture Vapor Emission Rate of Concrete Subfloor Using Anhydrous Calcium Chloride][INTERNATIONAL CONCRETE REPAIR INSTITUTE (ICRI)ICRI 03732(1997) Selecting and Specifying Concrete Surface Preparation for Sealers, Coatings, and Polymer Overlays][THE SOCIETY FOR PROTECTIVE COATINGS (SSPC)SSPC-TU 2(1997) Design, Installation, and Maintenance of Coating Systems for Concrete Used in Secondary Containment][U.S. GENERAL SERVICES ADMINISTRATION (GSA)FED-STD-595(Rev B; Am 1) Colors Used in Government Procurement][U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)29 CFR 1910.1000Air Contaminants29 CFR 1910.134Respiratory Protection29 CFR 1926.59Hazard 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.][for information only. When used, a designation following the
"G" designation identifies the office that will review the submittal for the Government.] Submit the following
in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-04 Samples
Joint Sealant[; G][; G, [_____]]
Epoxy Mortar Flooring System[; G][; G, [_____]]
White Aluminum Oxide Non-Skid Grit[; G][; G, [_____]]
SD-06 Test Reports
Joint Sealant[; G][; G, [_____]]
Epoxy Mortar Flooring System[; G][; G, [_____]]
Primer[; G][; G, [_____]]
Grout Coat[; G][; G, [_____]]
Urethane Topcoat[; G][; G, [_____]]
White Aluminum Oxide Non-Skid Grit[; G][; G, [_____]]
Patch Test Demonstration[; G][; G, [_____]]
Daily Inspection Report[; G][; G, [_____]]
Adhesion Testing[; G][; G, [_____]]
SD-07 Certificates
Work Plan[; G][; G, [_____]]
Flooring System Applicator Qualifications[; G][; G, [_____]]
Joint Sealant[; G][; G, [_____]]
Epoxy Mortar Flooring System[; G][; G, [_____]]
Warranty[; G][; G, [_____]]
SD-08 Manufacturer's Instructions
Joint Sealant[; G][; G, [_____]]
Epoxy Mortar Flooring System[; G][; G, [_____]]
Water-Based Alkaline Degreaser[; G][; G, [_____]]
SD-11 Closeout Submittals
Inspection Logbook[; G][; G, [_____]]
1.3 QUALITY ASSURANCE
1.3.1 Test Reports
1.3.1.1 Joint Sealant
Submit test results that confirm sealant complies with Table Ia requirements. Samples must have been tested
within the last three years.
1.3.1.2 Epoxy Mortar Flooring System
Submit test results that confirm the epoxy mortar flooring system complies with Table Ib requirements. Samples
must have been tested within the last three years.
1.3.1.3 Primer
Submit test results that confirm the primer complies with Table Ic requirements. Samples must have been tested
within the last three years.
1.3.1.4 Grout Coat
Submit test results that confirm grout coat complies with Table Id requirements. Samples must have been tested
within the last three years.
1.3.1.5 Urethane Topcoat
Submit test results that confirm urethane topcoat complies with Table Ie requirements. Samples must have been
tested within the last three years.
1.3.1.6 Daily Inspection Report
Submit one copy of the daily inspection report to the Contracting Officer within 24 hours of the date recorded.
1.3.2 Certificates
1.3.2.1 Work Plan
Submit schedule to complete work within approximately twelve (12) consecutive calendar days. Submit a written
plan describing in detail all phases of coating operations. Address work sequencing, surface preparation, flooring
system application, recoat and cure time projections, as well as how each step will be controlled, tested, and
evaluated. Address safety measures, work scheduling around weather, and record keeping. Assign one supervisor
to the job who is to remain on site throughout all phases of work and who is to act as the contractor's primary
point of contact. Identify this person in the submitted schedule.
1.3.2.2 Flooring System Applicator Qualifications
Minimum requirements for the installation contractor are as follows: Completed three or more jobs within the
past two years applying the specified materials to concrete surfaces in which the total area exceeds 18 587 square
meters 200,000 square feet. Submit documentation listing location of work, point of contact at job site, total
square footage of applied materials, listing of both materials and equipment used, and validation from coating
manufacturer documenting quality of materials purchased per job for work totalling 18 587 square meters 200,000
square feet within the past two years. In addition to the above requirements, installation contractor shall
be certified by the material manufacturer(s) to install the submitted coatings and sealant. Submit copy of certificates.
1.3.2.3 Joint Sealant
Submit literature documenting the sealant's past performance in automotive and/or aircraft maintenance shops.
Minimum requirements are two or more maintenance shops with joint work totaling 3048 linear meters 10,000 linear
feet whereby the sealant has performed for two years with less than one percent combined sealant failures and
defects. Include from sealant manufacturer a list of shop locations, total linear feet of sealant applied per
shop, shop point of contact, date sealant was applied, and the name of the installed sealant material.
1.3.2.4 Epoxy Mortar Flooring System
Submit literature documenting the coating system's past performance in aircraft maintenance shops and over floors
with high Moisture Vapor Emission (MVE) rates. Minimum requirements are two or more aircraft maintenance shops
totaling 3160 square meters 34,000 square feet where the coating system has performed for two years with less
than 0.05 percent combined premature coating failures, material defects and surface discoloration; no more than
0.03 percent discoloration from aviation chemicals, tire plasticizers, and UV exposure. Provide a minimum of
two additional case histories where successful installation occurred on floor slabs with no less than 254 micrograms
moisture per second, square meter 4.5 pounds moisture per 24 hours, 1000 square feet. Include from flooring
manufacturer a list of shop locations, total coated area per shop, shop point of contact, date coating system
was applied, successful installation to concrete with high MVE, and the names of the installed coating materials.
1.3.2.5 Warranty
Warrantee materials and workmanship for a minimum of one year following completion of flooring and sealant application.
The following terms and conditions form a part of the warranty: If the applied coating system develops blisters
(chemical), checks, softening, or lifting within one year following application, rework each area by installation
contractor at contractor's expense. The following conditions are excluded from the warranty: A) Concrete cracking,
flooring system mirrors cracks in concrete, B) cosmetic imperfections due to scratching and gouging, C) application
to metallic concrete finishes (Section 09 97 23), and D) application to concrete with a MVE rate greater than
282 micrograms moisture per second, square meter 5.0 pounds moisture per 24 hours, 1000 square feet. If the
coating system's adhesion is in question, perform one adhesion test per 9.3 square meters 100 square feet as
described in the Article entitled "ADHESION TESTING." To satisfy the warranty, adhesion testing shall produce
cohesive failures within the concrete, concrete removal over 95 percent of each pull-off coupon, and/or adhesion
no less than 2.8 MPa 400 psi. Each area failing to meet adhesion requirements shall require two additional adhesion
tests to confirm results. Within the warranty period, remove to sound material and rework all areas unable to
meet adhesion requirements. Zero percent sealant failures within one year is required. Within the warranty
period, remove and rework all sealant material with chemically attacked surfaces and/or lifting from joint walls.
Topcoat cracking over sealant is excluded from warranty.
1.3.3 Manufacturer's Instructions
1.3.3.1 Joint Sealant
Submit manufacturer's printed instructions to include detailed application procedures, minimum and maximum application
temperatures, and curing procedures. In accordance with 29 CFR 1926.59, include Material Safety Data Sheets
(MSDS) for the sealant to be used at the job site.
1.3.3.2 Epoxy Mortar Flooring System
Submit manufacturer's printed instructions to include detailed mixing, minimum and maximum application temperatures,
acceptable atmospheric and/or interior climatic conditions, application procedures, curing procedures, and procedures
for flooring system maintenance cleaning. Provide explicit instructions detailing surface preparation, recoat
windows and remedial actions in case recoat windows are missed, and, if applicable, solvent-wiping between coats
with acceptable types and grades of solvents. In accordance with 29 CFR 1926.59, include MSDSs for the coatings
to be used at the job site.
1.3.3.3 Water-Based Alkaline Degreaser
Submit manufacturer's printed instructions to include detailed mixing, dilution rate, application procedures,
and rinsing procedures. In accordance with 29 CFR 1926.59, include MSDSs for the water-based alkaline degreaser
to be used at the job site.
1.4 DELIVERY, STORAGE, AND HANDLING
Store coatings and sealant in spaces with temperatures from 5 - 24 degrees C
40 - 75 degrees F. Inspect materials on site for damage prior to use. Return to manufacturer any packaged materials
in dented, rusty, or leaking containers. Return to manufacturer materials with an expired shelf life for testing,
and if compliant, reissuing of shelf life extension.
1.5 COATING HAZARDS
NOTE: Include either Section 01 35 29 SAFETY AND OCCUPATIONAL HEALTH REQUIREMENTS
or prepare instructions detailing each safety element for use with this section.
Ensure that employees are trained in all safety plan aspects. Follow the coating manufacturer's written safety
precautions throughout mixing, application, and curing of coatings. Comply with respiratory protection requirements
in 29 CFR 1910.134 and safe levels of airborne contaminants in 29 CFR 1910.1000.
1.6 JOB SITE REFERENCES
Make available to the Contracting Officer at least one copy each of ASTM D 4541, ASTM D 6237, SSPC-TU 2, and
ICRI 03732, including replica standards ICRI-CSP 1 through ICRI-CSP 9, at the job site.
1.7 PATCH TEST DEMONSTRATION
NOTE: This is a very important part of the submittal process. While it is
unusual to require a test patch prior to the submitted materials' approval,
this flooring system is unusual in that it is required to perform significant
tasks for a long time. Proof of contractor claims, especially under conditions
to be encountered in the specific project, is considered necessary.
If customer dislikes non-skid grit level, adjustments to the specification can
be made. Grit coarser than #60 aluminum oxide is not recommended. On architectural
floors, non-skid grit broadcast rates can range from none to approximately half
the specified level. To confirm grit broadcast is acceptable, walk on cured
patch test under both dry and wet conditions. Water can be used to simulate
the wet condition.
Prior to the submitted flooring system's approval, apply the complete flooring system to a 3 meter by 3 meter
10 foot by 10 foot square concrete section as prepared in accordance with Part 3 "EXECUTION." Within this area,
perform three adhesion tests using procedures as detailed in the Article entitled "ADHESION TESTING." If adhesion
testing produces cohesive failures within the concrete, no less than 1 mm 40 mils concrete removed over 95 percent
of each pull-off coupon, and/or adhesion more than 2.75 MPa, 400 psi, patch test adhesion is acceptable. If concrete
surface preparation was insufficient, apply an additional coating system patch to properly prepared concrete
followed by the above adhesion testing. If adhesion results are unacceptable for both the topcoat and the coatings
below the grout coat, submit a new coating system manufactured by a different coating vendor. Apply new coating
system to a patch and subject this patch to the above requirements for adhesion prior to approval. If customer
dislikes non-skid grit application, adjustments to the specifications can be made. Grit coarser than #60 aluminum
oxide is not recommended. Immediately following "passing" adhesion results, remove urethane topcoats and grout
coat by sanding, repair patch test holes using epoxy mortar, and place a "Key-In Termination" adjacent patch
test perimeter. Coarse scarification and/or pneumatic scabbling can be required to remove patch tests failing
to meet adhesion requirements.
PART 2 PRODUCTS
NOTE: The specified materials are not appropriate for use in primary chemical
containment, secondary chemical containment, or on floors subjected to spills
from concentrated acids, bases, and organic solvents. Consult with the Naval
Facilities Engineering Service Center's (NFESC) Paints and Coatings Center of
Expertise for alternative coating systems to suit specific Navy needs.
NOTE: Tables Ia, Ib, Ic, Id, Ie, and II, are presented at the end of Part 3
"EXECUTION."
2.1 JOINT SEALANT
Formulate the joint sealant to exhibit the properties as listed in Table Ia.
2.2 EPOXY MORTAR FLOORING SYSTEM
A five-coat flooring system consisting of primer, epoxy mortar, grout coat, and two urethane topcoats. Apply
the system at a nominal thickness of 6.25 mm 1/4 inch and contain an aluminum oxide non-skid grit broadcast.
Formulate the complete flooring system to exhibit the properties listed in Table Ib. Additional requirements
for primer coat, grout coat, and urethane top coat are contained in the following sub-paragraphs.
2.2.1 Primer Coat
In addition to the epoxy mortar flooring system requirements, formulate the primer coat to exhibit the properties
as listed in Table Ic.
2.2.2 Grout Coat
In addition to the epoxy mortar flooring system requirements, formulate the grout coat to exhibit the properties
as listed in Table Id.
2.2.3 Urethane Topcoat
In addition to the epoxy mortar flooring system requirements, formulate the urethane topcoat to exhibit the properties
as listed in Table Ie.
2.3 WHITE ALUMINUM OXIDE NON-SKID GRIT
Size #60, dust-free (washed and dry), minimum 99 percent pure, having the following sieve analysis when tested
using a 1000 gram 2.2 pound sample
(ASTM E 11):
Sieve No. 40 100% passing
Sieve No. 50 15-30% retained
Sieve No. 60 70-85% retained
Sieve No. 70 0 -15% retained
2.4 PREAPPROVED MATERIALS
Table II is a list of vendors with "preapproved materials."
PART 3 EXECUTION
3.1 COATING SAMPLE COLLECTION
The Contracting Officer and QC Manager shall witness all material sampling. Notify the Contracting Officer a
minimum of three days in advance of sampling. Obtain liquid samples of each component (eg., primer, intermediate,
grout coat, topcoat) by random selection from sealed containers and in accordance with ASTM D 3925. Samples
may be either individual cans of liquid material or 1.0 liter 1.0 quart quantities of properly mixed, extracted,
and sealed liquid material. Label samples by designated name, specification number, batch number, project contract
number, sample date, intended use, and quantity involved. When the applied epoxy mortar system has met the requirements
defined in the Article entitled "ADHESION TESTING," return coating samples to the installation contractor for
proper disposal.
[3.2 TILE AND TILE ADHESIVE REMOVAL
NOTE: Delete "Tile and Tile Adhesive Removal" if concrete is not tiled.
Remove tile 100 percent, employing one or more of the following techniques: chipping, scraping, sanding, scarification,
high-pressure water, and various hand tools. Remove tile adhesive 100 percent, using solvents and power scrubbing.
Remove residual contamination using hot potable water under a minimum of 27.6 MPa 4,000 psi. Resulting surfaces
shall appear clean and display the gray color of concrete.
]3.3 JOINT MATERIAL REMOVAL, RE-SAW CUTTING, CRACK CHASING
Remove existing material 100 percent in all joints including material bonded to joint walls and base. Rigid
material may require saw cutting equipment to remove. Joints may be widened up to 3.2 mm 1/8 inch when re-saw
cutting. Chase concrete cracks identified for repair and open to a minimum depth of 12.5 mm 1/2 inch below crack
surface, resulting in crack(s) with smooth vertical walls.
3.4 DEGREASING
On both previously coated and uncoated concrete, degrease entire floor by scrubbing using a hot potable water
solution, 49 to 77 degrees C 120 to 170 degrees F, and a concentrated water-based alkaline degreaser. Perform
two complete degreasing cycles on the entire floor surface. Allow solution to soak into surfaces prior to scrubbing
and remove using hot potable water under a minimum of 27.6 MPa 4,000 psi. Rinsing shall be complete when the
rinse water appears clear. If the industrial detergent is not biodegradable, collect all rinse water and dispose
of as hazardous waste. Squeegees and shop vacuums may be used to collect pooling rinse water. Fans may be used
to aid drying of floor surfaces.
[3.5 COATING SYSTEM REMOVAL
NOTE: Delete "Coating System Removal" if concrete is uncoated.
Remove existing coating system 100 percent employing one or more of the following techniques: shot blasting,
chipping, scraping, sanding, scarification, high pressure water blasting, and various hand tools. Impact tools
such as scabblers may be used to remove unsound epoxy mortar flooring systems. In general, a coating system
cannot be completely removed by shot blasting and, to attain 100 percent coating removal, requires a combination
of the above techniques.
]3.6 SURFACE PREPARATION
Shot blast entire floor to produce a level of coarseness equal to ICRI 03732 CSP 3. Overlap each shot blasting
pass by 6.25 to 12.5 mm 1/4 to 1/2 inch. Add new shot to shot blasting equipment prior to blasting. Prepare
concrete surfaces inaccessible to shot blasting, perimeter wall bases and under secured equipment, using a diamond
disk grinding and/or light scarification to produce a level of coarseness equal to ICRI 03732CSP 2, ICRI 03732
CSP 4, respectively. Resulting surfaces shall appear clean and contain the appropriate surface coarseness level.
If the resulting cleanliness level cannot be determined, place numerous drops of water on surfaces that appear
contaminated. If the water drops soak into concrete, the surfaces are hydrocarbon contamination free (oils,
grease, skydrol). If the water drops bead up and do not flatten out, surfaces require additional degreasing
as detailed in the Article entitled "DEGREASING." Shot blasting coarse concrete and/or broom finished concrete
can produce a coarseness level equal to ICRI 03732 CSP 5: employ a best effort attempt to minimize excessive
removal of coarse concrete material. If coarse concrete is encountered, shot blasting to a level of coarseness
equal to ICRI 03732 CSP 5 is acceptable: however, extremely coarse concrete can require resurfacing prior to
the flooring system's installation. Sweep, vacuum, and run a high powered magnet over all surfaces to be coated,
including joints.
3.6.1 CMU Surface Preparation
NOTE: Delete paragraph if epoxy mortar is not to be applied to the CMU wall
bases.
A minimum remove 100 percent of coatings 100 mm 4 inches up the base of CMU walls adjacent the flooring space,
and prepare surface by power grinding to a resulting level of coarseness equal to ICRI 03732 CSP 2. If oils/grease
are present, degrease in accordance with the Article entitled "DEGREASING."
3.7 COVE STRIP INSTALLATION
NOTE: Delete paragraph if epoxy mortar is not to be applied to the CMU wall
bases.
Install a continuous cove strip at a nominal height of 100 mm 4 inches up each CMU perimeter wall base. Install
a solvent resistant cove strip using a solvent resistant adhesive.
3.8 KEY-IN TERMINATIONS
NOTE: If the epoxy mortar flooring system is to be applied up the CMU wall
bases, a Key-In termination is not required adjacent these walls.
Place the "Key-In" termination as detailed in SSPC-TU 2 Figure 8 at transition surfaces, directly below doorways,
and adjacent walls, floor drains, drain grates (interior side), and all other obstructions embedded into the
floor slab. The Key-In termination shall contain one vertical wall at a depth from 9.4 to 15.6 mm 3/8 to 5/8
inch and, leading down to the resulting vertical depth, a sloped surface from 37.5 to 50 mm 1-1/2 to 2 inches
. A hand held concrete saw can be used to cut the correct vertical depth followed by power tool grinding to
create a sloped surface. Remove concrete dust by vacuuming.
3.9 CRACK REPAIRS
Use the "Elastomeric Underlayer Crack-Bridging Design" as detailed in SSPC-TU 2 Figure 7 over the surface of
epoxy mortar filled cracks.
3.9.1 Install Bondbreaker
Install bondbreaker, either solvent resistant bondbreaker tape or a 3.2 to 6.25 mm 1/8 to 1/4 inch #20-#40 mesh
silica sand layer, to the base of previously chased cracks identified for repair. For cracks without a rigid
base, install suitably sized fiberboard to a depth of 12.5 mm 1/2 inch below floor level and with bondbreaker
over exposed fiberboard. Install bondbreaker to cover the crack's horizontal base and continuously span the
entire crack length. Bondbreaker application prevents epoxy mortar from penetrating deep into cracks. Use bondbreaker
tape no more than 150 microns 6 mils thick. In this application, the use of backer rod is prohibited.
3.9.2 Repair Cracks
Using the specified materials, prime interior crack walls and apply epoxy mortar directly into wet primer. Finish
epoxy mortar level with floor and without feathered edges. When cured, remove mortar imperfections by sanding
flush with adjacent concrete. Apply solvent resistant tape parallel to each side of the mortar filled crack(s)
at a minimum inner width of 100 mm 4 inches between tape. A 100 mm 4 inch inner tape width is generally suitable
for cracks less than 12.5 mm 1/2 inch wide whereas cracks more than 12.5 mm 1/2 inch wide can require an inner
tape width of
150 mm6 inches. Apply 1 mm 1/24 inch of the specified sealant, in one coat, directly over filled crack(s) and
spread flush with inner tape edges: a stiff bristled paintbrush can be used to spread the sealant. Use a Wet
Film Thickness (WTF) gage to confirm sealant application is between 875 to 1125 microns 35 to 40 mils wet. Remove
tape and allow sealant to cure a minimum of 24 hours prior to the epoxy mortar flooring system application.
Sealant application above 1250 microns 50 mils dry will require removal and reapplication.
3.10 PRE-APPLICATION TESTING FOR CONTAMINATION
Spot check surfaces for oil/grease contamination using the water break test. At a rate of 5 tests per 95 square
meters 1000 square feet place one to two water drops onto surfaces and observe for beading. Test all other surfaces
that show visible signs of potential contamination. Perform additional degreasing to surfaces displaying water
beading in accordance with the Article entitled "DEGREASING."
NOTE: At this point in the installation sequence, minor spalls and surface
deterioration to depths less than 75 mm 3 inches can be repaired. Use epoxy
mortar for repairs to depths no more than 50 mm. 2 inches. Use epoxy concrete
for repairs to depths from 25 to 75 mm. 1 to 3 inches. Contain repairs to depths
greater than 25 mm 1 inch in a rectangular geometry with saw cut edges. Finish
repairs to resemble surrounding concrete using a stainless steel trowel. Include
Section 03 01 30.71 CONCRETE REHABILITATION if concrete repairs if this nature
are required.
3.11 COATING APPLICATION
Prior to the flooring system application, vacuum flooring space and mark all joints.
3.11.1 Isolation (Expansion) and Construction Joint Treatment
Install into each isolation (expansion) and construction joint, a continuous length of round polyethylene backer
rod flush with the floor's surface and under 30 percent compression. Backer rod placement prevents epoxy mortar
from penetrating into isolation and construction joints.
3.11.2 Contraction Joint Treatment
Apply primer and epoxy mortar directly into all contraction joints. This quantity is in addition to the specified
6.25 mm 1/4 inch epoxy mortar thickness. This step may be performed either prior to, or during, the full epoxy
mortar application.
3.11.3 Primer Application
Apply primer to flooring space at a minimum of 250 microns 10.0 mils wet. Do not prime previously installed
patch test.
3.11.4 Epoxy Mortar Application
Apply epoxy mortar at 6.25 mm 1/4 inch directly into wet primer using a screed box or equal equipment. Finish
open areas using a power trowel with stainless steel blades. Perimeter edges and adjacent equipment footings
may require finishing by stainless steel hand trowel. Directly above areas with Key-In terminations and at
a distance from 25 to 37.5 mm 1 to 1-1/2 inches away from the mortar's outer edge, slope the mortar down and
flush with the concrete's surface. Terminate the resulting angle flush with the each Key-In termination vertical
cut. Apply epoxy mortar flush with previously installed patch test. Do not apply epoxy mortar onto patch test
surface. When sufficiently cured, sand entire mortar surface. Resulting surface shall appear level, contain
uniform thickness, and be free of surface imperfections including trowel marks.
3.11.5 Primer Application to CMU Walls
NOTE: Delete paragraph if epoxy mortar is not to be applied to CMU wall bases.
When the epoxy mortar has sufficiently cured, prime approximately 100 mm 4 inches up base of CMU walls to cove
strip and 50 mm 2 inches adjacent the wall's base using the specified primer.
3.11.6 Epoxy Mortar Application to CMU Walls
NOTE: Delete paragraph if epoxy mortar is not to be applied to CMU wall bases.
Apply epoxy mortar directly into wet primer at 4.5 mm to 6.25 mm 3/16 to 1/4 inch. Use a cove trowel to create
a rounded transition between floor surfaces and perimeter wall bases. When sufficiently cured, sand the base
and 100 mm 4 inches up perimeter walls. Resulting finish shall contain a rounded transition of uniform thickness
between flooring surfaces and CMU walls. When sufficiently cured, sand mortar surfaces. Resulting surface shall
be free of surface imperfections including trowel marks.
3.11.7 Grout Coat Application
NOTE: Selecta grout coat color identical to the selected topcoat color, either
white or ultra-light gray. Ultra-light gray is preferred to white.
Sweep and vacuum up residual dust from epoxy mortar sanding. Apply grout coat to epoxy mortar at a minimum of
250 microns 10 mils wet. Apply grout coat to previously install patch test. If applicable, up CMU wall bases.
If the cured grout coat feels oily/greasy, an amine blush has occurred which requires removal. Consult the coating
manufacturer to recommend an appropriate blush removal procedure. Epoxy amines can blush during cool temperatures
with high humidity.
3.11.8 Grout Coat Sanding
Sand grout coat using 100 grit or finer sandpaper to a dull appearance with visible scratches. Resulting surface
shall appear 100 percent absent of gloss with zero shiny spots. Lightly sand perimeter edges and around equipment
footings.
3.11.9 Saw Cutting and Sealing Joints
Use the "Conventional Sealed Joint" as detailed in Figure 1 of SSPC-TU 2 to seal each contraction and expansion
joint. Take care to reduce contamination from saw cutting equipment and foot traffic. Limit floor access to
essential contractor personnel. When performing joint work, including saw cutting, suggest placing clean rolled
cardboard adjacent joint surfaces to reduce coating system contamination.
3.11.9.1 Saw Cut Contraction Joints
Place saw cuts directly in the middle of each contraction joint 6.25 mm 1/4 inch wide, placed to a minimum depth
of 31.2 mm 1-1/4 inches, and span the joint's entire length.
3.11.9.2 Saw Cut Isolation (Expansion) and Construction Joints
Place saw cuts to the isolation (expansion) and construction joint's original width and to a minimum depth of
31.2 mm 1-1/4 inches. Completely remove the epoxy mortar across the joint's width and further remove the previously
installed backer rod.
3.11.9.3 Install Backer Rod
Install a continuous length of round, closed-cell polyethylene backer rod into each saw cut. For 12.5, 9.4 and
6.25 mm 1/2, 3/8 and 1/4 inch wide saw cuts, place backer rod to a depth of 9.4 mm 3/8 inch below the grout coat's
surface the highest point on the backer rod. For expansion joint saw cuts greater than or equal to 18.8 mm 3/4
inch wide, place backer rod to a depth of 15.6 mm 5/8 inch below the grout coat's surface. Fit backer rod tight
between joint walls under 30 percent compression and place using a backer rod tool. Remove and reinstall all
backer rod that is the incorrect size or at the incorrect depth. Following backer rod installation, apply painter's
tape to surfaces adjacent joints to protect from sealant.
3.11.9.4 Joint Sealant Application
Apply sealant directly into joints using a bulk-caulking gun. At room temperature, the resulting sealant application
shall exhibit a concave recess between 3.2 to 1.0 mm 1/8 to 1/24 inch below the grout coat's surface. Remove
and reapply cured sealant remaining either flush or greater. Following sealant application, remove painter's
tape and sealant drips on grout coat. Prior to topcoating, cure sealant a minimum of 24 hours.
3.11.10 Application of Topcoats
Apply two coats of urethane topcoat. Broadcast #60, white, aluminum oxide non-skid grit into the second urethane
topcoat.
3.11.10.1 Non-Skid Grit Broadcast
NOTE: Aircraft hangars servicing light aircraft with weight less than 18 140 kg 40,000 pounds may require a
higher non-skid grit loading. The additional grit will assist in towing aircraft under wet conditions; however,
the additional grit will decrease coating aesthetics. Up to 450 grams 1.0 pounds per 9.3 square meters 100
square feet of additional non-skid grit can be required.
On either warehouse or architectural floors, considerably less non-skid grit may be appropriate. Broadcast
rates can range from none to less than 450 grams 1.0 pound per 93 square meters 1000 square feet.
Broadcast non-skid grit at a rate of 680 grams 1.0 pound per 9.3 square meters 100 square feet into the second
urethane topcoat and backroll. Map floor into 55.8 square meters 600 square foot sections where 4080 grams 9.0
pounds of non-skid grit is pre-weighed, placed into clean buckets and used in its entirety per marked 55.8 square
meter 600 square foot section.
3.11.10.2 Grout Coat Cleaning
Inspect floor for shiny grease spots and, if detected, spot degrease using manufacturer approved solvent(s) with
clean, lint-free rags. Sweep and vacuum up all residual dirt and dust. Solvent wipe all surfaces using solvent(s)
and procedures as recommended by manufacturer of epoxy mortar flooring system.
3.11.10.3 First Topcoat
Apply a full coat of urethane topcoat at a spreading rate from 62.5 to 80 microns 2.5 to 3.2 mils Dry Film Thickness
(DFT). Stripe coat perimeter edges and around equipment footings. Monitor and record a minimum of one Wet
Film Thickness (WFT) reading per 55.8 square meters 600 square foot section of floor surface. Sealant is to
be lightly coated.
3.11.10.4 Second topcoat
Apply a second coat of urethane topcoat at a spreading rate from 62.5 to 80 microns 2.5 to 3.2 mils DFT. Stripe
coat perimeter edges and around equipment footings. Monitor and record a minimum of one WFT reading per 55.8
square meters 600 square foot section of floor surface prior to broadcasting non-skid grit. When the correct
WFT has been applied per 55.8 square meters 600 square feet of area, immediately and evenly broadcast non-skid
grit into the second urethane topcoat and backroll in two directions. Test the adhesion of the epoxy mortar
flooring system in accordance with the Article entitled "ADHESION TESTING."
3.11.10.5 Walkway Stripes
Place the walkway stripe and grounding rod marker, if applicable, according to Government drawings. When the
second topcoat is within its recoat window, apply a walkway stripe of the red/orange urethane topcoat at 75 microns
3.0 mils DFT. Lightly broadcast non-skid grit into the wet walkway stripe. Use solvent resistant tape to protect
the floor coating against stripe coat bleed. A thin clear coat of either epoxy or urethane may be required to
prevent stripe coat bleed prior to the full application of the colored stripe coat. Completely hide the topcoat
color with the red/orange stripe, in one coat. If insufficient hiding occurs, apply one additional walkway stripe
coat. Apply grounding rod markings using similar procedures, urethane topcoat, and colors and size according
to Government drawings.
3.12 CURING
Installed materials shall cure and display performance equal to manufacturer's product literature. Remove and
reapply improperly cured material.
3.13 FIELD TESTS AND INSPECTION
3.13.1 Coating Inspector
NOTE: Insert directly into Section 01 45 02 NAVFAC
QUALITY CONTROL requirement for NACE Coating Inspector. See Appendix A for
instructions on modifying Section 01 45 02 NAVFAC
QUALITY CONTROL. The NACE Coating Inspector will act as QC Specialist.
Consider the Coating Inspector a QC Specialist, working for the QC Manager, and be qualified in accordance with
Section 01 45 02 NAVFAC
QUALITY CONTROL. The Coating Inspector will be present during all field tests, surface preparation, flooring
application, initial cure of the flooring system, and during all flooring repair work. The Coating Inspector
will provide all tools/equipment necessary to perform field tests and inspection. The Coating Inspector will
be responsible for field tests and specified level of inspection.
3.13.2 Inspection
Document weather conditions, job site occurrences, and report conditions and occurrences potentially detrimental
to the flooring system. The listed inspection requirements are in addition to the QC inspection and reporting
requirements defined in Section 01 45 02NAVFAC QUALITY CONTROL CONTROL. The Coating Prepare a project reference
sheet outlining all requirements, tests, test methods, and evaluation criteria, and hold regular meetings with
contractor personnel, including shot blasting operators and applicators, to review requirements/evaluation criteria
for upcoming work prior to execution. At the start of coating operations and every 1.0 hour following until
daily work is complete, record air temperature, substrate temperature, and relative humidity. Following each
coat application, inspect surfaces for improperly cured material, blisters, inadequate and/or excessive coating
thickness, and other defects. Document each inspection, test, non-compliant area, and location of each non-compliant
area. List evaluation method, evaluation criteria, areas requiring rework, and all other pertinent observations.
3.13.2.1 Daily Inspection Report
Submit to the Contracting Officer one copy of the daily inspection report completed each day when performing
work under this Section. Use Appendix X1 "Inspection Checklist" of ASTM D 6237 to monitor daily activity and
to assist in preparing the daily inspection report. Note each non-compliant issue and each issue identified
for rework in accordance with the QC documentation procedures in Section 01 45 02 NAVFAC QUALITY CONTROL.
Use of forms containing entry blocks for all required data is encouraged. Present the data in a legible and
professional format. Submit report within 24 hours of the report date.
3.13.2.2 Inspection Logbook
Record all daily activity related to this Section in the Inspection Logbook. Record the daily inspection reports,
as well as all other pertinent observations and information, in the logbook. Use a hard or spiral bound book
with consecutively numbered pages. Prior to final payment, submit original Inspection Logbook to the Contracting
Officer upon completion of project.
3.13.2.3 Inspection Equipment
Use equipment in good condition, operational within its design range, and calibrated as required by the specified
standard for each device.
3.13.3 Adhesion Testing
Perform a minimum of three modified adhesion tests (ASTM D 4541) on the topcoat no less than forty-eight hours
following application. Select three random flooring locations spaced a minimum of 6 meters 20 feet between each
location. Vertically core completely through the epoxy mortar flooring system and a minimum of 9.4 mm 3/8 inch
into concrete using a suitable drill fitted with a 25 mm 1 inch diameter core bit. Throughout coring, a employ
a best effort attempt to avoid fracturing and/or overheating both the mortar system and concrete: improper coring
can affect adhesion results. Adhere directly to each cored surface's center a 18.75 mm 3/4 inch diameter pull-off
coupon. Lightly sand test area flooring surface prior to attaching pull-off coupons containing a grit-blasted
anchor profile. When pull-off coupon adhesive has sufficiently cured, test adhesion and evaluate results. If
testing produces cohesive failures within the concrete, no less than 1 mm 40 mils concrete removal over 95 percent
of each pull-off coupon, and/or adhesion more than 2.75 MPa 400 psi mortar system's adhesion is acceptable.
If the above requirements are not satisfied, then perform one adhesion test per 9.3 square meters 100 square
feet using the above procedures. Two additional tests will confirm results for each non-compliant area. Remove
and rework all areas unable to meet adhesion requirements to sound material. Fill core holes using primer, sand-filled
epoxy mortar, grout coat, and urethane topcoats. Finish resulting repairs flush with adjacent coatings, displaying
an equivalent appearance.
3.14 Final Cleanup
Following work completion, remove debris, equipment, and materials from site. Remove temporary connections to
Government or contractor furnished water and electrical services. Restore existing facilities in and around
the work areas to their original condition.
TABLE I
MATERIAL REQUIREMENTS
Table Ia - Sealant
Test Minimum Requirement
(maximum where indicated)
---------------------------------------------------------------
Sealant System Polysulfide (Manganese Cure; MnO2)
(two-pack: self-leveling) or Urethane
Percent Volume Solids 100 %
Chemical Resistance to JP-8+100 48 hours immersion:)
Fuel @ 210C 2.0% (max) weight increase,
(ASTM D 1308) (see note 1) 5.0% (max) volume increase,
2.0% (max) weight loss
Chemical Resistance to Motor 48 hours immersion:
Oils @ 210C 2.0% (max) weight increase
(ASTM D 1308) (see note 1) 5.0% (max) volume increase
2.0% (max) weight loss
Chemical Resistance to Skydrols 48 hours immersion:
@ 210C 2.0% (max) weight increase
(ASTM D 1308) (see note 1) 5.0% (max) volume increase
2.0% (max) weight loss
Hardness (ASTM D 2240: Shore A) 20
Tensile Strength (ASTM D 412) 1.0 MPa
(or ASTM D 638)
Percent Elongation (ASTM D 412) 500%
(or ASTM D 638)
Tack Free @ 18.30C 12 hours maximum
(ASTM C 679)
Adhesion to Sand Filled Epoxy 0.96 MPa
Polyamine
Adhesion to Urethane Topcoats 0.96 MPa
(paintable sealant)
NOTES:
(1) Immerse and test a minimum of three - 50 by 12.5 by 12.5 mm section of cured sealant.
TABLE I
MATERIAL REQUIREMENTS
Table Ia - Sealant
Test Minimum Requirement
(maximum where indicated)
---------------------------------------------------------------
Sealant System Polysulfide (Manganese Cure; MnO2)
(two-pack: self-leveling) or Urethane
Percent Volume Solids 100 %
Chemical Resistance to JP-8+100 48 hours immersion:)
Fuel @ 700F 2.0% (max) weight increase,
(ASTM D 1308) (see note 1) 5.0% (max) volume increase,
2.0% (max) weight loss
Chemical Resistance to Motor 48 hours immersion:
Oils @ 700 F 2.0% (max) weight increase
(ASTM D 1308) (see note 1) 5.0% (max) volume increase
2.0% (max) weight loss
Chemical Resistance to Skydrols 48 hours immersion:
@ 700F 2.0% (max) weight increase
(ASTM D 1308) (see note 1) 5.0% (max) volume increase
2.0% (max) weight loss
Hardness (ASTM D 2240: Shore A) 20
Tensile Strength (ASTM D 412) 150 psi
(or ASTM D 638)
Percent Elongation (ASTM D 412) 500%
(or ASTM D 638)
Tack Free @ 650F 12 hours maximum
(ASTM C 679)
Adhesion to Sand Filled Epoxy 140 psi
Polyamine
Adhesion to Urethane Topcoats 140 psi
(paintable sealant)
NOTES:
(1) Immerse and test a minimum three -2 by 1/2 by 1/2 inch section of cured sealant.
Table Ib - Epoxy Mortar Flooring System
Test Minimum Requirement
(maximum where indicated)
----------------------------------------------------------------
Compression Strength )ASTM C 579) 51.7 MPa
Tensile Strength (ASTM C 307) 9.0 MPa
Adhesion to Concrete (ASTM D 4541) 2.75 MPa or
(see note 1) 100 % failure in concrete
Heat Resistance, continuous exposure 600C
Heat Resistance, intermittent exposure 93.30C
Coefficient of Thermal Expansion 9.0 - 59.4 x 10-6mm/mm0C
-17.7 - 990C (ASTM C 531)
Thermal Compatibility between Concrete "pass"
(ASTM C 884/C 884M)
Chemical Resistance to JP-8+100 Fuel 48 hours immersion:
@210C (ASTM D 1308) 2.0% (max) weight increase
(see note 2) 2.0% (max) volume increase
2.0% (max) weight loss
Chemical Resistance to Motor Oils 49 hours immersion:
@210C (ASTM D 1308) 2.0% (max) weight increase
(see note 2) 2.0% (max) volume increase
2.0% (max) weight loss
Chemical Resistance to Skydrols 48 hours immersion:
@210C (ASTM D 1308) 2.0% (max) weight increase
(see note 2) 2.0% (max) volume increase
2.0% (max) weight loss
Lead (ASTM D 3335) 0.06% (max)
Cadmium (ASTM D 3335) 0.06% (max)
Chromium (ASTM D 3718) 0.00%
NOTES:
(1) When tested for adhesion, mortar system shall display 2.75 MPa adhesion and/or remove no less than 1.0 mm of
concrete over 95% of each pull-off coupon throughout service.
(2) Immediately following immersion, in addition to the listed requirements, mortar system shall be evaluated for
blisters, checks, discoloration, softening, and lifting. Mortar system shall be visually free of blisters, checks,
and discoloration, and display both substrate and intercoat adhesion no less than 2.4 MPa (ASTM D 4541).
Table Ib - Epoxy Mortar Flooring System
Test Minimum Requirement
(maximum where indicated)
----------------------------------------------------------------
Compression Strength )ASTM C 579) 7,500 psi
Tensile Strength (ASTM C 307) 1,300 psi
Adhesion to Concrete (ASTM D 4541) 400 psi or
(see note 1) 100 % failure in concrete
Heat Resistance, continuous exposure 1400F
Heat Resistance, intermittent exposure 2000F
Coefficient of Thermal Expansion 5.0 - 33.0 x 10-6in/in 0 F
0 - 2100F (ASTM C 531)
Thermal Compatibility between Concrete "pass"
(ASTM C 884/C 884M)
Chemical Resistance to JP-8+100 Fuel 48 hours immersion:
@ 700F(ASTM D 1308) 2.0% (max) weight increase
(see note 2) 2.0% (max) volume increase
2.0% (max) weight loss
Chemical Resistance to Motor Oils 49 hours immersion:
@ 700F(ASTM D 1308) 2.0% (max) weight increase
(see note 2) 2.0% (max) volume increase
2.0% (max) weight loss
Chemical Resistance to Skydrols 48 hours immersion:
@ 700F(ASTM D 1308) 2.0% (max) weight increase
(see note 2) 2.0% (max) volume increase
2.0% (max) weight loss
Lead (ASTM D 3335) 0.06% (max)
Cadmium (ASTM D 3335) 0.06% (max)
Chromium (ASTM D 3718) 0.00%
NOTES:
(1) When tested for adhesion, mortar system shall display 400 psi adhesion and/or remove no less than 40 mils of
concrete over 95% of each pull-off coupon throughout service.
(2) Immediately following immersion, in addition to the listed requirements, mortar system shall be evaluated for
blisters, checks, discoloration, softening, and lifting. Mortar system shall be visually free of blisters, checks,
and discoloration, and display both substrate and intercoat adhesion no less than 350 psi (ASTM D 4541).
Table Ic - Primer
Test Minimum Requirement
(maximum where indicated)
--------------------------------------------------------------------
Resin System (ASTM D 2621) Epoxy Polyamine (two-pack)
Percent Volume Solids (ASTM D 2697) 100%
Color Clear to Amber
Hydrolytic Stability No effect: 30 days immersion in
(see note 1) Sodium Hydroxide solution with pH
no less than 13.5
Moisture Insensitivity Throughout No effect: Insensitive to
Service (ASTM F 1869, ASTM D 4541) moisture vapor emission at rates
(see note 2) no more than 254 micrograms
moisture per second, square meter
Adhesion to Concrete Throughout 2.75 MPa or
Service (ASTM D 4541) 100% failure in concrete
(see note 3)
NOTES:
(1) Immediately following immersion, evaluate primer for blisters, checks, discoloration, softening, and substrate
lifting. Primer shall be visually free of blisters, checks and moderate discoloration, and display wet adhesion
no less than 2.4 MPa (ASTM D 4541).
(2) During and following application, primer shall remain unaffected by Moisture Vapor Emmsion (MVE) at rates no
more than 254 micrograms moisture per second, square meter: primer shall meet the requirements of note 3. Signs
of moisture sensitivity include blisters, softening, lifting, and discoloration (whitening).
(3) When tested for in-situ adhesion, primer shall display 400 psi adhesion and/or remove no less than 1.0 mm of
concrete over 95% off each pull-off coupon.
Table Ic - Primer
Test Minimum Requirement
(maximum where indicated)
--------------------------------------------------------------------
Resin System (ASTM D 2621) Epoxy Polyamine (two-pack)
Percent Volume Solids (ASTM D 2697) 100%
Color Clear to Amber
Hydrolytic Stability No effect: 30 days immersion in
(see note 1) Sodium Hydroxide solution with pH
no less than 13.5
Moisture Insensitivity Throughout No effect: Insensitive to
Service (ASTM F 1869, ASTM D 4541) moisture vapor emission at rates
(see note 2) no more than 4.5 pounds
moisture/24 hours, 1000
square feet
Adhesion to Concrete Throughout 400 psi or
Service (ASTM D 4541) 100% failure in concrete
(see note 3)
NOTES:
(1) Immediately following immersion, evaluate primer for blisters, checks, discoloration, softening, and substrate
lifting. Primer shall be visually free of blisters, checks and moderate discoloration, and display wet adhesion
no less than 350 psi (ASTM D 4541).
(2) During and following application, primer shall remain unaffected by Moisture Vapor Emmsion (MVE) at rates no
more than 4.5 pounds moisture per 24 hours, 1000 square feet: primer shall meet the requirements of note 3. Signs
of moisture sensitivity include blisters, softening, lifting, and discoloration (whitening).
(3) When tested for in-situ adhesion, primer shall display 400 psi adhesion and/or remove no less than 40 mils of
concrete over 95% off each pull-off coupon.
Table Id - Grout Coat
Test Minimum Requirement
(maximum where indicated)
-------------------------------------------------------------------
Resin System (ASTM D 2621) Epoxy Polyamine (two-pack)
Percent Volume Solids (ASTM D 2697) 100%
Color 17925 (white),
or 17875 (ultra-light gray)
Hardness (ASTM D 2240: Shore D) 80
Adhesion to Epoxy Mortar (ASTM D 4541) 2.75 MPa
Table Id - Grout Coat
Test Minimum Requirement
(maximum where indicated)
-------------------------------------------------------------------
Resin System (ASTM D 2621) Epoxy Polyamine (two-pack)
Percent Volume Solids (ASTM D 2697) 100%
Color 17925 (white),
or 17875 (ultra-light gray)
Hardness (ASTM D 2240: Shore D) 80
Adhesion to Epoxy Mortar (ASTM D 4541) 400 psi
Table Ie - Urethane Topcoat
Test Minimum Requirement
(maximum where indicated)
-------------------------------------------------------------------
Resin System (ASTM D 2621) Aliphatic Urethane (two-pack)
Percent Volume Solids (ASTM D 2697) 51%
Topcoat Color (FED-STD-595) 17925 (white)
or 17875 (ultra-light gray)
Walkway Strip Color: Red/Orange, 22197 (red/orange)
semi-gloss (FED-STD-595)
Application Thickness per Coat 62.5 - 80 microns
Dry Film Thickness(DFT)
Hiding Power: Red/Orange Complete hiding of white coatings
at 80 microns DFT
(one coat)
Sunlight Resistance Non-yellowing
Heat Resistance, continuous exposure 600C
Heat Resistance, intermittent exposure 93.30C
Chemical Resistance to JP-8+100 Fuel 48 hours immersion:
@210C (ASTM D 1308) 1.0% (max) weight increase
(see note 1) 1.0% (max) volume increase
1.0% (max) weight loss
Chemical Resistance to Motor Oils 48 hour immersion:
@210C (ASTM D 1308) 1.0% (max) weight increase
(see note 1) 1.0% (max) volume increase
1.0% (max) weight loss
Chemical Resistance to Skydrols 48 hours immersion:
@210C (ASTM D 1308) 1.0% (max) weight increase
(see note 1) 1.0% (max) volume increase
1.0% (max) weight loss
NOTES:
(1) Immediately following immersion, in addition to the listed requirements, evaluate urethane topcoat for blisters,
checks, discoloration, softening, and lifting. Urethane topcoat shall be visually free of blisters, checks, and
discoloration, and display adhesion no less than 2.4 MPa (ASTM D 4541).
Table Ie - Urethane Topcoat
Test Minimum Requirement
(maximum where indicated)
-------------------------------------------------------------------
Resin System (ASTM D 2621) Aliphatic Urethane (two-pack)
Percent Volume Solids (ASTM D 2697) 51%
Topcoat Color (FED-STD-595) 17925 (white)
or 17875 (ultra-light gray)
Walkway Strip Color: Red/Orange, 22197 (red/orange)
semi-gloss (FED-STD-595)
Application Thickness per Coat 2.5 - 3.5 mils
Dry Film Thickness(DFT)
Hiding Power: Red/Orange Complete hiding of white coatings
at 3.2 mils DFT
(one coat)
Sunlight Resistance Non-yellowing
Heat Resistance, continuous exposure 1400F
Heat Resistance, intermittent exposure 2000F
Chemical Resistance to JP-8+100 Fuel 48 hours immersion:
@ 700F (ASTM D 1308) 1.0% (max) weight increase
(see note 1) 1.0% (max) volume increase
1.0% (max) weight loss
Chemical Resistance to Motor Oils 48 hour immersion:
@ 700F (ASTM D 1308) 1.0% (max) weight increase
(see note 1) 1.0% (max) volume increase
1.0% (max) weight loss
Chemical Resistance to Skydrols 48 hours immersion:
@ 700F (ASTM D 1308) 1.0% (max) weight increase
(see note 1) 1.0% (max) volume increase
1.0% (max) weight loss
NOTES:
(1) Immediately following immersion, in addition to the listed requirements, evaluate urethane topcoat for blisters,
checks, discoloration, softening, and lifting. Urethane topcoat shall be visually free of blisters, checks, and
discoloration, and display adhesion no less than 350 psi
(ASTM D 4541).
TABLE II
PREAPPOROVED MATERIALS*
Vendors Materials
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Stonhard Primer: Standard Primer
(856) 779-7500 Epoxy Mortar: Stonclad GS
Grout Coat: Stonkote GS4
Topcoat: Stonseal GS6
Sealant: Vulkem 245
Polyspec Primer: 300EX
(281) 397-0033 Epoxy Mortar: Tuffrez 200
Grout Coat: Tuffrez 203
Topcoat: Tuffrez 235
Sealant: T-2235SL
Tennant Primer: Eco-MPE )
(800) 553-8033 Mortar Coat: Eco-PT 250
Grout Coat: Eco-PT
Topcoat: VOC-CRU
Sealant: N/A **
Crawford Labs Primer: Florock 4700
(800) 356-7625 Epoxy Mortar: Florock 4700
Grout Coat: Florock 4700
Topcoat: Florock Super CRU
Sealant: N/A **
General Polymers Primer: #3578, Universal Primer
(800) 543-7694 Epoxy Coat: #3562, Mortar Binder Resin
Grout Coat: #3744GP, Novo-Flo
Topcoat: #4618, Polyurethane Enamel
Sealant: Cor-Seal PS
NOTES:
* Other products may meet specification requirements. Up to specification's date of issue, preapproved materials
met specification requirements. It is the users' responsibility to confirm preapproved material formulations have
not changed and specification requirements will be met. **Polyspec T-2235SL sealant may be used.
APPENDIX A
INSTRUCTIONS FOR MODIFYING SECTION 01 45 02 NAVFAC
QUALITY CONTROL to add NACE INSPECTOR.
Modify Section 01 45 02 NAVFAC
QUALITY CONTROL to include NACE Coating Inspector as follows:
1. In the Article entitled "Submittals," add submittal requirement "SD-07 Certificates,"
add "NACE Coating Inspector; G" and add the following paragraph below the addition
of "NACE Coating Inspector; G."
Submit documentation confirming each coating inspector is classified no less
than "Intermediate" Coating Inspector under the National Association of Corrosion
Engineers (NACE) Coating Inspector Program (NACE CIP). Include successfully
completed, as a minimum, "Session III" of NACE CIP. Include NACE Coating Inspector
identification number, date of qualification, expiration date, and copy of "Session
III" certificate or copy of "NACE Certified" certificate. The NACE Coating
Inspector shall work directly for the prime construction contractor as part
of the prime's Quality Control (QC) Organization. Automatically disqualify
NACE Coating Inspectors with prior and/or current business relations to job
site subcontractors, material suppliers, and equipment suppliers. Submit documentation
confirming NACE Coating Inspectors have met the aforementioned requirements
over the past two years.
2. Add the following to the table in the Article entitled "QC Specialists Duties
and Qualification:"
under the heading "Qualification/Experience in Area of Responsibility, add "NACE
Coating Inspector;" under the heading "Area of Responsibility," add "Surface
preparation, flooring system installation, field tests, and field inspection;"
and under the heading "Frequency" add "Full-time during surface preparation,
flooring system installation, field tests, and field inspection."
3. Use NACE Coating Inspector on all flooring projects or, as a minimum, on
flooring projects with greater than 232.25 square meters 2,500 square feet.