Section 03055 EPOXY BONDING REINFORCING BARS AND RODS IN CONCRETE

Section 03055

EPOXY BONDING REINFORCING BARS AND RODS IN CONCRETE

PART 1 - GENERAL

1.1 THE REQUIREMENT

A. The CONTRACTOR furnish all materials for bonding reinforcing bars and all thread rods in concrete using epoxy adhesive, in accordance with the provisions of the Contract Documents.

1.2 RELATED WORK SPECIFIED ELSEWHERE A. Section 03200, Reinforcement Steel

B. Section 03300, Cast-in-Place Concrete

C. Section 05120, Structural Steel

1.3 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. American National Standards Institute (ANSI):

Standard B212.15 Carbide Tipped Masonry Drills and Blanks for Carbide

Tipped Masonry Drills

B. American Society for Testing and Materials (ASTM):

C 881 Specification for Epoxy-Resin-Base Bonding Systems for

Concrete

C. Steel Structures Painting Council (SSPC):

SP-10 Near-White Blast Cleaning

1.4 SUBMITTALS

A. Product Data: Furnish technical data for epoxy adhesives, including installation instructions, independent laboratory results, and handling and storage instructions.

B. Quality Control Submittals:

1. Manufacturer’s past project experience data on at least 3 similar projects supplied with proposed products within the last 3 years.

2. Batch test reports for each batch of product delivered to site. Provide manufacturer’s written certification that each batch delivered meets these Specifications, the intended uses on project, including capability to bond to damp concrete surfaces. Certification shall include batch test results for each product.

3. Manufacturer’s written letter of certification identifying CONTRACTOR’s employees qualified for operation of manufacturer’s equipment and certified for installation of products, trained through jobsite instruction conducted by manufacturer.

4. Copy of manufacturer’s equipment service and repair manuals for each type of equipment delivered to project site.

5. Special Inspection: Provide detailed step-by-step instructions for the special inspection procedure, as required by International Building Code.

1.5 DELIVERY, STORAGE AND HANDLING A. Storage of Epoxy Components:

1. Store epoxy components on pallets or shelving in a covered-storage area.

2. Control temperature above 60 degrees F and dispose of product if shelf life has expired.

3. If stored at temperatures below 60 degrees F, test components prior to use to determine if they still meet specified requirements.

PART 2 - PRODUCTS

2.1 GENERAL

A. Like Items of Materials: Use end products of one manufacturer in order to achieve structural compatibility and singular responsibility.

2.2 EPOXY ADHESIVE FOR SELF-CONTAINED CARTRIDGE SYTEM

A. Meet ASTM C 881, Type IV, Grade 3, Class B or C depending on site conditions. B. Two-component, 100 percent solids, insensitive to moisture, and gray in color.

C. Cure Temperature, Pot Life, and W orkability: Compatible for intended use and environmental conditions.

D. Container Markings: Include manufacturer’s name, product name, batch number, mix ratio by volume, product expiration date, ANSI hazard classification, and appropriate ANSI handling precautions.

E. Manufacturer’s: One of the following, Or Equal:

1. Simpson Anchor Systems, Dublin, CA, SET Epoxy-Tie Anchoring Adhesive.

2. Hilti, Tulsa, OK, HSE 2421 High Strength Epoxy Doweling System.

2.3 EPOXY ADHESIVE FOR METER AND MIXING PUMP SYSTEM

A. Meet ASTM C 881, Type IV, Grade 3, Class B or C depending on site conditions. B. Two-component, 100 percent solids, insensitive to moisture, and gray in color.

C. Cure Temperature, Pot Life, and W orkability: Compatible for intended use and environmental conditions.

D. Container Markings: Include manufacturer’s name, product name, batch number, mix ratio by volume, product expiration date, ANSI hazard classification, and appropriate ANSI handling precautions.

E. Manufacturers: One of the following, Or Equal:

1. Sika, Santa Fe Springs, CA, Sikadur 31, Hi-Mod Gel., Euclid Chemical Company, Cleveland, OH.

2.4 ALL THREAD BARS

A. As specified in Section 05120, Structural Steel.

2.5. REINFORCING BARS

A. As specified in Section 03200, Reinforcement Steel.

PART 3 - EXECUTION

3.1 GENERAL

A. Dispensing, Metering, or Mixing Epoxy Adhesive Components: Use portable, automatic metering and mixing device or machine capable of maintaining prescribed mix ratio within deviation of 5 percent or less, by volume.

B. Dispense epoxy components through specially designed static mixing nozzle that thoroughly mixes epoxy components and places mixed epoxy at base of predrilled hole.

C. Mixing Nozzles: Disposable and manufactured in several sizes to accommodate different size and depth of holes.

D. Where large meter and mixing pumps are impractical, provide epoxy adhesive packaged, as follows:

1. Disposable, self-contained cartridge system capable of dispensing both epoxy components in the proper mixing ratio, and fit into a manually or pneumatically operated caulking gun.

2. Dispense components through a mixing nozzle that thoroughly mixes components.

3.2 TESTING OF AUTOMATIC METERING AND MIXING PUMP SYSTEMS A. Tests for Proper Ratio:

1. Retain small amount of dispensed adhesive for inspection after each time the pump is refilled.

2. Operator shall check these samples for color change.

3. Should change in color occur, operator shall follow manufacturer’s service instructions to obtain proper operation.

B. Frequency of Tests: Make full ration check after each 100 gallons of adhesive is dispensed or if color of mixed adhesive becomes noticeably darker or lighter.

C. Ratio Check Procedure:

1. Disconnect dispensing head behind ON/OFF valve.

2. Place a 1 cup volume container and a 2-cup volume container under the “B” and

“A” component hose ends.

3. Actuate the pump until both cups are filled to proper proportion as recommended by epoxy manufacturer.

3.3 HOLE SIZE AND INSTALLATION A. Drilling Holes:

1. Do not damage or cut existing reinforcing bars, electrical conduits, or other items embedded in the existing concrete without acceptance by ENGINEER.

2. The location of reinforcing bars or other obstructions shall be determined with a non-destructive indicator device.

B. Hole Drilling Equipment:

1. Electric or pneumatic rotary impact type with medium or light impact.

2. Drill Bits: Carbide-tipped in accordance with ANSI B212-15.

3. Hollow drills with flushing air systems are preferred. Air shall be free of oil, water, or other contaminants, which will reduce bond.

4. Where edge distances are less than 2 inches, use lighter impact equipment to prevent microcracking and concrete spalling during drilling process.

C. Hole Diameter:

1. Reinforcing bar diameter or all thread rod diameter plus 1/8 inch. D. Obstructions in Drill Path:

1. If the drill hits an existing reinforcing bar or other obstruction, stop drilling and fill the hole with drypack mortar. Relocate the hole to miss the obstruction and drill another hole. Repeat the above until the hole has been drilled to the required depth.

2. Avoid drilling an excessive number of holes in an area which would excessively weaken the structural member being drilled and endanger the stability of the structure. When required, drypack holes which hit obstructions and allow drypack to reach strength equal to the existing concrete being drilled before drilling adjacent holes. Epoxy grout may be substituted for drypack when acceptable to ENGINEER.

3. When existing reinforcing steel is encountered during drilling and when acceptable to ENGINEER, enlarge the hole by 1/8 inch, core through the existing reinforcing steel at the larger diameter, and resume drilling at original hole diameter.

4. Bent Bar Dowels: Where edge distances are critical, and striking reinforcing steel is likely, and if acceptable to the ENGINEER, drill hole at 10 degree angle or less from axis of reinforcing bar or all thread and rod being installed.

E. Install reinforcing bars and all thread rods to depth, spacings, and locations as indicated on the Drawings.

F. Cleaning Holes:

1. Insert long air nozzle into hole and blow out loose dust. Use air which is free of oil, water, or other contaminants which will reduce bond.

2. Use a stiff bristle brush to vigorously brush hole to dislodge compacted drilling dust.

3. Repeat step 1.

4. Repeat above steps as required to remove drilling dust or other material which will reduce bond. The hole shall be clean and dry.

G. Cleaning Reinforcing Bars and All Thread Rods:

1. Degrease and sandblast reinforcing bars or all thread rods over embedment length to near-white metal in accordance with Steel Structures Painting Council, SP-

10 finish. The reinforcing bar or all thread rod shall be free of oil, grease, paint, dirt, mill scale, rust, or other coatings that will reduce bond.

H. Filling Hole with Epoxy:

1. Fill the hole with epoxy before inserting the reinforcing bar or all thread rod. Fill hole with epoxy starting from back of the hole. Fill hole without creating air voids.

2. Fill the hole with sufficient epoxy so that excess epoxy is extruded out of the hole when the reinforcing bar or all thread rod is inserted into the hole.

3. Do not install prior to receiving epoxy manufacturer’s onsite training.

3.4 TESTING INSTALLED BARS AND RODS

A. A minimum of 10 percent of the bars and rods installed each day shall be tested to the allowable tension specified in the ICC report for the anchor system. Interpolations shall be made for embedment depth, concrete strength, and steel strength as described in the relevant ICBO report.

B. If any installed anchor fails the test, all anchors installed that day shall be tested.

3.5 MANUFACTURERS’ SERVICES

A. Furnish manufacturer’s representative to conduct jobsite training for proper installation, handling, and storage of epoxy, for personnel who will perform actual installation. ENGINEER may attend training sessions.