standard specification for producing a skid-resistant surface on concrete by the use of a multi-component epoxy s

Standard Specification for Producing a Skid-Resistant Surface on Concrete by the Use of a Multi-Component Epoxy System ( ACI 503.3-92,reapproved 1997, 2003 )* Reported by ACI Committee 503 R.W. Gaul Chairman Russell H. Brink George Horeczko Harold C. Klassen Joseph A. McElroy Committee voting on the 1992 revisions: Raymond J. Schutz Chairman Milton D. Anderson Roger W. Black John P. Cook Floyd E. Dimmick Wolfgang E. Eisenhut Jack J. Fontana Robert W. Gaul Paul R. Hollenbach Leonard J. Mitchell Myles A. Murray Leonard Pepper David P. Hu T. Michael Jackson Troy D. Madeley Albert Mayer Joseph A. McElroy Paul F. McHale Peter Mendis This specification describes rhe work of producing a skid-resistant surface on hardened concrete by the application of a multi-component epoxy adhesive such as defined for this purpose in ASTM C 881. It includes controls for adhesive labeling, storage, handling, mixing nnd application, surface evaluation and preparation as well as inspectron nnd quality control. In addition, it describes an aggregate to be used with the coating. Keywords: aggregates; coatings; concrete pavements; epoxy resins; hardened concrete; quality control; skid resistance; specifications; standards. FOREWORD This foreword is included for explanatory purposes only; it does not form a part of Standard Specification ACI 503.3. ACI Committee Reports, Guides, Standard Practices, and Commentaries are intended for guidance in designing, plan- ning, executing, or inspecting construction and in preparing specifications. References to these documents shall not be made in the Project Documents. If items found in these documents are desired to be a part of the Project Docu- ments, they should be phrased in mandatory language and incorporated into the Project Documents. George Selden Secretary G.M. Scales Raymond J. Schutz George W. Whitesides Myles A. Murray Secretary Richard Montani Joseph M. Plecnik Hamid Saadatmanesh W. Glenn Smoak Joe Solomon Michael M. Sprinkel Douglas G. Walters Standard Specification 503.3 is a reference standard which the Architect/Engineer may cite in the project spe- cification(s) for any building project, together with sup- plementary requirements for the specific project. This specification is written in the section and three-part format of the Construction Specifications Institute, but with the numbering system modified to ACI requirements. The language is generally imperative and terse. A specification guide and checklist are included as a preface to, but not forming a part of, Standard Specification ACI 503.3. The purpose of this guide is to assist the Archi- tect/Engineers designer(s) and specifier(s) to properly choose and specify the necessary supplementary require- ments for the project specification(s). * Adopted as a standard of the American Concrete Institute effective June 1979, i n accordance with the Institute’s standardization procedure. It was revised according to the expedited procedure effective March 1992. Copyright @ 1978 American Concrete Institute. All rights reserved including rights of reproduction and use in any form or by any means. including the making of copies by any photo process, or by any elec- Ironic or mechanical device. printed or written or oral, or recording for sound or visual reproduction or for use in any knowledge or retrieval system or device. unless permission in writing is obtained from the copyright proprietors. 503.3-I 503.3-2 ACI STANDARD Specification guide, pg. 503.3-2 Specification checklist, pg. 503.3-2 Section l-General requirements, pg. 503.3-4 l.l-Scope 1.2-Notation 1.3-Specification wording 1.4-Reference standards Section 2-Materials and application, pg. 503.3-4 Part 2.1-Genera1, pg. 503.3-4 2.1.1-Description 2.1.2-Submittals 2.1.3-Quality assurance 2.1.4-Delivery, storage, and handling 2.1.5-Project conditions Part 2.2-Products, pg. 503.3-5 2.2. l-Epoxy coating 2.2.2-Skid-resistant aggregate Part 2.3-Execution, pg. 503.3-5 2.3.1-Preparation of surfaces 2.3.2-Inspection of surface prior to coating application 2.3.3-Coating mixes 2.3.4-Coating application 2.3.5-Field quality control 2.3.6-Cleanup 2.3.7-Safety SPECIFICATION GUIDE SGl-Standard Specification ACI 503.3 is intended to be used essentially in its entirety, by citation in the project specification, to cover all usual requirements for producing a skid-resistant surface on concrete by the ap- plication of a multi-component epoxy system. Individual sections, parts, and articles should not be copied into project specifications since taking them out of context may change their meanings. SG2-However, adjustments to the needs of a parti- cular project shall be made by the Architect/Engineer’s designers and specifiers by reviewing each of the items indicated in this specification guide and checklist and then including their decisions on each as mandatory re- quirements in the project specification. SG3-These mandatory requirements shall designate specific qualities, procedures, materials, and performance criteria for which alternatives are permitted or for which provision is not made in Standard Specification ACI 503.3. Or exceptions shall be taken to Standard Spe- cification ACI 503.3 if required. SG4 - A statement such as the following will serve to make Standard Specification ACI 503.3 an official part of the contract requirements: The producing of an epoxy system skid-resistant sur- face on concrete shall conform to all requirements of “Standard Specification for Producing a Skid-Resistant Surface on Concrete by the Use of a Multi-Com- ponent Epoxy System (ACI 503.3),” published by the American Concrete Institute, Detroit, Mich., except as modified by the requirements of this project speci- fication. SG5-The specification checklist that follows is ad- dressed to each item of ACI 503.3 that requires the designer/specifier to make a choice where alternates are indicated, or to add provisions where they are not in- dicated in ACI 503.3, or to take exceptions to ACI 503.3. The checklist consists of section, part, and article heads of ACI 503.3, with accompanying notes to the designer/ specifier to indicate the action required of them. SPECIFICATION CHECKLIST Section/Part/Article of ACI 503.3 I Notes to the Designer/Specifier Section l-General requirements 1.1 Scope 1.4 Reference standards Section 2-Materials and application Indicate specific scope. Review applicability of cited references and take excep- tions if required. EPOXY RESINS 503.3-3 SPECIFICATION CHECKLIST (cont.) Section/Part/Article of ACI 503.3 Notes to the Designer/Specifier 2.1.2 Submittals 2.1.3.2 Application control 2.1.4.2 Storage of materials 2.1.5.1 Environmental requirements 2.2.2 Skid-resistant aggregate 2.2.2.2 Weight loss of aggregate 2.2.2.3 Aggregate moisture content 2.3.2.2 Pullout strength test 2.3.2.4 Concrete surface To whom sent? Mixing and application procedures submitted must be in accordance with product manufacturer’s instructions. Storing epoxy compounds at other than specified tem- perature range may result in degradation of the product. If such storage takes place, manufacturer should be contacted before product is used. Performance of epoxy systems may be affected by tem- perature, humidity, and surface water. Strict adherence to the manufacturer’s recommendations should be maintained. Where other unusual conditions are en- countered, the material manufacturer should be con- sulted before application. The aggregate described in this section will provide a suitable nonskid surface for vehicular traffic. For sur- faces limited to pedestrian traffic only, the designer may desire to choose a less coarse aggregate grada- tion. The preparation and inspection of a small sample using the proposed aggregate and coating at their pro- posed rate of application prior to publication of a spe- cification will enable the designer to anticipate the ap- pearance and texture of the surface. Suitable aggregates meeting these specifications are generally a heterogeneous combination of minerals with a coarse grained microstructure of hard particles cemented by a slightly softer matrix. Examples are cor- undum-rich materials employed by the grinding wheel industry such as calcined bauxite and emery; well- cemented sandstones and certain metamorphised sand- stone such as metagreywacke. The test method specifies the bonding of a steel pipe cap to the concrete surface with an epoxy adhesive. If the test results not in failure of the concrete but in cohesion of the epoxy resin adhesive or any failure in adhesion, the test shall be repeated. Repeated failures in adhesion, or cohesion in the adhesive, indicate im- proper cleaning of the concrete, incorrect adhesive, or faulty adhesive application techniques. When concrete surface is not dry, materials manu- facturer should be consulted regarding suitability of system and adequacy of application techniques. Some epoxy adhesives may be capable of wetting the con- crete surface at temperatures below 40 F. The speci- fication should allow such use only if test data is available which conclusively demonstrates adequate bond at the actual concrete temperature expected. 503.3-4 ACI STANDARD SPECIFICATION CHECKLIST (cont.) Section/Part/Article of ACI 503.3 Notes to the Designer/Specifier 2.3.4.1 Coating application 2.3.4.2 Aggregate application 2.3.5 Field quality control SECTION l-GENERAL REQUIREMENTS l.l-Scope 1.1.1 This standard specification covers the producing of a skid-resistant surface on hardened concrete by the application of a multi-component epoxy coating system. 1.1.2 The provisions of this standard specification shall govern unless otherwise specified in the contract docu- ments. In case of conflicting requirements, the contract documents shall govern. 1.2-Notation 1.2.1 ACI: American Concrete Institute P.O. Box 19150 Detroit, MI 48219 1.2.2 ASTM: American Society for Testing and Materials 1916 Race Street Philadelphia, PA 19103 1.3-Specification wording 13.1 The language of this standard specification is generally imperative and terse, and may include incom- plete sentences. Omissions of phrases and of words such as “the contractor shall,” “in accordance with,” “shall be,” “as indicated,” “a,”“an, ” “the,” “all,” etc., are intentional. Omitted phrases and words shall be supplied by in- ference. 1.4-Reference standards This rate of coating application is suitable for the aggregate gradation specified in Article 2.2.2.1 and ag- gregate rate of application specified in Article 2.3.4.2. If either of these is changed the coating application rate may have to be adjusted. A sample should be pre- pared to evaluate the resulting surface, This rate of aggregate application is suitable for the aggregate gradation specified in Article 2.2.2.1 and coating rate of application specified in Article 2.3.4.1. If either of these is changed the aggregate application rate may have to be adjusted and a sample should be prepared to evaluate the resulting surface. Satisfactory performance using this test assures that the skid-resistant aggregate is adequately bonded to the epoxy adhesive coating and that the coating is adequately bonded to the concrete. Care must be taken when bonding the pipe cap to the skid resistant surface with epoxy adhesive that all voids are filled with adhesive. 1.4.1 The standards referred to in this Standard Speci- fication ACI 503.3 are listed in Article 1.4.2 of this sec- tion, with their complete designation and title including the year of adoption or revision and are declared to be a part of this Standard Specification ACI 503.3 the same as if fully set forth herein, unless otherwise indicated in the contract documents. 1.4.2 ASTM standards C 131-81 Standard Test Method for Resistance to De- (Reap- gradation of Small-Size Coarse Aggregate by proved Abrasion and Impact in the Los Angeles 1987) Machine C 136-84a Standard Method for Sieve Analysis of Fine and Coarse Aggregates C 566-84 Standard Test Method for Total Moisture Content of Aggregate by Drying C 881-87 StandardSpecificationforEpoxy-Resin-Base Bonding Systems for Concrete SECTION 2-MATERIALS AND APPLICATION Part 2.1-General 2.1.1 Description-This section covers the require- ments for materials and application of the multi- component epoxy coating system. 2.1.2 Submittals 2.1.2.1 Contractor shall submit manufacturer’s certification verifying performance to material spe- EPOXY RESINS 503.3-5 cifications specified in Part 2.2. 2.1.3 Quality assurance 2.1.3.1 Labeling-Clearly mark all containers with the following information: a) Name of manufacturer b) Manufacturer’s product identification C) Manufacturer’s instructions for mixing d) Warning for handling and toxicity 2.1.3.2 Application control-Submit mixing and ap- plication procedures for approval prior to use. 2.1.4 Product delivery, storage, and handling 2.1.4.1 Delivery of materials-Deliver all materials in sealed containers with labels legible and intact. 2.1.4.2 Storage of materials Store all materials at temperatures between 40-100 F (5-38 C) unless otherwise recommended by manufacturer. 2.1.4.3 Handling of materials-Handle all materials in a safe manner and in a way to avoid breaking con- tainer seals. 2.1.5 Project conditions 2.1.5.1 Environmental requirements-Contractor shall comply with manufacturer’s recommendations as to environmental conditions under which the epoxy com- pound may be applied. Part 2.2-Products 2.2.1 Epoxy coating-ASTM C 881. Curing temper- ature requirements (Class) and viscosity (Grade) shall be determined by supplier and contractor and approved by architect/engineer after project conditions have been established. 2.2.2 Skid-resistant aggregate 2.2.2.1 Aggregate shall meet the following gradation when tested in accordance with ASTM C 136: Sieve size Y4 100 6 97-100 8 55-75 16 0-3 Percent passing 2.2.2.2 When tested in accordance with ASTM C 131, aggregate shall have a maximum weight loss of 20 percent at 500 revolutions. 2.2.2.3 Moisture content of the aggregate shall not exceed 0.15 percent when tested in accordance with ASTM C 566, Standard Test Method for Total Moisture Content of Aggregate by Drying. Part 2.3-Execution 2.3.1 Preparation of surfaces 2.3.1.1 Concrete surfaces to which epoxies are to be applied shall be newly exposed parent concrete free of loose and unsound materials. Prepare surfaces by mech- anical abrasion. 2.3.1.2 Mechanical abrasion-Use sandblasting, scarifying, waterblasting, or other approved means. 2.3.2 Inspection of surface prior to coating application 2.3.2.1 Inspect all concrete surfaces prior to ap- plication of coating to insure that requirements of this Article 2.3.2 are met. 2.3.2.2 Surfaces shall be sound concrete which exhibits a minimum 100 psi pullout strength when tested in accordance with Appendix A “Use of Epoxy Com- pounds with Concrete,” reported by ACI Committee 503. 2.3.2.3 Surface shall be free of any deleterious materials such as laitance, curing compounds, dust, dirt, and oil, and materials resulting from surface preparation, as specified in Article 2.3.1, shall be removed. 2.3.2.4 All concrete surfaces shall be dry as defined in Article 2.3.2.5 below unless a water-insensitive coating is used. Surface temperature shall be at least 40 F to permit wetting of concrete surface by epoxy coating. 2.3.2.5 Evaluate moisture content for concrete by determining if moisture will collect at bond lines between old concrete and epoxy coating before epoxy has cured. This may be accomplished by taping a 4 x 4 ft poly- ethylene sheet to concrete surface. If moisture collects on underside of polyethylene sheet before epoxy would cure, then allow concrete to dry sufficiently to prevent the possibility of moisture between old concrete and new epoxy. 2.3.3 Coating mixes 2.3.3.1 Mix epoxy components in a clear container free of harmful residue or foreign particles. 2.3.3.2 Condition epoxy compound components to be at a temperature between 60-100 F (16-38 C), unless otherwise recommended by manufacturer. 2.3.3.3 Thoroughly blend epoxy components with a mechanical mixer to a uniform and homogeneous mix- ture. Mix small batches (up to 1 qt) by use of spatulas, palette knives, or similar devices. 2.3.4 Coating application 2.3.4.1 Apply epbxy coating to concrete surface by brush, roller, broom, squeegee, or spray equipment. Ap- ply epoxy compound at a uniform thickness of 60 + 10 mils. 2.3.4.2 Apply skid-resistant aggregate while coating is still fluid at the rate of 12 + 1 lb&d 2.3.5 Field quality control-The inspector shall deter- mine that coating and skid-resistant aggregate are applied at a rate at least equal to that specified and that ag- gregate and coating are securely bonded. The pullout strength of the cured skid-resistant surface to the con- crete shall be a minimum 100 psi when tested in accor- dance with Appendix A of “Use of Epoxy Compounds with Concrete,” reported by ACI Committee 503. The failure shall be cohesive within the concrete. There shall be no failures in adhesion. 2.3.6 Cleanup 503.3-6 ACI STANDARD 2.3.6.1 Protect concrete surfaces, beyond limits of 2.3.7 Safety-Epoxy materials are skin irritants or surface receiving coating, against spillage. sensitizers to many people. Accordingly, advise appli- 2.3.6.2 Immediately remove any epoxy compound caors to avoid contact with eyes and skin, inhalation of applied or spilled beyond desired areas. Perform cleanup vapors and ingestion. Make protective and safety equip- with material designated by epoxy coating manufacturer. ment available on site. Heed all label warnings by manu- Avoid contamination of work area. facturer. . epoxy system skid-resistant sur- face on concrete shall conform to all requirements of Standard Specification for Producing a Skid-Resistant Surface on Concrete by the Use of a Multi-Com- ponent. This standard specification covers the producing of a skid-resistant surface on hardened concrete by the application of a multi-component epoxy coating system. 1.1.2 The provisions of this standard. evaluate the resulting surface. Satisfactory performance using this test assures that the skid-resistant aggregate is adequately bonded to the epoxy adhesive coating and that the coating is adequately