extremeconcrete®
December 2016
Merge Design Company
3001-105 Spring Forest Road
Raleigh, NC 27616
Phone(919) 800-7970
Website
Product Guide Specification
Specifier Notes: This product guide specification is written according to the Construction Specifications Institute (CSI) 3-Part Format,including MasterFormat, SectionFormat, and PageFormat,as described in The Project Resource Manual—CSI Manual of Practice, Fifth Edition.
The section must be carefully reviewed and edited by the Architect to meet the requirements of the project and local building code. Coordinate this section with other specification sections and the Drawings. Delete all “Specifier Notes” after editing this section.
Section numbers are from MasterFormat 2016Edition.
Specifier Notes: This section coversMerge Design products. ConsultMerge Design for assistance in editing this section for the specific application.
SECTION 12 36 13 - CONCRETE COUNTERTOPS
PART 1 GENERAL
1.1 SUMMARY
A. This Section includes eco-sensitive concrete surfacing for the following applications:
1. Countertops
2. Transaction tops
3. Reception areas
4. Bathroom vanities
5. Tabletops
6. Conference tables
7. Other interior applications as shown on drawings
Related Sections
1. Section 05500 - Metal Fabrications: Blocking
2. Section 06100 - Rough Carpentry: Blocking
3. Section 06200 - Finish Carpentry: Plywood substrate
4. Section 06410 - Custom Cabinets: Casework substrate
5. Section 07900 - Joint Sealers: Joint sealant and backing materials
6. Section 11450 - Residential Equipment: Cooktops
7. Section 15410 - Plumbing Fixtures: Sinks, faucets
1.2REFERENCES
Specifier Notes: List standards referenced in this section, complete with designations and titles. This article does not require compliance with standards, but is merely a listing of those used.
A.ASTM Testing Standards:
1.ASTM C33- Specification for concrete aggregates
2. ASTM C97- Absorption and Bulk Specific Gravity of Dimensional Stone.
3. ASTM C109- Compressive Strength of Hydraulic Cement Mortars (2 inch Cube Specimens)
4.ASTM C150- Specification for Portland Cement
5. ASTM C157- Length Change of Hardened Hydraulic-Cement Mortar and Concrete
6. ASTM C293- Flexural Strength of Concrete (Simple Beam with Center-Point Loading)
7. ASTM C305- Standard Practices for mechanical mixing of hydraulic cement
8. ASTM C511- Specification for mixing room.
9. ASTM C642- Density, Absorption, and Voids in Hardened Concrete
10. ASTM C666- Resistance of Concrete to Rapid Freezing and Thawing (Procedure B)
11. ASTM C979- Specification for coloring pigments for integrated pigmented concrete
B. Others
1. NSF/ANSI 51- Food Contact.
1.3SUBMITTALS
A. Submit under provisions of Section 01300
B. Product Data: Submit manufacturer’s product data, storage and handlingrequirements and recommendations, fabrication instructions and recommendations, installation methods, care and maintenance instructions, and available colors, styles, patterns and textures.
C.Shop Drawings: Submit shop drawings, including plans and elevations, indicating overall dimensions, component sizes, edge profiles, exposed faces, arrangement of joints, cutouts, blocking/support structure and annotation of finished eco-sensitive concrete products/surfaces and their location.
D.Samples: Submit manufacturer’s samples of materials, finishes, and colors. Sample will be representative of the general range of variations in appearance characteristics (i.e. color, texture, porosity, aggregate distribution and finish).
E. Warranty: Manufacturer’s standard warranty.
F. Manufacturer Certificates:
1. Compliance Certificate: Signed by manufacturer indicating compliance with specified
performance requirements.
- Food contact certification: Certify that materials meet NSF/ANSI 51 Food Contact.
G. LEED Submittals: Submit the following for LEED Projects;
1. Credit IEQ 4.1: Low-emitting materials: Adhesives & Sealants
2. Credit ID Innovation in Design: Recycled content 30% or greater
3. Credit MR 4.1: Recycled Content: 10%
4. Credit MR 4.2: Recycled Content: 20%
5. Credit MR 5.1: Regional Materials: 20% manufactured regionally
6. Credit MR 5.2: Regional Materials: 10% extracted and manufactured regionally
H. Closeout Submittals:
1. Manufacturer’s standard warranty.
2. Manufacturer’s Care and Maintenance document.
1.4QUALITY ASSURANCE
A.Manufacturer’s Qualifications: Manufacturer regularly engaged in manufacture of eco-sensitive concrete products since 1999.
B.Product Support: Products are supported with complete technical documents and design patents.
C.Base Worth: An installed base of products worth in excess of thirty million dollars.
D.Production: Orders are filled within a 60-day schedule.
E.Facility Operator: ISFA certified fabricators.
1.5DELIVERY, STORAGE, AND HANDLING
A.Delivery: Handle and transport precast eco-sensitive concrete surfaces in position consistent with their shape and design and to prevent chipping, breakage, soiling or other damage. Consult with manufacturer for recommended handling procedures.
B.Storage:
1.Thoroughly inspect all slabs prior to storage.Store all units face to face and back to back off ground and in a manner to prevent cracking, distortion, warping, staining or other physical damage.
2.Store all units in a clean, dry and room temperature area. Units should not be stored in direct sunlight or exposed to intense freeze/thaw conditions.
3.Provide protective coverings to prevent physical damage or staining immediately following installation for the duration of project.
C.Handling: Protect materials and finish during handling and installation to prevent damage.
1.6PROJECT CONDITIONS
A.Maintain environmental conditions (temperature, humidity and ventilation) within limits recommended by manufacturer and reference standards for optimum results from commencement of installation to final use.
B.Field verified dimensions or templates of supporting structures and other adjacent elements should be forwarded to manufacturer prior to commencement of manufacturing.
1.7WARRANTY
A.Provide Manufacturer’s Limited Lifetime Warranty.
Warranty Information includes but not limited to:
-Products will be free from manufacturing defects for the life of the product from the date of invoice.
-The warranty is non-transferable and does not apply to damage resulting from accident, heat alteration, misuse, tampering, negligence, or abuse.
- Merge Design shall, at its option, repair, replace, or refund the purchase price of any items found defective upon inspection by an authorized Merge Design service representative.
-Purchasers should be aware that normal use of these high quality products can result in superficial damage affecting the finish. Scratches, nicks, staining, hairline cracking, warping and dents are to be considered normal wear and tear, and are not the responsibility of the manufacturer.
-See Manufacturer’s standard warranty for complete warranty information.
PART 2PRODUCTS
2.1MANUFACTURERS
A.Approved Manufacturer: Merge Design Co., 3001-105 Spring Forest Road, Raleigh, NC 27616. Phone (919) 800-7970. Website: E-mail: .
2.2MATERIAL
A.Approved Product: extremeconcrete® as manufactured by Merge Design Co.
B.Size and weight:
1.Slab Size:
a.Standard slabs are:108 incheslong x 60 inches wide x 3 centimeters thick (nominal)
b.Custom size: ______
2. Slab Weight is approximately 14 pounds per square foot at 3 centimeters thick.
C.extremeconcrete®Materials:
1.monochrome™
2.Xposed™
3.eco-X™
4.micro™
5.Custom______
Specifier Notes: Consult Merge Design for selection of standard colors and finishes as well as availability of custom colors and finishes (non-standard finishes include Sandblasted, Mold-Finished, Wood Grain, Tekstur™, Custom) .
D. Color:
1. Provide color(s) ______
E.Composition:
1.Portland cement: Type I, white and/or gray, ASTM C150
2.Fine aggregates: Recycled aggregate, ASTM C 33
3.Colors: Inorganic iron oxide pigments, ASTM C979
4.Water: Clean, fresh and potable.
F.Physical Performance Characteristics/Properties:
1.Density: 132 lbs/ft3 (~16.5 lbs/ft² at 1-1/2” thick)
2.Compressive strength: > 12,000 PSI -Conform to ASTM C109
3.Flexural Strength: >800 psi Conform to ASTM C293
4.Absorption: <0.17% (unsealed) Conform to ASTM C642
5.Freeze Thaw: <0.05% Conform to ASTM C666 (Procedure B)
6.Specific Gravity: 2.18 g/cm3 Conform to ASTM C97
7.Shrinkage: <0.061% Conform to ASTM C157
2.4RECYCLED CONTENT
pre-consumer / post-consumer / total content / recyclablemonochrome™ / 24% / 9% / 33% / 100%
Xposed™ / 41% / 9% / 50% / 100%
eco-X™ / 65% / 9% / 74% / 100%
micro™ / 65% / 9% / 74% / 100%
Custom / Up to 85% / 100%
2.5FINISHES
A.Provide color/texture as specified or match sample approved by Architect.
B.Exposed surfaces, unless otherwise specified, shall exhibit that of the approved sample.
C.Variation: All products are hand-made with recycled materials therefore variation in color, texture, porosity, aggregate distribution and finish of actual product should be expected. Slight anomalies are inherent character traits of eco-sensitive concrete surfaces and products.
2.6REINFORCING
A.Fiber reinforcing:
1.Reinforce units when necessary for safe handling and structural integrity.
2.Reinforcement shall be fibrous.
3.Area of reinforcement in unit shall be dispersed three-dimensionally, randomly throughout the eco-sensitive concrete matrix.
2.7FABRICATION
A.Fabricator: Firm shall have experience fabricating natural or engineered stone and be equipped with standard stone fabricating equipment. Firm shall read and followall of the manufacturer’s fabrication guidelines and call their manufacturer’s Representative if more information or clarification is needed.
B.Inspect Material:
1. Visually inspect slabs under similar lighting conditions as will be found at the job site to ensure that an acceptable color match is achieved.Due to the nature of concrete products and the sourcing of recycled and natural materials,differences in color, surface texture, porosity, gauge, dimensional tolerance, aggregate size & distribution, and finish will vary each and every time and are inherent valued qualities of our products. Non-structural hairline cracking may occur and handmade characteristics are to be expected.
2. For larger projects or materials that are adjacent to each other, it is highly recommended to purchase slabs from the same batch and bear labels with the same dates and color name whenever possible.
3. Record Slab ID numbers of all material for warranty purposes.
C.Shop Assembly: Fabricate using standard stone fabricating equipment in accordance with manufacturer's fabrication guidelines.
D.Layout: Fabricate components to greatest extent practical to sizes and shapes indicated, in accordance with approved shop drawings and manufacturer's fabrication guidelines.
E. Cutouts:
1. Provide factory cutouts for plumbing fittings and bath accessories as indicated on approved shop drawings.
2. All rough and finished openings shall be supported with reinforcing rods.
3. Cutouts shall have 1/4 inch minimum inside radius.
4. All exposed edges shall be honed and any/all air holes and voids should be filled with a colored matched grout or travertine fill and then polished after it has cured.
F. Aprons and Built up Edges: All visible built up edges and aprons shall be mitered to avoid the visual effect of segregation.
G. Sealing: Apply manufacturer’s recommended sealer to entire finished surface following the manufacturer’s instructions to help protect against staining.
2.8RELATED MATERIALS
A.Supports – Structural supports (wood, steel or other) to be designed by a licensed structural engineer and installed by a qualified contractor at the expense of the Owner unless otherwise noted.
B. Mounting Adhesives: Provide clear 100% silicone adhesive as recommended by manufacturer.
C. Joint Sealants: Provide Clear 100% Silicone or color matched two-part polyester, epoxy or acrylic joint adhesive as recommended by manufacturer.
D. Sealer: Provide sealer as recommended by manufacturer in Fabrication guidelines.
E. Cleaner: Provide a pH neutral cleaner as recommended by manufacturer in care and maintenance guidelines.
PART 3EXECUTION
3.1EXAMINATION
A.Verify that all substrates, supports and cabinets are smooth, clean, square, plumb and level within acceptable tolerances and are ready to receive finished concrete surfaces.
B.Notify Architect of conditions that would adversely affect installation or subsequent use.
C.Do not begin installation until unacceptable conditions are corrected.
3.2PREPARATION
A.Protect surrounding work from damage.
B.Vacuum clean surfaces and remove objects that may interfere with installation.
C.Prepare subsurface for adhesive installation.
3.3TOLERANCES
A.Units to be fabricated within a tolerance of approximate +/- 1/8”.
B.Set unit within plane of adjacent unit unless noted otherwise on the architectural drawings.
3.4INSTALLATION
A.All precast concrete surfaces shall be installed in accordance with manufacturer’s recommendations. Please follow manufacturer’s Fabrication guidelines and contact for specific installation procedures or if more information is needed.Secure surfacing to substrate using a clear 100% silicone adhesive to allow for movement and to avoid cracking.
3.5SEAMING
A.Seam size: Joints between units shall be 1/16” +/- unless noted otherwise on the architectural drawings.
B. Joint material:
1. Use a clear or pigmented siliconized latex, acrylic, urethane or two-part polyester joint sealant as required. The use of a pigmented latexor epoxy cementitious grout can also be used. Apply per manufacturer’s specifications.
2. Joint sealant may shrink therefore reapplication may be necessary following initial installation.
C. Location of joints:
1. As shown on approved shop drawings.
2.Unless otherwise shown: at areas recommended by manufacturer.
3.6SHIPPING & UNCRATING
A.All cast concrete components will be shipped to the Fabricator unless prior arrangements are made.
B.Each pallet may weigh in excess of 2000+/- lb. Cardboard packages may weigh in excess of 400 +/- lb. Arrangements should be made to unload pallets from delivery truck with a forklift or similar material handling equipment.
C.All units should be handled with care, kept vertical and carried on their ends (similar to glass).
D.Units should be kept covered and stored in a cool and temperature stable area. This allows the units to slowly acclimate to ambient temperature thus minimizing the risk of warping or curling.
3.7CLEANING
A.At completion of work, remove all dirt and blemishes from exposed surfaces using a non-abrasive, non-ammoniated and non-chlorinated cleaning solution. Warm water and soap or a neutral cleanser is recommended.
B.Do not use harsh cleaning materials or methods that could damage finish. Touch-up, repair, or replace damaged materials in a satisfactory manner.
3.8INSPECTION AND ACCEPTANCE
A.Due to the nature of concrete products and the sourcing of recycled and natural materials, the following are NOT cause for rejection:differences in color, surface texture, porosity, gauge, dimensional tolerance, aggregate size & distribution, and variations in finish. Non-structural hairline cracking may occur and handmade characteristics are to be expected.
3.9PROTECTION
A.Protect newly installed finished concrete surfaces from impact, vibration, heavy hammering, soiling (food products and chemicals) and all other damages until final acceptance.
END OF SECTION
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