Industrial Polished Concrete Floor Slabs (with shake) ME- Building Group

SECTION 033040 - INDUSTRIAL POLISHED CONCRETE FLOOR SLABS (WITH SHAKE)

PART 1 - GENERAL

1.1  RELATED DOCUMENTS

  1. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division1 Specification Sections, apply to this Section

1.2  SUMMARY

  1. This Section specifies concrete floor slab work, which includes, but not limited to:
  2. Steel fiber reinforcing.
  3. Cast-in-place concrete.
  4. Concrete slab poured and finished to be Diamond Ground and Polished
  5. Diamond Grind and Polish i.e. Polished Concrete Process applied to slab surface.
  6. Related Work Specified In Other Sections:
  7. Division 3 Section "Cast-In-Place Concrete" for basic concrete work.
  8. Division 3 Section “Architectural Concrete Floors” for office floor slabs
  9. Division 3 Section “Industrial And Polished Concrete Floor Slabs With Shake” for floor slabs with shake
  10. Division 3 Section “Elevated Industrial and Polished Concrete Floor Slabs” for elevated floor slabs
  11. Division 5 Section “Metal Fabrications” for items cast in to floor slabs.
  12. Division 7 Section “Joint Sealants” for elastomeric joint sealants in contraction and other joints in cast-in-place concrete.

1.3  SLAB DESIGN REQUIREMENTS

  1. Engineering Responsibility: Engage a qualified professional engineer to prepare or supervise the preparation of mix designs data for steel fiber reinforced concrete.
  2. Professional Engineer Qualifications: A professional engineer who is legally qualified to practice in the jurisdiction where Project is located and who has not less than ten years experience in providing engineering services for steel fiber reinforced concrete floor slabs, and who is normally engaged in this type of work. Engineering services are defined as those performed for design of industrial floor slabs-on-grade that are similar to those indicated for this Project in material, design, execution and extent.
  3. Performance design of floor slabs shall be prepared by the Contractor's engineer in accordance with the following criteria. Base Bid Design: Use stipulated design loads and furnish required fiber quantity for the most economical slab design.
  4. Minimum 28 Days Flexural Strength: 700 psi unless otherwise indicated.
  5. Minimum 28 Days Compressive Strength: 4000 psi unless otherwise indicated.
  6. Minimum Slab Thickness: 8 inches
  7. Minimum Modulus Of Subgrade Reaction: K= 100 pci
  8. Minimum Re,3 Value of 60 percent.
  9. Minimum Uniformly Distributed Loads: 1200 psf
  10. Minimum Concentrated Loads:
  11. Forklift Truck Loads:

Wheel Spacing Axle Loads Capacity

Single wheel solid tire 35”-37” 25 kips 12 kips

Single pneumatic tire 35”-37” 25 kips 12 kips

Dual wheel pneumatic tire 41”/10” 27 kips 13 kips

  1. Post Loads:

Base Plate 8”x8” Base Plate 12”x12” Spacing

Max point loads-2 loads 25 kips 25 kips 24”

Max point loads-3 loads 25 kips 25 kips 36”- 36”

Max point loads-4 loads 25 kips 27 kips 36”-24”-36”

1.4  POLISHED CONCRETE PERFORMANCE REQUIREMENTS

  1. Installation of polished concrete floor system for interior concrete floor by dry grinding and polishing with various size grit metal-bonded and resin-bonded diamonds and application of concrete densifier.
  2. Slabs to receive Diamond Grind and Polish Process must have a minimum 1/8” of cream and fines at surface. Proof of cream and fines will be required via core samples taken at random perimeter locations at 2’ from edge of any pour by testing agency. Locations of cores will be determined by Owner or Owners Representative. Visual inspection and approval by testing agency, Owner or Owners Representative will validate required deliverable.
  3. Definition: Polished Concrete Process is “cracking the cap” by diamond grinding the concrete surface, removing imperfections left by concrete installer, spraying on deep penetrating lithium chemistry densifier per manufactures instructions, grinding off any densifier residue from surface of slab, begin diamond polishing to desired gloss meter reading requirements, spraying on final deep penetrating lithium poly silicate concrete sealer per manufacturers instructions and finish cleaning the polished slab with common scrubber, soft white nylon heads and neutral PH soap specifically designed to clean Polished Concrete surfaces. The result is a polished concrete floor that will not dust, is resistant to penetration from oils, provides an additional 35 percent or more reflected light and slip coefficients that surpass standard code requirements/ recommendations.
  4. Process may be either a proprietary system from specialty contractor or use specified products with acceptable detailed process in compliance with definition above and approved by Owner and Owners Representative.
  5. Acceptable Diamond Grinding Methods: Equipment and techniques defined above that .produce documented results of concrete finishes meeting or exceeding the following: Required FF, FL, Gloss Meter readings, light reflected percentages as measured with a specular gloss measurement device, and slip coefficient minimums as defined in this specification. Specifically, a min diamond grind of not less then 1/64 ”; or as required, will be removed from the slab surface to eliminate imperfections left from the concrete finishing process i.e.: float ridges and trowel marks including swirl patterns and black scorch marks from concrete finishing.
  6. Specular Gloss/Reflectance, ASTM D 523: Specular gloss/reflectance to be measured and recorded in a consistent 25 foot grid pattern between each grit series. Final reflectance per Concrete Polishing Association of America (CPAA) and International Polished Concrete Institute (IPCI) Level 4 Gloss Shine – 3000 grit. Gloss Meter reading of local min. 30 with an overall average of 40 measured at a 60 deg angle at floor surface as measured by Horida IG-320 High-resolution digital gloss meter.
  7. Polished Concrete Process shall be dry diamond method utilizing direct connect HEPA filtration system, Metal bonded diamond heads for grind w/ resin and or epoxy bonded diamond heads for polishing on a multi-orbital planetary action opposing rotational head machine(s) acceptable to Owner or Owner’s Representative.
  8. Coordination: Contractor shall coordinate the following:
  9. Concrete placement, floating, vibrating, panning, pure wet curing, location of cores and review of cores providing evidence of 1/8” cream and fines at slab surface will be coordinated with the polisher, Owner and Owners Representative for approval prior to beginning grind and polish procedure.
  10. Schedule of slab pour sequence in conjunction with Polished Concrete Process (grind, densifier, polish, sealer and cleaning) sequence as well as detailed specific grind, polish, application of densifier/sealer and cleaning procedures, means and methods will be placed in writing and provided to Owner and Owners Representative for approval prior to beginning work.
  11. Grind and Polishing Process can begin at 7 to 10 days after wet cure when slab has attained sufficient strength so not to displace aggregate or fiber reinforcing as determined by the Polishing provider after field inspection.
  12. Scheduling of joint sealant installation will be provided to Owner and Owners Representative for approval. Joints will be places at specified time after polish completion.
  13. Cleaning of concrete surface prior to and after of Polished Concrete Process will be preformed by concrete installer. Cleaning completion procedures and materials pre and post polish will comply with Polishing contractor’s recommendations to maintain finished polish floor surface.
  14. Polishing contractor will clean finished Polished Concrete Floors at min three (3) times as part of Polished Concrete Process prior to requesting final inspection by Owner and Owners representative.
  15. Slip Resistance: Static coefficient of friction shall be 0.6 for level floors and 0.8 for ramped surfaces as recommended by the ADA Accessibility Guidelines (ADAAG).
  16. Testing shall be in accordance with ASTM C1028 or use of similar devices recognized by ADAAG.

1.5  SUBMITTALS

  1. Source of ready-mixed concrete for approval.
  2. LEED Submittals:

Retain first subparagraph below if recycled content is required for LEED-NC or LEED-CI CreditsMR4.1 and MR4.2. An alternative method of complying with CreditMR4.1 and MR4.2 requirements is to retain requirement in Division01 Section "Sustainable Design Requirements" that gives Contractor the option and responsibility for determining how CreditMR4.1 and MR4.2 requirements will be met.

  1. Product Data for Credit MR4: For products having recycled content, documentation indicating percentages by weight of postconsumer and pre-consumer recycled content.
  2. Include documentation from product manufacturer indicating costs for each product having recycled content.

"Product Certificates for CreditMR5.1(and CreditMR5.2)" Subparagraph below applies to LEED-NC, LEED-CS, and LEED for Schools.

  1. Product Data for Credit MR 5: For products and materials to comply with requirements for regional materials, provide documentation indicating location of product or material manufacturing location and the point of extraction, harvest, or recovery for each raw material.
  2. Include documentation on distance to project, contractor cost for each regional material, and percent by weight that is considered regional.
  3. Product Data for IEQ 4.3 for liquid floor treatments and curing and sealing compounds, documentation including printed statement of VOC content.

Retain subparagraph below if ground granulated blast-furnace slag, is used as portland cement replacements for LEED-NC Credit ID1.1. To achieve this credit, replacement materials must be substituted for min. 25 to max. 40 percent of the portland cement that would otherwise be used.

  1. Design Mixtures for Credit ID1.1: For each concrete mixture containing a replacement for Portland Cement, and for equivalent concrete mixtures that do not contain Portland Cement replacements.
  2. With the Bid, submit the following:
  3. Name of trade to perform diamond grind & polish
  4. Synopsis of concrete polishing process and description of equipment intended to be used.
  5. Qualification data for those to perform concrete polishing.
  6. Manufacturer's product data, performance criteria and other documentation for each material specified in this Section that is proposed for use, including:
  7. Admixtures.
  8. Liquid curing/sealing compound.
  9. If products have not been reviewed and accepted by Chrysler Health or Environmental groups, include MSDS information as a separate submittal directed to the Owner for review.
  10. Premolded joint filler.
  11. Reinforcing fibers.
  12. Bonding agent.
  13. Joint sealants.
  14. Shop drawings including the following:
  15. Locations of drains, trenches, manholes, and other items.
  16. Floor joint layout indicating:
  17. Number and sequence of placements.
  18. Sizes and shapes of placements (shapes shall be square or rectangular only).
  19. Types (construction or control) and spacing of joints.
  20. Shop drawings for reinforcement detailing fabricating, bending, and placing concrete reinforcement. Comply with ACI 315.99 "Manual of Engineering and Placing Drawings for Reinforced Concrete Structures" showing bar schedules, stirrup spacing, bent bar diagrams, and arrangement of concrete reinforcement.
  21. Include the following:
  22. Proposed method for bulkheads and formwork.
  23. Proposed placement equipment.
  24. Schedule of events and casting plan regarding placement operations, and records of concrete casts.
  25. Mill test certification for steel fiber reinforcement in accordance with ASTM A820.
  26. Certification of chloride ion content from admixture suppliers.
  27. Fiber supplier to include steel fiber Identity Chart with submittal to support the proposed dosage rate to meet a Re,3 value of 60 percent.
  28. Concrete Mix Design: Submit concrete supplier's concrete mix design information based on requirements specified in "Concrete Mix Proportions".
  29. Submit a concrete mix design prepared by either the “laboratory trial batch” or the field experience” method as specified in the latest issue of ACI 318, Section 5.3 or CSA A 23.1 for approval. Provide proportions of cement, fine aggregate, coarse aggregate, and water.
  30. Submit Steel Fiber Reinforced Concrete (SFRC) design to meet the performance criteria listed in the specification indicating the dosage rate per cubic yard of concrete.
  31. Include product data sheet including ASTM fiber type, wire tensile strength, fiber dimensions, aspect ratio, number of fibers per pound, and shape of the steel fiber.
  32. Mix design shall be sealed by a professional engineered registered in the State of [Insert project location].
  33. Submit concrete mix design approval from the steel fiber manufacturer.
  34. Samples of aggregates shall be furnished by the Contractor as required, together with tests for hardness, durability, density, absorption, etc., referenced in the latest issue of ASTM C33.
  35. Certificates: Each load of ready mixed concrete shall be accompanied by triplicate certificates (batch tickets) submitted for approval for each batch discharged indicating project identification name and number, mix type, and listing ingredients, including quantities and types of admixtures, total water, time when water was introduced into the mix, place and date of delivery, amount of concrete in cubic yards, mix time, reading of revolution counter at first addition of water, etc. Identify separately amounts of water added at batch plant and water added on site. To be submitted to Owner after each pour.
  36. Completed pre-pour sign-off cards.
  37. Survey of slab base prior to pour and signed off by Owner or Owner’s representative.
  38. Schedule: Submit schedule of pour sequence including slab pour duration, slab polishing, and joint sealant installation on plan drawings.
  39. Qualification Data: For those performing concrete polishing.
  40. Polishing Process: Contractor to submit detailed means and methods for slab polishing process including step by step polishing procedures to be used on the project. This includes identification of machines for grinding process being used, diamond pad grits through the process, application of densifier/sealer, and cleaning procedure.
  41. Field quality-control reports:
  42. Material Test Reports: For the following, from a qualified testing agency, indicating compliance with requirements:
  43. Aggregates. Include service data indicating absence of deleterious expansion of concrete due to alkali aggregate reactivity.
  44. Floor surface flatness and levelness measurements including compliance with specified tolerances.
  45. Minutes of pre-installation conference.

1.6  QUALITY ASSURANCE

  1. Comply with applicable provisions of Division 3 Section "Cast-In-Place Concrete".
  2. Codes and Standards: Comply with provisions of the following codes, specifications, and standards, except where more stringent requirements are shown or specified:
  3. American Concrete Institute Latest Issue of ACI 301, "Specifications for Structural Concrete for Buildings."
  4. Latest Issue of ACI 318, "Building Code Requirements for Reinforced Concrete."
  5. Concrete Reinforcing Steel Institute (CRSI) "Manual of Standard Practice."
  6. Installer Qualifications: A qualified installer who employs on Project personnel qualified as ACI-certified Flatwork Technician and Finisher and a supervisor who is an ACI-certified Concrete Flatwork Technician.
  7. Manufacturer Qualifications: A firm experienced in manufacturing ready-mixed concrete products and that complies with the latest issue of ASTMC94/C94M requirements for production facilities and equipment.

Retain subparagraph below if required.

  1. Manufacturer certified according to NRMCA's "Certification of Ready Mixed Concrete Production Facilities."

Retain first paragraph below if Contractor or manufacturer retains testing agency for concrete mixture design, material test reports, or field quality control. Retain option if field quality-control testing agency employed by Contractor must be approved by authorities having jurisdiction.