Standard Specification for Bonding Hardened Concrete, Steel, Wood, Brick, and Other Materials to Hardened Concrete with

a Multi-Component EpoxyAdhesive (AC1 503.1-92, reapproved 1997)*

Reported by AC1 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 D. Eisenhut Jack J. Fontana Robert W. Gaul Paul R. Hollenbach David P. Hu T. Michael Jackson Troy D. Madeley Albert Mayer Joseph A. McElroy Paul F. McHale Pctcr Mendis Myles A. Murray Secreaiy Richard Montani Joseph M. Plecnik Hamid Saadatmanesh W. Glenn Smoak Joe Solomon Michael M. Sprinkel Douglas G. Walters
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George Selden Secreaiy Leonard J. Mitchell Myles A. Murray Leonard Pepper G.M. Scales Raymond J. Schutz George W. Whitesides

This specification describes the work o bonding hardened concrete. steel, f wood, brick and other materials to hardened concrete with a multi-component epoxy adhesive such as defined for this purpose in ASTM C 881. It includes controls for adhesive labeling, storage, handling, mixing and application, surface evaluation andpreparation as well as inspection and quality control.

Keywords: adhesives; aluminum; bond (concrete to concrete); bonding; bricks; concrete construction; copper; epoxy resins; hardened concrete: quality control; safety: specifications; standards; steels; wood.

FOREWORD

his foreword is included for explanatory purposes only; it does not form a part of Standard Specification ACI 503.1. T h i s specification is a reference standard which the Architect /Engineer m a y cite in the project specifications, together with the supplemental requirements for the specific project. I t is written i n terse, imperative language and is
AC1 Committee Reports, Guides, Standard Practices, and Commentaries are intended for guidance in designing, planning, 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 Documents, they should be phrased in mandatory language and incorporated into the Project Documents.

divid& into two sections: general requirements and materials and applications, including a on the a l ~ important surface preparation. his document and methods for bonding concrete, steel, wood, brick, aluminum, copper, and other materials to hardened concrete. 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. A specification guide and checklist are included as a preface to, but not forming a part ofl Standard Specification A C I 503.1. The purpose o f this guide and checklist is to assist the Architect I Engineers designer(s) and specifier(s) to properly choose and specify, the necessary supplemental requirements for the project specifications.

Adopted as a standard of the American Concrete Institute effective June 1979, in accordance with the Institutes standardization procedure. I t was revised according to the expedited procedure effective October 1986 and March 1992. CopyiigMC1978 and 1986 American Concrctc 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 electronic 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.

503.1-1
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503.1-2

AC1 STANDARD

CONTENTS

SPECIFICATION GUIDE

1 .l-Scope 1.2-Notation 1.3-Specification wording 1.4-Reference standards

Part 2.1-General, pg. 503.1-4

2.1.1-Description 2.1.2-Submittals 2.1.3-Quality assurance 2.1.4-Product delivery, storage, and handling 2.1.5-Project conditions
Part 2.2-Products, pg. 503.1-4 2.2. 1-Epoxy adhesive Part 2.3-Executioq pg. 503.1-4

SG1-Standard Specification AC1 503.1 is intended to be used essentially in its entirety, by citation in the project specification, to cover all usual requirements for bonding hardened concrete, steel, wood, brick, and other materials to hardened concrete with a multi-component epoxy adhesive. Individual sections, parts, or articles should not be copied into project specifications since t a h g them out of context may change their meaningsSG2-However, adjustments to the needs of a particular project shall be made by the ArchitectEngineers 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 requirements 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 AC1 503.1. Or exceptions shall be taken to Standard Specification AC1 503.1 if required. SG4-A statement such as the following will serve to make Standard Specification AC1 503.1 an official part of the contract requirements: The use of an epoxy adhesive for bonding hardened concrete, steel, wood, brick, and other materials to hardened concrete shall conform to all requirements of Standard Specification for Bonding Hardened Concrete, Steel, Wood, Brick, and Other Materials to Hardened Concrete with a Multi-Component Epoxy Adhesive (AC1 503.1), published by the American Concrete Institute, Detroit, Mich., except as modified by the requirements of this project specification. SGS-The specification checklist that follows is addressed to each item of AC1 503.1 that requires the designedspecifier to make a choice where alternates are indicated, or to add provisions where they are not indicated in AC1 503.1, or to take exceptions to AC1 503.1. The checklist consists of section, part, and article heads of AC1 503.1, and accompanying notes to the designers/ specifiers to indicate the action required of them.
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2.3.1 -Preparation of concrete surfaces 2.3.2-Preparation of carbon steel surfaces 2.3.3-Preparation of galvanized steel surfaces 2.3.4-Preparation of aluminum surfaces 2.3.5-Preparation of copper and copper-alloy surfaces 2.3.6-Preparation of wood surfaces 2.3.7-Inspection of concrete surfaces prior to adhesive application 2.3.%Adhesive mixes 2.3.9-Adhesive application and placing of elements to be bonded 2.3.10-Cleanup 2.3.1 1-Safety
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EPOXY RESINS

503.1-3

SPECIFICATION CHECKLIST
Section/Part/Article of AC1 503.1 Section 1-General requirements 1.1 Scope
1.4 Reference standards

Notes to the Designer/Specier

Indicate specific scope. Review applicability of cited references and take exceptions if required.

Section 2-Materials and applications Part 2.1-General 2.1.2 Submittals

To whom sent? To whom sent? Specifj any which would specifically affect this work.

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2.1.3.2 Application control 2.1.5 Project conditions

Part 2.2-Products

2.2.1 Epoxy adhesive

Specifj Class and Grade as indicated. Also specifj additional performance requirements andor approved suppliers, as advisable.

Part 2.3-Execution

2.3.1 Preparation of concrete surfaces 2.3.2 Preparation of carbon steel surfaces 2.3.6.2 Moisture content of wood

Specifj limitations, if any, on use of mechanical abrasion and on disposal of waste products. If sand abrasive not suitable, specifj grit or shot. A commercially available probe type moisture meter should be used except for plywood which will require a flat plate type with a depth of field suitable for plywood. For a durable adhesive bond to wood the wood should be sealed on all exposed sides to reduce absorption of moisture which will swell the wood and stress (to rupture) the wood fibers which are restrained by the cured adhesive.

SECTION 1-GENERAL REQUIREMENTS 1.1-Scope 1.1.1 This standard specification covers the bonding of

1.2.3 SSPC:

hardened concrete, steel, wood, brick, and other materials to hardened concrete with a multi-component epoxy adhesive. 1.1.2 The provisions of this standard specification shall govern unless otherwise specified in the contract documents. In case of conflicting requirements, the contract documents shall govern.
1.2-Notation 1.2.1 ACI:

1916 Race Street Philadelphia, PA 19103 Steel Structures Painting Council 4400 Fifth Avenue Pittsburgh, PA 15213

1.3-Specification wording 1.3.1 The language of this standard specification is

1.2.2 ASTM:

American Concrete Institute P.O. Box 19150 Detroit, MI 482 19 American Society for Testing and Materials

generally imperative and terse, and may include incomplete 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 inference.
1.4-Reference standards 1.4.1 The standards referred to in this Standard Spe-

cification AC1 503.1 are listed in Articles 1.4.2 and 1.4.3

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503.1-4

AC1 STANDARD

of this section, with their complete designation and title including the year of adoption or revision and are declared to be a part of this Standard Specification AC1 503.1 the same as if fully set forth herein, unless otherwise indicated in the contract documents.

2.1.5.1 Environmental requirements-Contractor shall comply with manufacturers recommendations as to environmental conditions under which the epoxy compound may be applied. Part 2.2-Products 2.2.1 Epxy adhesive-ASTM C 881 Type I for non-

1.4.2 ASTMstandard

C 881-87

Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete

1.4.3 SSPC standards

Vis 1-67T Surface Preparation Standard No. 1-Pictorial Surface Preparation. Standards for Painting Steel Surfaces SP1-63 Surface Preparation Specification No. 1, Solvent Cleaning SP2-63 Surface Preparation Specification No. 2, Hand Tool Cleaning, SP3-63 Surface Preparation Specification No. 3, Power Tool Cleaning SP6-63 Surface Preparation Specification No. 6, Commercial Blast Cleaning SECTION 2-MATERIALS AND APPLICATION
Part 2.1-General 2.1.1 Description-This section covers the re-

load bearing or Type IV for load bearing applications. Curing temperature requirements (Class) shall be determined by supplier and contractor after project conditions have been established. Use Grade 2 (medium viscosity) for bonding mating surfaces. Use Grade 3 (nonsagging) for overhead, or vertical, or sloping, surfaces, and for nonmating surfaces.

quirements for surface preparation of specified materials and for application of the multi-component epoxy adhesive. 2.1.2 Submittals 2.1.2.1 Contractor shall submit manufacturers certification verifying conformance to material specifications specified in Part 2.2. 2.13 Quality assurance 2.1.3.1 Labeling-Clearly mark all containers with the following information: a) Name of manufacturer b) Manufacturers product identification c) Manufacturers instructions for mixing d) Warning for handling and toxicity
2.1.3.2 Application con tro I- Submit mixing and application procedures for approval prior to USC. 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 (S-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 b r e h g container seals. 2.1.5 Project conditions
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Part 2.3-Execution 2.3.1 Preparation o concrete surfaces f 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 mechanical abrasion. 2.3.1.2 Mechanical abrasion-Use sandblasting, scarifying, waterblasting, or other approved means. 2.3.2 Preparation o carbon steel surfaces f 2.3.2.1 Blast-clean carbon steel surfaces, using SSPC SP6, to give a surface condition corresponding to ASa2, BSa2, CSa2 of SSPC Vis 1, depending on the initial surface condition of the steel surface. Use sand abrasive. 2.3.2.2 Prior to blast-cleaning, clean surfaces with SSPC SP1, SP2, and SP3, as required. 2.3.2.3 Remove blast-cleaning residue with compressed air from an oil-and-water-free compressed air source. 2.3.3 Preparation o galvanized steel surfaces f 2.3.3.1 Scrub galvanized steel surfaces thoroughly in accordance with SSPC SP1, wash well with lime water, and dry. 2.3.3.2 For galvanized steel surfaces showing signs of subsurface corrosion, blast-clean as specified in Article 2.3.2 for carbon steel. 2.3.4 Preparation o aluminum surfaces f 23.4.1 Scrub aluminum surfaces thoroughly with a nonchlorinated cleaner and then etch with proprietary chromate treatment in strict compliance with manufacturers application instructions and safety warnings. 2.3.4.2 After etching, wash surface with distilled water and then dry thoroughly. 2.3.5 Preparation o copper and copper-alloy surfaces f 2.3.5.1 Blast-clean copper and copper-alloy surfaces as specified in Article 2.3.2 for carbon steel. 2.3.5.2 Where blast-cleaning is not practical, clean the copper or copper-alloy surfaces with aqueous household ammonia, wash surfaces with distilled water, and then dry thoroughly. 2.3.6 Preparation o wood surfaces f 2.3.6.1 Clean wood surfaces of all visible loose or foreign particles or contaminants by sanding. Remove
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503.1-5

sanding or filling dust by wiping with an alcohol-soaked rag, or clean with oil-and-water-free compressed air. 2.3.6.2 For use with moisture-sensitive epoxy adhesives, reduce moisture content of wood to below 12 percent by weight, or the wood should appear dry to touch. 2.3.7 Inspection of concrete surfaces prior to adhesive application 2.3.7.1 Inspect all concrete surfaces prior to application of adhesive to insure that requirements of this Article 2.3.7 are met. 2.3.7.2 Surfaces shall be sound and have coarse aggregate exposed. Coarse aggregate requirement may be waived when preparation is in accordance with Article 2.3.1.3. 2.3.7.3 Surfaces shall be free of any deleterious materials such as laitance, curing compounds, dust, dirt, and oil. Materials resulting from surface preparation specified in Article 2.3.1 shall be removed. 2.3.7.4 All concrete surfaces shall be dry unless a water-insensitive adhesive is used. Surface temperature of the concrete shall be w i t h the limits recommended by the adhesive manufacturer. 2.3.7.5 Evaluate moisture content for concrete by determining if moisture will collect at bond lines between old concrete and epoxy adhesive before epoxy has cured. This may be accomplished by taping a 4 x 4 fi polyethylene 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 a moisture barrier between old concrete and new epoxy. 2.3.8 Adhesive mixes 23.8.1 Mix epoxy components in a clean container free of harmful residue or foreign particles. 2.3.8.2 Condition epoxy compound components to be at a temperature between 60-100 F (16-38Q unless
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otherwise recommended by manufacturer. 2.3.8.3 Thoroughly blend epoxy components with a mechanical mixer to a uniform and homogeneous mixture. Mix small batches (up to 1 qt) by use of spatulas, palette knives, or similar devices. 2.3.9 Adhesive application and placing of elements to be bonded 2.3.9.1 Apply epoxy adhesive to concrete surface by brush, roller, broom, squeegee, or spray equipment. Apply epoxy adhesive at a thickness sufficient to fill, with slight excess, the gap between substrate and the element to be bonded. 2.3.9.2 Position elements to be bonded w i t h contact time of adhesive as recommended by manufacturer. 2.3.9.3 If movement of elements to be bonded may occur on sloping, vertical, or overhead positions, temporarily fasten or shore these elements. 2.3.9.4 If epoxy adhesive cures to extent of losing its tack before elements are in contact with adhesive, remove or slightly abrade frst coat before placing second coat. 2.3.9.5 Do not disturb elements being bonded until the adhesive has attained required strength. 2.3.10 Cleanup 2.3.10.1 Protect concrete surfaces, beyond limits of surface receiving adhesive, against spillage. 2.3.10.2 Immediately remove any epoxy compound applied or spilled beyond desired areas. Perform cleanup with material designated by epoxy adhesive manufacturer. Avoid contamination of work area. 2.3.11 Safety-Epoxy materials may be skin irritants or sensitizers to many people. Accordingly, advise applicators to avoid contact with eyes and skin, inhalation of vapors, and ingestion. Make protective and safety equipment available on site. Heed all label warnings by manufacturer.

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Standard Specification for Bonding Plastic Concrete to Hardened Concrete with a Multi-Component Epoxy Adhesive (AC1 503.2-92, reapproved 1997)*
Reported by AC1 Committee 503
R.W. Gaul Chairman Russell H. Brink George Horeczko Harold C. Klassen Joseph A. McElroy Leonard J. Mitchell Myles A. Murray Leonard Pepper George Selden
Secretary

G.M. Scales Raymond J. Schutz George W. Whitesides

Committee voting on the 1992 revisions: Raymond J. Schutz Chairman Milton D. Anderson Roger W. Black John P. Cook Floyd E. Dimmick Wolfgang D. Eisenhut Jack J. Fontana Robert W. Gaul Paul R. Hollenbach
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Myles A. Murray Secretary David P. Hu T. Michael Jackson Troy D. Madeley Albert Mayer Joseph A. McElroy Paul F. McHale Peter Mendis Richard Moniani Joseph M. Plecnik Hamid Saadatmanesh W. Glenn Smoak Joe Solomon Michael M. Sprhkel Douglas G. Walters

This specification describes the work of bonding plastic concrete to hardened concrete with a multi-component epoxy adhesive such as defined for this purpose in ASTMC 881. It includes controls for adhesive labeling, storage, hundling, m x n and application, surface evaluation and preiig purution as well as inspection and qupli- control.

Keywords: adhesives; bond (concrete to concrete); bonding; concrete construction; epoxy resins; fresh concretes; hardened concrete; quality control; repairs; specifications; standards.

FOREWORD This foreword is included for acylanato~purposes only; it f does not form a part o Standard Speci$cation ACI 503.2. Standard Specijcation 503.2 is a reference standard

which the Architect/Engineer may cite in the project speci$cation@) for any building project, together with supplementary requirements for the specijc project. This specijcation is written in the section and three-part format o the Construction Specijcations Institute, but with f the numbering system modijed to ACI requirements. The language is generally imperative and terse. A specijcation p i d e is included as a preface to, but not forming apart of; Standard Speci$cation ACI 503.2. The f purpose o this p i d e is to assist the Architect/Engineers designer@) and speci$er(s) to property choose and specify the necessary supplementary requirements for the project spec ijcation (s).

AC1 Committee Reports, Guides, Standard Practices, and Commentaries are intended for guidance in designing, planning, 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 Documents, they should be phrased in mandatory language and incorporated into the Project Documents.

*Adopted as a standard of the American Concrete Institute effective June 1979. In accordance with the Institutes standardization procedure. It was revised according to the expedited procedure effective October 1986 and March 1992. Copyright Q 1978 and 1986 American Concrete Institute. Au 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 electronic 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.

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503.2-2

AC1 STANDARD

CONTENTS

SPECIFICATION GUIDE

1.1-Scope 1.2-Notation 1.3-Specification wording 1.4-Reference standards

Part 2.1-General, pg. 503.2-4

2.1.1-Description 2.1 .L-Submittals 2.1.3-Quality assurance 2.1.4-Product delivery, storage, and handling 2.1 S-Project conditions
Part 2.2-Products, pg. 503.2-5
2.2.1-Epoxy adhesive 2.2.2-Plastic concrete

SGl -Standard Specification AC1 503.2 is intended to be used essentially in its entirety, by citation in the project specification, to cover all usual requirements for bonding plastic concrete to hardened concrete with a multi-component epoxy adhesive. Individual sections, parts, and articles should not be copied? into project specifications since takmg them out of context may change their meanings. SG2 -However, adjustments to the needs of a particular project shall be made by the ArchitectEngineer?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 requirements 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 AC1 503.2. Or exceptions shall be taken to Standard Specification AC1 503.2 if requiredSG4 -A statement such as the following will serve to make Standard Specification AC1 503.2 an official part of the contract requirements:
The use of an epoxy adhesive for bonding plastic concrete to hardened concrete shall conform to all requirements of ?Standard Specification For Bonding Plastic Concrete To Hardened Concrete with a Multicomponent Epoxy Adhesive (AC1 503.2),?published by the American Concrete Institute, Detroit, Mich., except as modified by the requirements of this project specification.

Part 2.3-Execution, pg. 503.2-5

2.3.1-Preparation of concrete surfaces 2.3.2-Inspection of concrete surfaces prior to adhesive application 2.3.3-Adhesive mixes 2.3.4-Adhesive application and concrete placement 2.3.5-Cleanup 2.3.6-Safety 2.3.7-Field quality performance requirements

1.1 Scope 1.4 Reference standards

Section 2-Materials and application
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SG5 -The specification checklist that follows is addressed to each item of AC1 503.2 that requires the designedspecifier to make a choice where alternates are indicated, or to add provisions where they are not indicated in AC1 503.2, or to take exceptions to AC1 503.2. The checklist consists of section, part, and article heads of AC1 503.2, with accompanying notes to the designer/ specifier to indicate the action required of them.

SPECIFICATION CHECKLIST SectionIPartlArticle of AC1 503.2 Section 1-General requirements

Notes to the DesignerISpecier

Indicate specific scope. Review applicability of cited references and take exceptions if required.

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503.2-3

SPECIFICATION CHECKLIST (cont.)

Section/Part/Article of AC1 503.2 Part 2.1-General

2.1.2 Submittals 2.1.3.2 Application control

Notes to the Designer/Specifier

To whom sent? Mixing and application procedures submitted must be in accordance with product manufacturers instructions. Specifj any which would specifically affect this work. Performance of epoxy systems may be affected by ternperature, humidity, and surface water. Strict adherence to the manufacturers recommendations should be maintained. Where other unusual conditions are encountered, the material manufacturer should be consulted before application.

2.1.5 Project conditions 2.1.5.1 Environmental requirements

Part 2.2-Products
2.2.1 Epoxy adhesive Specifj Class and Grade as indicated. Also specifj additional performance requirements andor approved suppliers, as advisable. Specifj concrete requirements.

2.2.2 Plastic concrete

Part 2.3-Execution
2.3.1 Preparation of surfaces 2.3.2 Inspection of concrete surfaces 2.3.2.2 Minimum pullout strength Specifj limitations, if any, on use of mechanical abrasion and on disposal of waste products. Specifj if architect/engineer will also inspect, and if hold points are required. 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 improper cleaning of the concrete, incorrect adhesive, or faulty adhesive application techniques. Some epoxy adhesives may be capable of wetting the concrete surface at temperatures below 40 F. The specification should allow such use only if test data is available which conclusively demonstrates adequate bond at the actual concrete temperature expected. Review applicability of referenced standards and take exceptions if required. Also specify any unusual ambient conditions. The rate at which the epoxy should be applied is generally a function of the surface texture and viscosity of the epoxy system. Therefore, the rate at which the epoxy should be applied should be in accordance with the manufacturers recommendations.
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2.3.2.4 Surface moisture content

2.3.4.1 Ambient temperature control

2.3.4.2 Coverage rate

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503.2-4

AC1 STANDARD

SPECIFICATION CHECKLIST (cont.) SectionIPartlArticle of AC1 503.2

I

Notes to the DesignerISpecier

2.3.4.3 Consolidation of concrete 2.3.4.4 Curing

Review applicability of referenced standard and take exceptions if required. Specify procedure to be used. Also specify additional performance requirements andor approved suppliers, as advisable. Are specified test methods (sounding and coring) suitable? Are additional requirements necessary? Specify test methods that will be used, and size of cores.

2.3.7 Field quality performance requirements

SECTION 1-GENERAL REQUIREMENTS 1.1-Scope 1.1.1 This standard specification covers the bonding of

1.4.3 ACI standard

301-89 plastic concrete to hardened concrete with a multicomponent epoxy adhesive. 1.1.2 The provisions of this standard specification shall govern unless otherwise specified in the contract documents. In case of conflicting requirements, the contract documents shall govern.
1.2-Notation 1.2.1 ACI:

Specifications for Structural Concrete for Buildings

SECTION 2-MATERIALS AND APPLICATION

Part 2.1-General 2.1.1 Description - T h i s section covers the require-

American Concrete Institute P.O. Box 19150 Detroit, MI 482 19 Materials 1916 Race Street Philadelphia, PA 19103

1.2.2 ASTM: American Society for Testing and

ments for surface preparation of the hardened concrete and for materials and for application of the multicomponent epoxy adhesive and the plastic concrete. 2.1.2 Submittals 2.1.2.1 Contractor shall submit manufacturers certification verifying conformance to material specifications specified in Part 2.2. 2.1.3 Quality assurance 2.1.3.1 Labeling-Clearly mark all containers with the following information: a) b) c) d) Name of manufacturer Manufacturers product identification Manufacturers instructions for mixing Warning for handling and toxicity

1.3-Specification wording 1.3.1 The language of this standard specification is

generally imperative and terse, and may include incomplete sentences. Omissions of phrases and 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 inference.
1.4-Reference standards 1.4.1 The standards referred to in this Standard Spe-

cification AC1 503.2 are listed in Articles 1.4.2 and 1.4.3 of this section, with their complete designation and title including the year of adoption or revision and are declared to be a part of this Standard Specification AC1 503.2 the same as if fully set forth herein, unless otherwise indicated in the contract documents. 1.4.2 ASTMstandard C 83 1-87 Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete
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2.1.3.2 Application Control-Submit mixing and application 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 b r e h g container seals. 2.1.5 Project conditions 2.1.5.1 Environmental requirements-Contractor shall comply with manufacturers recommendations as to environmental conditions under which the epoxy compound may be applied.
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EPOXY RESINS

503.2-5

Part 2.2-Products 2.2.1 Epoxy adhesive-ASTM C 881 Type II for non-

Part 2.3-Execution 2.3.1 Preparation of concrete m$ma 2.3.1.1 Concrete surfaces to which epoxies are to be

applied shall be exposed parent concrete free of loose and unsound materials. Prepare surfaces by mechanical abrasion. 2.3.1.2 Mechanical abrasion-Use sandblasting, scarifymg, waterblasting, or other approved means. 2.3.2 Inspection of concrete surfaces prior to adhesive application 2.3.2.1 Inspect all concrete surfaces prior to application of adhesive 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 of Use of Epoxy Compounds with Concrete, reported by AC1 Committee 503. 2.3.2.3 Surfaces shall be free of any deleterious materials such as laitance, curing compounds, dust, dirt, and oil. Materials resulting from surface preparation specified in Article 2.3.1 shall be removed. 2.3.2.4 All concrete surfaces shall have a moisture content not exceeding saturated surface dry condition. Surface temperature shall be at least 40 F to permit wetting of concrete surface by epoxy adhesive. 2.3.2.5 Evaluate moisture content for concrete by determining if moisture will collect at bond lines between old concrete and epoxy adhesive before epoxy has cured. This may be accomplished by taping a 4 x 4 ft polyethylene 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 a moisture barrier between old concrete and new epoxy. 2.3.3 Adhesive mixes 2.3.3.1 Mix epoxy components in a clean 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 mixture. Mix small batches (up to 1 qt) by use of spatulas, palette knives, or similar devices. 2.3.4 Adhesive application and concrete placement 2.3.4.1 Ambient temperature is critical during
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a) Tapping fresh concrete with a blunt metal instrument b) Dragging a heavy steel chain across the surface (for horizontal surfaces only)

2.3.7.3 Detection of a hollow sound in any area shall be reason to suspect inadequate bonding, and contractor shall then core each such area, as requested by the Architect/Engineer, to determine bonding adequacy. 2.3.7.4 Coring shall be through the new concrete and into the existing concrete. Core diameter shall be as required by the Architect/Engineer. Length of cores shall be twice the core diameter, or twice the thickness of new concrete, or as requested by the Architect/Engineer. 2.3.7.5 Cores will be visually inspected, and fw-ther testing required, if any, will then be determined by the Archt ect/Engineer.

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load bearing or Type V for load bearing applications. Curing temperature requirements (Class) and viscosity (Grade) shall be determined by supplier and contractor after project conditions have been established. 2.2.2 Plastic concrete-As required by the project specification.

application of epoxy adhesives and concrete placement. Work shall be performed in accordance with Chapters 7 and 3 of AC1 301. 2.3.4.2 Apply epoxy adhesive to concrete surface by brush, roller, broom, squeegee, or spray equipment, Apply epoxy compound at a thickness not less than that recommended by manufacturer. 2.3.4.3 Place fresh plastic concrete while adhesive is still tacky. If epoxy adhesive cures to extent of losing its tack before plastic concrete is placed, remove or slightly abrade frst coal before placing second coat. 2.3.4.4 Consolidate freshly placed plastic concrete in accordance with AC1 301 to insure full bonding of new concrete. 2.3.4.5 Upon completion of f i n i s h g operations, cure concrete in accordance with procedures defined in Chapter 12 of AC1 301 and as indicated in the project specification. 2.3.5 Cleanup 2.3.5.1 Protect concrete surfaces, beyond limits of surface receiving adhesive, against spillage. 2.3.5.2 Immediately remove any epoxy compound applied or spilled beyond desired areas. Perform cleanup with material designated by epoxy adhesive manufacturer. Avoid contamination of work area. 2.3.6 Safety-Epoxy materials are skin irritants or sensitizers to many people. Accordingly, advise applicators to avoid contact with eyes and s h , inhalation of vapors, and ingestion. Make protective and safety equipment available on site. Heed all label warnings by manufacturer. 2.3.7 Field quality performance requirements 2.3.7.1 The Architect/Engineer shall evaluate bonding of fresh concrete to existing concrete after the fresh concrete has cured for not less than 28 days. 2.3.7.2 The evaluation shall be performed by sounding, using one of the following, or similar, methods:

Standard Specification for Producing a Skid-Resistant Surface on Concrete by the Use of a Multi-Component Epoxy System (AC1 503.3-92,reapproved 1997)*
Reported by AC1 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 David P. Hu T. Michael Jackson Troy D. Madeley Albert Mayer Joseph A. McElroy Paul F. McHale Peter Mendis Myles A. Murray Secretary Richard Moniani Joseph M. Plecnik Hamid Saadatmanesh W. Glenn Smoak Joe Solomon Michael M. Sprinkel Douglas G. Walters Leonard J. Mitchell Myles A. Murray Leonard Pepper George Selden Secretary
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G.M. Scales
Raymond J. Schutz George W. Whitesides

This specijcation describes die work ofproducing a skid-resistant surface on hardened concrete by the application of a multi-component epoxy adhesive such us defined f o r this purpose in ASTM C 881. It includes controls f o r &labeling, storage, handling, mixing nnd application, evaluation and preparation as we as inspectron nn quality control. In addition, it describes an a p g u t e to be used with the coating.

Standard Specijcation 503.3 is a reference standard spewhich the Architect/Engineer may cite in the ciJication(s) any building project, together with supfor plementary requirements for the speciJic project. %is specijcation is written in the section and three-part format of the Construction Speci&ations Institute, but with the numbering system modiJied to ACI requirements. The Keywords: aggregates; coatings; concrete pavements; epoxy resins; language is generally imperative and terse. hardened concrete; quality control; skid resistance; specifications; A specijcation guide and checklist are included as a standards. preface to, but not forming a part OJ; Standard Specijcation AC1503.3. The purpose of this guide is to assist the Architect/Engineers designer@) and specijer(s) to properly FOREWORD choose and specify the necessary supplementary requirements for the project speciJication(s). This foreword is included for explanatory purposes only; it does not form a part of Standard SpeciJication ACI 503.3.

AC1 Committee Reports, Guides, Standard Practices, and Commentaries are intended for guidance in designing, planning, 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 Documents, they should be phrased in mandatory language and incorporated into the Project Documents.

*Adopted as a standard of the American Concrete Institute effective June 1979, in accordance with the Institutes standardizaon procedure. It was revised according to the expedited procedure effective March 1992. Copyright iQ 1978 American Concrete Institnte. 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 elecIronic 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.

503.3-1
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503.3-2

AC1 STANDARD

SPECIFICATION GUIDE
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1.1-Scope 1.2-Notation 1.3-Specificationwording 1.4-Reference standards

Part 2.1-General, 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. 1-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

SG1-Standard Specification AC1 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 application 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 particular project shall be made by the Architect/Engineers 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 requirements 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 AC1 503.3. Or exceptions shall be taken to Standard Specification AC1 503.3 if required.

SG4-A statement such as the following will serve to make Standard Specification AC1 503.3 an official part of the contract requirements:
The producing of an epoxy system skid-resistant surface on concrete shall conform to all requirements of Standard Specification for Producing a Skid-Resistant Surface on Concrete by the Use of a Multi-Component Epoxy System (AC1 503.3), published by the American Concrete Institute, Detroit, Mich., except as modified by the requirements of this project specification. SGS-The specification checklist that follows is addressed to each item of AC1 503.3 that requires the designedspecifier to make a choice where alternates are indicated, or to add provisions where they are not indicated in AC1 503.3, or to take exceptions to AC1 503.3. The checklist consists of section, part, and article heads of AC1 503.3, with accompanying notes to the designer/ specifier to indicate the action required of them.

SPECIFICATION CHECKLIST

Section 1-General requirements 1.1 Scope 1.4 Reference standards

Section 2-Materials and application
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Indicate specific scope. Review applicability of cited references and take exceptions if required.

I
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EPOXY RESINS

5033-3

SPECIFICATION CHECKLIST (cont.) SectionIPartlArticle of AC1 503.3 Notes to the DesignerISpecier

2.1.2 Submittals 2.1.3.2 Application control 2.1.4.2 Storage of materials

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To whom sent? Mixing and application procedures submitted must be in accordance with product manufacturers instructions. Storing epoxy compounds at other than specified temperature 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 temperature, humidity, and surface water. Strict adherence to the manufacturers recommendations should be maintained. Where other unusual conditions are encountered, the material manufacturer should be consulted before application. The aggregate described in this section will provide a suitable nonskid surface for vehicular traffic. For surfaces limited to pedestrian traffic only, the designer may desire to choose a less coarse aggregate gradation. The preparation and inspection of a small sample using the proposed aggregate and coating at their proposed rate of application prior to publication of a specification will enable the designer to anticipate the appearance 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 corundum-rich materials employed by the gnnding wheel industry such as calcined bauxite and emery; wellcemented sandstones and certain metamorphised sandstone 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 improper cleaning of the concrete, incorrect adhesive, or faulty adhesive application techniques. When concrete surface is not dry, materials manufacturer should be consulted regarding suitability of system and adequacy of application techniques. Some epoxy adhesives may be capable of wetting the concrete surface at temperatures below 40 F. The specification should allow such use only if test data is available which conclusively demonstrates adequate bond at the actual concrete temperature expected.

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

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503.3 -4

AC1 STANDARD

SPECIFICATION CHECKLIST (cont.) Section/Part/Article of AC1 503.3

2.3.4.1 Coating application

Notes to the Designer/Specifier

This rate of coating application is suitable for the aggregate gradation specified in Article 2.2.2.1 and aggregate 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 prepared 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.

2.3.4.2 Aggregate application

2.3.5 Field quality control

SECTION 1-GENERAL REQUIREMENTS 1.1-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 documents. 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 482 19 American Society for Testing and Materials 1916 Race Street Philadelphia, PA 19103

1.4.1 The standards referred to in this Standard Specification AC1 503.3 are listed in Article 1.4.2 of this section, with their complete designation and title including the year of adoption or revision and are declared to be a part of this Standard Specification AC1 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 (Reapproved 1987) C 136-84a C 566-84 Standard Test Method for Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine Standard Method for Sieve Analysis of Fine and Coarse Aggregates Standard Test Method for Total Moisture Content of Aggregate by Drying StandardSpecificationforEpoxy-Resin-Base Bonding Systems for Concrete

1.2.2 ASTM:

C 88 1-87

1.3-Specification wording 13.1 The language of this standard specification is generally imperative and terse, and may include incomplete 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 inference. 1.4-Reference standards
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SECTION 2-MATERIALS AND APPLICATION Part 2.1-General 2.1.1 Description-This section covers the requirements for materials and application of the multicomponent epoxy coating system. 2.1.2 Submittals 2.1.2.1 Contractor shall submit manufacturers certification verifying performance to material speDocument provided by IHS Licensee=Aramco HQ/9980755100, User=, 09/22/2003 03:02:52 MDT Questions or comments about this message: please call the Document Policy Group at 1-800-451-1584.

EPOXY RESINS

5033-5

be applied shall be newly exposed parent concrete free of loose and unsound materials. Prepare surfaces by mechanical abrasion. 2.3.1.2 Mechanical abrasion-Use sandblasting, scarisling, waterblasting, or other approved means. a) Name of manufacturer 2.3.2 Inspection of suface prior to coating application b) Manufacturers product identification 2.3.2.1 Inspect all concrete surfaces prior to apc) Manufacturers instructions for mixing plication of coating to insure that requirements of this d) Warning for handling and toxicity Article 2.3.2 are met. 2.3.2.2 Surfaces shall be sound concrete which 2.1.3.2 Application control-Submit mixing and ap- exhibits a minimum 100 psi pullout strength when tested plication procedures for approval prior to use. in accordance with Appendix A Use of Epoxy Com2.1.4 Product delivery, storage, and handling pounds with Concrete, reported by AC1 Committee 503. 2.1.4.1 Delivery of rnaterials-Deliver all materials 2.3.2.3 Surface shall be free of any deleterious in sealed containers with labels legible and intact. materials such as laitance, curing compounds, dust, dirt, 2.1.4.2 Storage of rnaterials--Store all materials at and oil, and materials resulting from surface preparation, temperatures between 40-100 F (5-38 C) unless otherwise as specified in Article 2.3.1, shall be removed. 2.3.2.4 All concrete surfaces shall be dry as defined recommended by manufacturer. 2.1.4.3 Handling of rnaterials-Handle all materials in Article 2.3.2.5 below unless a water-insensitive coating in a safe manner and in a way to avoid breakmg con- is used. Surface temperature shall be at least 40 F to tainer seals. permit wetting of concrete surface by epoxy coating. 2.1.5 Project conditions 2.3.2.5 Evaluate moisture content for concrete by 2.1.5.1 Environmental requirernents-Contractor determining if moisture will collect at bond lines between shall comply with manufacturers recommendations as to old concrete and epoxy coating before epoxy has cured. environmental conditions under which the epoxy com- This may be accomplished by taping a 4 x 4 ft polyethylene sheet to concrete surface. If moisture collects on pound may be applied. underside of polyethylene sheet before epoxy would cure, Part 2.2-Products then allow concrete to dry sufficiently to prevent the possibility of moisture between old concrete and new 2.2.1 Epoxy coating-ASTM C 881. Curing temperature requirements (Class) and viscosity (Grade) shall be epoxy. 2.3.3 Coating mixes determined by supplier and contractor and approved by 2.3.3.1 Mix epoxy components in a clear container archtect/engineer after project conditions have been free of harmful residue or foreign particles. established. 2.2.2 Skid-resistan t aggregate 2.3.3.2 Condition epoxy compound components to 2.2.2.1 Aggregate shall meet the following be at a temperature between 60-100 F (16-38 C), unless gradation when tested in accordance with ASTM C 136: otherwise recommended by manufacturer. 2.3.3.3 Thoroughly blend epoxy components with a mechanical mixer to a uniform and homogeneous mixPercent passing Sieve size ture. Mix small batches (up to 1 qt) by use of spatulas, palette knives, or similar devices. Y 4 1O0 2.3.4 Coating application 6 2.3.4.1 Apply epbxy coating to concrete surface by 97-100 brush, roller, broom, squeegee, or spray equipment. Ap8 55-15 ply epoxy compound at a uniform thickness of 60 2 10 mils. 16 0-3 2.3.4.2 Apply skid-resistant aggregate while coating is still fluid at the rate of 12 Ilb/yd. 1 2.3.5 Field puli@ control-The inspector shall deter2.2.2.2 When tested in accordance with ASTM C 131, aggregate shall have a maximum weight loss of 20 mine that coating and skid-resistant aggregate are applied at a rate at least equal to that specified and that agpercent at 500 revolutions. gregate and coating are securely bonded. The pullout 2.2.2.3 Moisture content of the aggregate shall not exceed 0.15 percent when tested in accordance with strength of the cured skid-resistant surface to the concrete shall be a minimum 100 psi when tested in accorASTM C 566, Standard Test Method for Total Moisture dance with Appendix A of Use of Epoxy Compounds Content of Aggregate by Drying. with Concrete, reported by AC1 Committee 503. The failure shall be cohesive w i t h the concrete. There shall Part 2.3-Execution be no failures in adhesion. 2.3.1 Preparation of surfaces 2.3.6 Cleanup 2.3.1.1 Concrete surfaces to which epoxies are to

cifications specified in Part 2.2. 2.13 Quality assurance 2.1.3.1 Labeling-Clearly mark all containers with the following information:

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503.3-6

AC1 STANDARD

2.3.6.1 Protect concrete surfaces, beyond limits of surface receiving coating, against spillage. 2.3.6.2 Immediately remove any epoxy compound applied or spilled beyond desired areas. Perform cleanup with material designated by epoxy coating manufacturer. Avoid contamination of work area.
COPYRIGHT 2003; ACI International [American Concrete Institute]

2.3.7 Safety-Epoxy materials are s h irritants or sensitizers to many people. Accordingly, advise applicaors to avoid contact with eyes and s h , inhalation of vapors and ingestion. Make protective and safety equipment available on site. Heed all label warnings by manufacturer.
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Standard Specification for Repairing Concrete with Epoxy Mortars (AC1 503.4-92, Reapproved 1997)
Reported by AC1 Committee 503
R.W. Gaul Chairman Russell H. Brink George Horeczko Harold C. Klassen Joseph A. McElroy Leonard J. Mitchell Myles A. Murray Leonard Pepper George Selden Secreaiy

G.M. Scales Raymond J. Schulz George W. Whitesides

Committee voting on the 1992 revisions: Raymond J. Schutz Chairman Milton D. Anderson Roger W. Black John P. Cook Floyd E. Dimmick Wolfgang D. Eisenhut Jack J. Fontana Robert W. Gaul Paul R. Hollenbach David P. Hu T. Michael Jackson Troy D. Madeley Albert Mayer Joseph A. McElroy Paul F. McHale Peter Mendis Myles A. Murray Secretary Richard Montani Joseph M. Plecnik Hamid Saadatmanesh W. Glenn Smoak Joe Solomon Michael M. Sprinkel Douglas G. Walters

This specification describes the work o repairing defects in hardened f portland cement concrete with a sand-filled mortar using an adhesive binder such as defined in ASTM C 881. It inciudes controls for adhesive labeling storage, hundzg, mixing and application, surface evaluation and preparation as well as inspection and quality control.

Keywords: bond (concrete to concrete); concrete construction; epoxy resins, hardened concrete; mortars (material); quality control; repairs; resurfacing; specifications; standards.

FOREWORD
Thk foreword is included for explanatory purposes only; it does not form apart of Standard Specification ACI 503.4. Standard Specification 503.2 is a reference standard which the ArchitectBngineer may cite in the project speciA C I Committee Reports, Guides, Standard Practices, and Commentaries are intended for guidance in designing, planning, 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 Documents, they should be phrased in mandatory language and incorporated into the Project Documents.

fication($ for any building project, together with supplementary 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 A C I requirements. The language is generally imperative and terse. A specification guide and checklist are included as a preface to, but not forming a part 4 Standard Specification AC7503.4. The purpose of this guide and checklist is to assist the ArchitecUEngineers' d e s i g n e Y (s) a n d specifier(s) to properly choose and specify the necessary supplementary requirements for the project specification (s).

* Adopted as a standard of the American Concrete Institute effective June 1979. in accordance with the Institute's standardization procedure. It was revised according to the expedited procedure effective October 1986 and March 1992,. Copyright O 1978 and 1986 American Concrete Institute. All rights resewed 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 electronic or mechanical device. printed or written or oral, or recording for sound or visual reproduction or for use in anv knowledge or retrieval system or device, unless permission in writing is obtained fi-om the copyright proprietors.

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503.4-1
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503.4-2

AC1 STANDARD

CONTENTS

SPECIFICATION GUIDE SG1-Standard Specification AC1 503.4 is intended to be used essentially in its entirety, by citation in the project specification, to cover all usual requirements for repairing concrete with epoxy mortars. Individual sections, parts, and articles should not be copied into project specifications since t a h g them out of context may change their meanings. SG2-However, adjustments to the needs of a particular project shall be made by the ArchitectEngineers 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 requirements 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 AC1 503.4. Or exceptions shall be taken in Standard Specification AC1 503.4 if required. SG4-A statement such as the following will serve to make Standard Specification AC1 503.4 an official part of the contract requirements: Repairing concrete with epoxy mortars shall conform to all requirements of Standard Specification for Repairing Concrete with Epoxy Mortars (AC1 503.4), published by the American Concrete Institute, Detroit, Mich., except as modified by the requirements of this project specification.
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1.1-Scope 1.2-Notation 1.3--Specification wording 1.4-Reference standards

Part 2.1-General, pg. 503.4-4 2.1.1-Description 2.1.2-Submittals 2.1.3-Quality assurance 2.1.4-Product delivery, storage, and handling 2.1.5-Project conditions Part 2.2-Products, pg. 503.4-4 2.2.1-Epoxy mortar Part 2.3-Execution, pg. 503.4-4 2.3.1 -Preparation of concrete surfaces 2.3.2-Inspection of concrete surfaces prior to mortar application 2.3.3-Mortar mixes 2.3.4-Mortar application 2.3.5-Cleanup 2.3.6-Safety

SG5-The specification checklist that follows is addressed to each item of AC1 503.4 that requires the designedspecifier to make a choice where alternates are indicated, or to add provisions where they are not indicated in AC1 503.4, or to take exceptions to AC1 503.4. The checklist consists of one column identif$ng sections, parts, and articles of AC1 503.4, and a second column of notes to the designedspecifier to indicate the action required of them.

SPECIFICATION CHECKLIST Section/Part/Article of AC1 503.4 Section 1-General requirements 1.1 Scope 1.4 Reference standards
Section 2-Materials and application

Notes to the Designer/Specifier

Indicate specific scope. Review applicability of cited references and take exceptions if required.

2.1.2 Submittals
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To whom sent?
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EPOXY RESINS

503.43

SPECIFICATION CHECKLIST (cont.) Section/Part/Article of AC1 503.4

2.1.3.2 Application control 2.1.4.2 Storage of materials

Notes to the Designer/Specifier

Mixing and application procedures submitted must be in accordance with product manufacturers instructions. Storing epoxy compounds at other than specified temperature 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 temperature, humidity, and surface water. Strict adherence to the manufacturers recommendations should be maintained. Where other unusual conditions are encountered, the material manufacturer should be consulted before application. Epoxy mortars consist of a two component epoxy system plus aggregate which may or may not be incorporated in one or both components. Since the amount and type of aggregate is important to the performance of the mortar, the supplier and contractor must be in full agreement on selection and use. If the aggregate is furnished with proper instructions by the supplier the problem is minimized. The amount and type of aggregate selected can result in a mortar mix that will not adequately wet the concrete substrate and thus can result in a poor bond. The manufacturers recommendations should be closely followed regarding the need for and application of a primer for the mortar mix selected. Speci@ limitations, if any, on use of mechanical abrasion, and on disposal of waste products. Speci@ if architect/engineer will also inspect, and if hold points are required. 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 improper cleaning of the concrete, incorrect adhesive, or faulty adhesive application techniques. Surface condition of the concrete must be in accordance with the suppliers recommendation. Some mortars require a dry surface and a test method should be available to the applicator. Some epoxy adhesives may be capable of wetting the concrete surface at temperatures below 40 F. The specification should allow such use only if test data is available which conclusively demonstrates adequate bond at the actual concrete temperature expected.
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2.1.5.1 Environmental requirements

2.2.1 Epoxy mortar

2.3.1 Preparation of surfaces 2.3.2 Inspection of surfaces 2.3.2.2 Pullout strength tests

2.3.2.4 Surface condition of concrete

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503.4-4

AC1 STANDARD

SPECIFICATION CHECKLIST (cont.)

Section/Part/Article of AC1 503.4

2.3.4.1 Mortar application

Notes to the Designer/Specifier

Too thin an application of epoxy mortar can result in a surface without adequate integrity for intended use. Too thick an application can result in delamination caused by temperature changes. See Use of Epoxy Compounds with Concrete reported by Committee 503 for a more complete explanation.

SECTION 1-GENERAL REQUIREMENTS 1.1-Scope 1.1.1 This standard specification covers repairing of
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defects in hardened portland cement concrete with sandfiied epoxy mortar. 1.1.2 The provisions of this standard specification shall govern unless otherwise specified in the contract documents. In case of conflicting requirements, the contract documents shall govern.
1.2-Notation 1.2.1 ACI:

2.1.1 Descriytion - This section covers the requirements for surface preparation of hardened concrete and for materials and application of the epoxy mortar. 2.1.2 Submittals 2.1.2.1 Contractor shall submit manufacturers certification verifying conformance to material specifications specified in Part 2.2. 2.1.3 Quality assurance 2.1.3.1 Labeling-Clearly mark all containers with the following information:
a)

American Concrete Institute P.O. Box 19150 Detroit, MI 482 19

b)

cl

d)

Name of manufacturer Manufacturers product identification Manufacturers instructions for mixing Warning for handling and toxicity

1.2.2 ASTM: American Society for Testing and Materials 1916 Race Street Philadelphia, PA 19103 1.3-Specification wording 1.3.1 The language of this standard specification is generally imperative and terse, and may include incomplete 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 inference. 1.4-Reference standards 1.4.1 The standards referred to in this Standard Specification AC1 503.4 are listed in Article 1.5.2 of this section, with their complete designation and title including the year of adoption or revision and are declared to be a part of this Standard Specification AC1 503.4 the same as if fully set forth herein, unless otherwise indicated in the contract documents. 1.4.2 ASTMstandard C 88 1-87 Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete
SECTION 2-MATERIALS AND APPLICATION

2.1.3.2 Application control-Submit mixing and application 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 breakmg container seals. 2.1.5 Project conditions 2.1.5.1 Environmental requirements-Contractor shall comply with manufacturers recommendations as to environmental conditions under which the epoxy compound may be applied. Part 2.2-Products 2.2.1 Epoxy mortar-ASTM C 881 Type III. Curing temperature requirements (Class) and viscosity (Grade), as well as special requirements regarding filling of either the components or the final system, shall be determined by supplier and contractor after project conditions have been established. Part 2.3-Execution 2.3.1 Preparation of concrete sufaces 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-

Part 2.1-General
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EPOXY RESINS

503.4-5

anical abrasion. 2.3.1.3 Mechanical abrasion-Use sandblasting, scarisling, waterblasting, or other approved means. 2.3.2 Inspection o concrete surfaces prior to mortar apf plication 2.3.2.1 Inspect all concrete surfaces prior to application of mortar 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 of Use of Epoxy Compounds with Concrete, reported by AC1 Committee 503. 2.3.2.3 Surfaces shall be free of any deleterious materials such as laitance, curing compounds, dust, dirt, and oil. Materials resulting from surface preparation 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 fi polyethylene 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 Mortar mixes 2.3.3.1 Mix epoxy components in a clean 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 mixture. Mix small batches (up to 1 qt) by use of spatulas, palette knives, or similar devices. 2.3.4 Mortar application 23.4.1 Apply epoxy mortar to concrete surface by trowel or screed. Thickness shall be within the limits recommended by the manufacturer. 2.3.4.2 Work mortar into place and consolidate thoroughly so that all contact surfaces are wet by the mortar and entrained air is reduced to the level recommended by manufacturer. 2.3.4.3 Finish surface of mortar to texture, color, and smoothness required for the specific application. 2.3.4.4 Upon completion of f i n i s h g operations, allow mortar to cure in accordance with manufacturers recommendations. 2.3.5 Cleanup 2.3.5.1 Protect concrete surfaces, beyond limits of surface receiving mortar, against spillage. 2.3.5.2 Immediately remove any epoxy compound applied or spilled beyond desired areas. Perform cleanup with material designated by epoxy mortar manufacturer. Avoid contamination of work area. 2.3.6 Safely-Epoxy materials may be skin irritants or sensitizers to many people. Accordingly, advise applicators to avoid contact with eyes and s h , inhalation of vapors, and ingestion. Make protective and safety equipment available on site. Heed all label warnings by manufacturer. Make application in accordance with applicable safety laws.

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COPYRIGHT 2003; ACI International [American Concrete Institute]

Document provided by IHS Licensee=Aramco HQ/9980755100, User=, 09/22/2003 03:02:52 MDT Questions or comments about this message: please call the Document Policy Group at 1-800-451-1584.