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	SECTION 03540
	CEMENTITIOUS UNDERLAYMENT
	Copyright 2011 ARCAT, Inc. - All rights reserved
	** NOTE TO SPECIFIER ** Dayton Superior Chemical and Cement Products; Cementitious underlayment products. . This section is based on the products of Dayton Superior Chemical and Cement Products, which is located at: 4226 Kansas Ave. Kansas City, KS 66106 Tel: Toll Free: (866) 329-8724 Fax: (913) 279-4800 www: daytonsuperiorchemical.com
	e-mail: chemicals@daytonsuperior.com [ Click Here ] for additional information.
	Dayton Superior is the leading manufacturer of cutting-edge chemical solutions to solve concrete construction and repair problems. Our products are distributed throughout North America and globally by the largest, best-backed and trained dealer/distributor network in the construction supply industry supported by over 20 factory service centers and manufacturing locations. Dayton's worldwide experience and product emplacement record can solve your problems. This specification includes cementitious self leveling underlayment products. .
	PART 1	GENERAL
	1.1	SECTION INCLUDES
	** NOTE TO SPECIFIER ** Delete items below not required for project.
		A.	Self-Leveling Concrete Underlayment
		B.	Bonding Agent
	1.2	RELATED SECTIONS
	** NOTE TO SPECIFIER ** Delete any sections below not relevant to this project; add others as required.
		A.	Section 01100 - Alteration Project Procedures.
		B.	Section 02070 - Selective Demolition for Remodeling.
		C.	Section 03300 - Cast-In-Place Concrete.
		D.	Section 03415 - Precast Concrete Hollow Core Planks: Precast concrete floor substrate.
		E.	Section ________ - ____________: Wood floor substrate
		F.	Section 09000 - Finishes.
	1.3	REFERENCES
	** NOTE TO SPECIFIER ** Delete references from the list below that are not actually required by the text of the edited section.
		A.	ASTM C 109 Modified - Compressive Strength of Hydraulic Cement Mortars.
		B.	ASTM C 150: Standard Specification for Portland Cement.
		C.	C 191 - Test Method for Time of Setting of Hydraulic Cement by Vicat Needle.
		D.	ASTM C 348 - Flexural Strength of Hydraulic Cement Mortars.
	1.4	SUBMITTALS
		A.	Submit under provisions of Section 01300.
		B.	[ Product Data ]: Manufacturer's data sheets on each product to be used, including:
			1.	Preparation instructions and recommendations.
			2.	Storage and handling requirements and recommendations.
			3.	Installation methods.
		C.	Manufacturer's certification that the product is Portland cement-based having an inorganic binder content which is a minimum 80 percent Portland cement when tested per ASTM C 150.
	1.5	QUALITY ASSURANCE
		A.	Manufacturer Qualifications: Company specializing in manufacturing Products specified in this section with minimum five years documented experience.
	** NOTE TO SPECIFIER ** Include a mock-up if the project size and/or quality warrant taking such a precaution. The following is one example of how a mock-up on a large project might be specified. Delete if not required.
		B.	Mock-Up: Provide a mock-up for evaluation of surface preparation techniques and application workmanship.
			1.	Prepare area designated by Architect.
			2.	Mock-up area shall be 6 feet by 6 feet (1.83 m by 1.83 m).
			3.	Do not proceed with remaining work until workmanship, is approved by Architect.
			4.	Incorporate mock-up into final construction upon approval.
	1.6	DELIVERY, STORAGE, AND HANDLING
		A.	Store products in manufacturer's unopened packaging until ready for installation.
		B.	Store products in a dry area at a temperature between 30 and 100 degrees F (minus 1 and plus 38 degrees C). Provide adequate ventilation and keep away from ignition sources.
	1.7	PROJECT CONDITIONS
		A.	Maintain environmental conditions (temperature, humidity, and ventilation) within limits recommended by manufacturer for optimum results. Do not install products under environmental conditions outside manufacturer's absolute limits.
		B.	Do not install below 50 degrees F surface temperature. Install quickly if floor is warm and follow hot weather precautions. Do not mix with cement or additives.
		C.	Ventilate spaces during curing process to remove excess moisture.
	PART 2	PRODUCTS
	2.1	MANUFACTURERS
		A.	Acceptable Manufacturer: Dayton Superior, which is located at: 1125 Byers Rd. ; Miamisburg, OH 45342; Toll Free Tel: 888-977-9600; Tel: 937-428-6360; Email: request info; Web: www.daytonsuperior.com
	** NOTE TO SPECIFIER ** Delete one of the following two paragraphs; coordinate with requirements of Division 1 section on product options and substitutions.
		B.	Substitutions: Not permitted.
		C.	Requests for substitutions will be considered in accordance with provisions of Section 01600.
	** NOTE TO SPECIFIER ** The following paragraphs include various type of cementitious underlayment. LeveLayer I, II and III are intended for interior use and each has differing properties that make it more suitable for specific applications. LeveLayer IV is intended for exterior applications. Select the products required from the following paragraphs and delete those not required.
	2.2	MATERIALS
	** NOTE TO SPECIFIER ** LeveLayer I is intended for use in new and existing conditions to provide a smooth surface on interior concrete floors. It can be used to correct rough or unfinished concrete over existing ceramic tile or terrazzo floors and is approved by the Ceramic Tile Institute.
		A.	Cementitious Underlayment: LeveLayer I Self- Leveling Underlayment. Technical Data as follows:
			1.	Compressive Strength: 5,400 psi (37.2 MPa) @ 28 days (Air curing samples) when tested in conformance with ASTM C 109.
			2.	Flexural Strength: 1,000 psi (6.9 Mpa) @ 28 days when tested in conformance with ASTM C 348.
			3.	Initial Set: 90 minutes when tested in accordance with ASTM C 191.
			4.	Final Set 2-1/2 hours when tested in accordance with ASTM C 191.
			5.	Working Time: 20 minutes at 70 degrees F (21 degrees C).
	** NOTE TO SPECIFIER ** LeveLayer II is intended for use in new and existing conditions to provide a smooth surface on interior concrete floors. It can be used to correct rough or unfinished concrete over existing ceramic tile or terrazzo floors. LeveLayer II will set-up faster than LeveLayer I.
		B.	Cementitious Underlayment: LeveLayer II Self- Leveling Underlayment. Technical Data as follows:
			1.	Compressive Strength: 4,200 psi (28.9 MPa) @ 28 days (Air curing samples) when tested in conformance with ASTM C 109.
			2.	Flexural Strength: 1,200 psi (6.9 Mpa) @ 28 days when tested in conformance with ASTM C 348.
			3.	Initial Set: 1 hour and 15 minutes when tested in accordance with ASTM C 191.
			4.	Final Set 1 hour and 30 minutes when tested in accordance with ASTM C 191.
			5.	Working Time: 20 minutes at 70 degrees F (21 degrees C).
	** NOTE TO SPECIFIER ** LeveLayer III is intended for use in new and existing conditions to provide a smooth surface on interior concrete floors. It can be used to correct rough or unfinished concrete in industrial applications. LeveLayer III has a greater compressive strength but has a shorter working time during installation.
		C.	Cementitious Underlayment: LeveLayer III Self- Leveling Underlayment. Technical Data as follows:
			1.	Compressive Strength: 7,000 psi (48.3 MPa) @ 28 days (Air curing samples) when tested in conformance with ASTM C 109.
			2.	Flexural Strength: 950 psi (6.6 Mpa) @ 28 days when tested in conformance with ASTM C 348.
			3.	Initial Set: 65 minutes when tested in accordance with ASTM C 191.
			4.	Final Set 1-1/2 hours when tested in accordance with ASTM C 191.
			5.	Working Time: 15 minutes at 68 degrees F (20 degrees C).
	** NOTE TO SPECIFIER ** LeveLayer IV is intended for use in new and existing conditions to provide a smooth surface on exterior concrete floors. It can be used to correct rough or unfinished on sidewalks, balconies, patios, driveways, garage floors, loading docks and other similar conditions.
		D.	Cementitious Underlayment: LeveLayer IV Self- Leveling Underlayment. Technical Data as follows:
			1.	Compressive Strength: 5,135 psi (35.4 MPa) @ 28 days (Air curing samples) when tested in conformance with ASTM C 109.
			2.	Tensile Strength: 345 psi (2.4 Mpa) @ 28 days when tested in conformance with ASTM C 348.
			3.	Initial Set: 1 hour when tested in accordance with ASTM C 191.
			4.	Final Set 2 hours when tested in accordance with ASTM C 191.
			5.	Working Time: 20 minutes at 70 degrees F (21 degrees C).
	** NOTE TO SPECIFIER ** Use the following primer with all cementitious underlayment specified. The following primer is for use over standard absorbent concrete and for non-porous subfloors, cutback and other non-water soluble adhesive residues, metal, and wooden subfloors.
		E.	Primer: LeveLayer Bonding Agent (J-42).
	** NOTE TO SPECIFIER ** Aggregate is required for underlayment installed in thicknesses over 1-1/2 inch thick. Delete if not required.
		F.	Aggregate shall be well graded, washed gravel, 1/8 inch to 1/4 inch. Use for underlayment installed in thicknesses over 1-1/2 inch thick.
		G.	Water shall be clean and potable.
	2.3	MATERIALS
		A.	Mix materials in accordance with manufacturer's instructions.
		B.	Standard Mix: Mix in accordance with manufacturers instructions.
			1.	Mix in 2-bag batches.
			2.	Use quantity of water per 50 pound bag as recommended by manufacturer.
			3.	Use cool water not over 70 degrees F.
			4.	Mix using a 1/2 inch heavy-duty drill with blending paddle at a minimum of 650 rpm. Mix thoroughly for approximately 2-3 minutes to obtain a lump-free mixture.
		C.	Aggregate Mix: For areas to be installed over 1-1/2 inch thick.
			1.	Mix as specified for standard mix.
			2.	Add from 1/3 to 1 part by volume of 1/8 inch to 1/4 inch aggregate and mix thoroughly to evenly distribute aggregate.
			3.	Do not use sand.
		D.	Pumped Mix:
			1.	Mix as specified for standard mix. Do not overwater.
			2.	Check the consistency of the product on the floor to ensure a uniform distribution of the sand aggregate at both the top surface and bottom of the pour. If settling is occurring, reduce the water amount and recheck.
			3.	Conditions during the installation, such as variations in water, powder, substrate, and ambient temperature, require that the water setting be monitored and adjusted carefully to avoid overwatering.
	PART 3	EXECUTION
	3.1	EXAMINATION
		A.	Do not begin installation until substrates have been properly prepared.
		B.	If substrate preparation is the responsibility of another installer, notify Architect of unsatisfactory preparation before proceeding.
	3.2	PREPARATION
		A.	Clean surfaces thoroughly prior to installation.
		B.	Prepare surfaces using the methods recommended by the manufacturer for achieving the best result for the substrate under the project conditions.
			1.	All subfloors must be sound, solid, clean, and primed.
			2.	Concrete subfloors shall be of adequate strength, clean and free of all oil, grease, dirt, curing compounds and any substance that might act as a bond breaker before priming. Mechanically clean if necessary using shot blasting or other methods. Acid etching and the use of sweeping compounds and solvents are not acceptable.
			3.	Wooden subfloors shall be clean and free of all foreign matter. Sand to bare wood then vacuum to remove all dust. Re-nail any loose boards exhibiting movement.
			4.	Metal subfloors shall be clean and free of all rust and foreign matter. Contact manufacturer for specific applications over metal floors.
			5.	Cutback and other non-water soluble adhesive residues must be wet scraped to a thin, well-bonded layer.
			6.	Non-porous subfloors such as ceramic and quarry tile as well as terrazzo should be clean and free of all waxes and sealers.
			7.	Inspect moisture content of substrates. Correct for moisture or any other conditions that could affect the performance of the underlayment or the finished floor covering.
		C.	Joint Preparation: Repair and reinforce all cracks in the subfloor to minimize telegraphing through the underlayment.
			1.	Moving Joints: Continue or treat all expansion and isolation joints up through the underlayment.
			2.	Fill all non-moving joints with Dayton Superior Polyfast a minimum of 24 hours prior to application of underlayment as required.
		D.	Close floor openings.
	** NOTE TO SPECIFIER ** Edit the following paragraphs to suit the requirements of the project. Delete the paragraphs for conditions that do not apply.
	3.3	APPLICATION OF PRIMER
		A.	Install products in accordance with manufacturer's instructions.
		B.	Prime standard absorbent concrete subfloors with LeveLayer Bonding Agent (J-42).
			1.	Mix bonding agent 1:1 with water and apply evenly with a soft push broom.
			2.	Do not leave any bare spots. Remove all puddles and excess primer.
			3.	Allow to dry (a minimum of 3 hours and a maximum of 24 hours) to a clear, thin film.
			4.	Do not apply underlayment until the primer is dry.
			5.	Primer coverage is approximately 400 to 600 sq. ft. per gallon depending on surface texture.
		C.	Prime extremely absorbent concrete subfloors with an initial application of LeveLayer Bonding Agent (J-42) mixed with 3 parts water using a soft push broom.
			1.	Do not leave any bare spots. Remove all puddles and excess primer.
			2.	Allow to dry thoroughly before proceeding with the standard application of primer as specified above for standard absorbent concrete.
		D.	Prime non-porous subfloors, wooden or metal subfloors, or cutback and other non-water soluble adhesive residues over concrete as follows:
			1.	Prime with J-42 (undiluted).
			2.	Apply with a short-nap or sponge paint roller, leaving a thin coat of primer no heavier than a thin coat of paint. Do not leave any bare spots. Remove all puddles and excess primer.
			3.	Allow to dry (minimum 3 hours, maximum 24 hours)to a clear, slightly tack film.
			4.	Underlayment shall not be installed until primer is dry. Primer coverage is approximately 200 to 400 square feet per gallon.
			5.	Minimum drying time for over cutback adhesive is 18 hours.
	** NOTE TO SPECIFIER ** Edit the following paragraphs to suit the requirements of the project. Delete the paragraphs for conditions that do not apply.
	3.4	APPLICATION OF UNDERLAYMENT
		A.	Wooden Subfloors:
			1.	After priming, install 3.2 or 3.4 galvanized diamond metal lath over wood subfloors.
			2.	Staple mesh to wood subfloor approximately 6 inches on center.
		B.	Steel Subfloors:
			1.	Clean steel and primed with an anti-corrosive paint.
			2.	When paint is totally dry, prime surface with (J-42 undiluted).
		C.	Placing:
			1.	Mix underlayment as specified.
			2.	Pour or pump the underlayment and spread in place with the spreader.
			3.	Use smoother for featheredge and touch-up.
			4.	Wear baseball or soccer shoes with non-metallic cleats to avoid leaving marks in the liquid LeveLayer.
			5.	Underlayment can be walked on in 2-3 hours at 70 degrees F.
		D.	Preparation For Finish Flooring Installation:
			1.	Underlayment can accept finish floor covering materials after 16 hours at 70 degrees F and 50 percent relative humidity.
			2.	Due to the wide range of adhesives that are used to install floor coverings, some adhesives may dry more quickly over underlayment than over other substrates.
			3.	If this condition occurs, prime the surface of the underlayment with LeveLayer Bonding Agent (J-42) diluted 1:3 with water.
			4.	Allow the primer to dry 1-3 hours before proceeding with the adhesive installation.
	3.5	PROTECTION
		A.	Protect installed products until completion of project.
		B.	Do not permit traffic over unprotected floor underlayment surfaces.
		C.	Protect the surface of the underlayment from abuse by other trades by the use of plywood, Masonite or other suitable protection course until finished flooring is installed.
		D.	Touch-up, repair or replace damaged products before Substantial Completion.
	END OF SECTION