SECTION 03 35 13

HIGH-WEAR HEAVY-DUTY CONCRETE OVERLAY

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PART 1    GENERAL
1.1	SECTION INCLUDES
A.	High-Strength Emery Aggregate Topping.
B.	Accessories.
1.2	RELATED SECTIONS
A.	Section 03 30 00 - Cast-In-Place Concrete.
B.	Section 03 35 00 - Concrete Finishing.
C.	Section 03 35 43 - Polished Concrete Finishing.
D.	Section 03 39 00 - Concrete Curing.
E.	Section 03 39 35 - Concrete Densifier/Sealer/Hardener.
F.	Section 07 92 00 - Joint Sealants.
1.3	REFERENCES
A.	American Concrete Institute (ACI):
1.	ACI 301-20 Specification for Structural Concrete for Buildings
2.	ACI 302.1R-15 Guide to Concrete Floor and Slab Construction
3.	ACI 305 R-20 Guide to Hot Weather Concreting
4.	ACI 306 R-16 Guide to Cold Weather Concreting
5.	ACI 308 R-16 Guide to External Curing of Concrete
B.	American Society for Testing Materials (ASTM):
1.	ASTM A 36-19 Standard Specification for Carbon Structural Steel
2.	ASTM C 33-18 Standard Specification for Concrete Aggregates
3.	ASTM C109 Standard Test Method for Compressive Strength of Hydraulic Cement Mortars
4.	ASTM C78-09 Standard Test Method for Flexural Strength of Concrete
5.	ASTM C 171-20 Standard Specification for Sheet Materials for Curing Concrete
6.	ASTM C 666/666M Standard Test Method for Resistance of Concrete to Rapid Freezing and Thawing
7.	ASTM C 779-12 Standard Test Method for Abrasion Resistance of Horizontal Concrete Surfaces
8.	ASTM C 1315-19 Liquid Membrane-Forming Compounds Having Special Properties of Curing and Sealing Concrete
C.	International Concrete Repair Institute (ICRI):
1.	ICRI 320.1R-19 Guideline for Selecting Application Methods for the Repair of Concrete Surfaces
1.4	DEFINITIONS
A.	Concrete Overlay and Topping are used interchangeably.
1.5	SUBMITTALS
A.	Submit under provisions of Section 01 30 00.
B.	Product Data:
1.	Manufacturer's data sheets on each product to be used.
2.	Preparation instructions and recommendations.
3.	Storage and handling requirements and recommendations.
4.	Typical installation methods.
C.	Shop Drawings: Include details of materials, construction, and finish. Include relationship with adjacent construction.
D.	Other manufacturers wishing to have their products included in the work must submit a written request for approval to bid those products not less than fourteen (14) calendar days prior to bid opening, and may only bid their products if they are added to the pre-approved list of manufacturers and products by a bid addendum. 
1.6	QUALITY ASSURANCE
A.	The Contractor installing the manufacturer's products must be certified by the manufacturer as trained, experienced, and fully qualified to install the floor topping materials and system.
B.	The manufacturer-certified Contractor must have completed at least three similar floor topping projects using the approved products within the previous five (5) years.
1.	The completed projects will have been not less than 5,000 sq.ft. (465 sm) in area.
2.	Submit documentation of the Contractor's qualifications with the bid.
3.	Failure to submit the Contractor's qualifications will automatically disqualify a bid. 
C.	Source Limitations: Provide each type of product from a single manufacturing source to ensure uniformity.
1.7	PRE-INSTALLATION CONFERENCE
A.	Convene a conference approximately two (2) weeks before scheduled commencement of the Work. Attendees will include Architect, Contractor and trades involved. Agenda will include schedule, responsibilities, critical path items and approvals.
1.8	DELIVERY, STORAGE, AND HANDLING
A.	Store and handle in strict compliance with manufacturer's written instructions and recommendations.
B.	Protect from damage due to weather, excessive temperature, and construction operations.
1.9	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 recommended limits.
1.10	WARRANTY
A.	The finish work will be warranted against defects in materials and workmanship, and from premature wear, for a period of two (2) years from the date that the finished floor is placed back in service by the Owner.
B.	The warranty will be co-signed by the Manufacturer and the Contractor and will be on the manufacturer's standard warranty form. 
PART 2    PRODUCTS
2.1	MANUFACTURERS
A.	Acceptable Manufacturer: Metalcrete Industries, which is located at:<BR />4133 Payne Ave.<BR />Cleveland, OH 44103<BR />Toll Free Tel: 800-526-5602<BR />Tel: 440-526-5600<BR />Fax: 440-526-5601<BR />Email: request info (sales@metalcreteindustries.com);Web: https://metalcreteindustries.com 
B.	Substitutions: Not permitted.
C.	Requests for substitutions will be considered in accordance with the provisions of Section 01 60 00.
2.2	PERFORMANCE REQUIREMENTS
A.	Emery Aggregate Concrete Topping:
1.	Minimum compressive strength of 12,000 psi at 28 days, per ASTM C 109.
2.	Minimum flexural strength of 1,300 psi at 28 days, per ASTM C 78.
3.	Wear resistance of not more than 0.024 inches in 60 minutes, per ASTM C 779.
2.3	HIGH-STRENGTH EMERY AGGREGATE FLOOR TOPPING
A.	Basis-of-Design Product: Met-Top E - High Strength Emery Aggregate Topping, as manufactured by Metalcrete Industries.
B.	The cement-based emery aggregate concrete overlay will be a prepackaged system designed as a concrete patching / overlay material.
C.	The product will be recommended by the manufacturer to be able to be placed as thin as 2 inches (50 mm) and up to a thickness of 6 inches (152 mm).
2.4	ACCESSORIES 
A.	Bonding Agent: Metco Low-Mod epoxy Bonding Agent as manufactured by Metalcrete Industries.
B.	Bond Coat Sand: High purity No. 12 or coarser quartz sand.
C.	Curing Compound: Seal N Kure as manufactured by Metalcrete Industries.
D.	Moisture Retaining Cover: A combination of 10 mil burlap and 12 mil polyethylene sheeting.
E.	Mechanical Anchors: Zinc-coated, alloy steel, round head, split drive anchors 1/2 inch (12 mm) diameter with not less than 1-1 /2 inch (38 mm) embedment in pre-drilled holes. Powder-actuated placement of mechanical anchors will not be used.
F.	Control Joint Filler: Jointfill 302 as manufactured by Metalcrete Industries.
G.	Non-Shrink Rapid Cure Epoxy Grout: Diamite FS Epoxy Grout as manufactured by Metalcrete Industries.
PART 3    EXECUTION
3.1	GENERAL
A.	Do not begin installation until the substrates have been properly constructed and prepared.
B.	If substrate preparation is the responsibility of another installer, notify Architect in writing of unsatisfactory preparation before proceeding.
3.2	REFERENCE FLOOR ELEVATIONS AND JOINT LOCATIONS
A.	Prior to proceeding with surface preparation, establish reference floor elevations and existing floor joint locations by survey and other methods.
B.	Reference elevations will be used when setting screeds to ensure that the finished floor drainage pattern matches the original floor drainage pattern and provides positive drainage from East to West and ends at the compacter chutes.
C.	Reference floor joint locations to be used when saw cutting joints in the new topping layer so that these align with joints in the underlying floor slab.
3.3	SURFACE PREPARATION FOR CONCRETE RESURFACING
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.
C.	Comply with manufacturer's written instructions for cleaning, saw cutting, scarifying / grinding, and shot blasting.
D.	Saw cut where overlay abuts compacter chute steel and the existing concrete which does not receive resurfacing. Saw cut will be to produce a minimum depth of concrete topping of not less than 2 inches (50 mm).
E.	Avoid cutting rebar.
F.	Avoid damaging adjacent steel and concrete surfaces.
G.	Mechanically scarify the entire area to receive resurfacing.
H.	Shotblast scarified surface with heavy steel shot to remove any loose, unsound, or unbonded concrete or existing overlay and produce a roughened substrate.
I.	Roughed surface will have an amplitude of 1/4-inch (6 mm) with exposed aggregate or compared with a surface roughness of at least seven (7) as defined by the International Concrete Repair Institute. Use shotblasting equipment to achieve a minimum surface profile of CSP-5.
J.	Pressure wash shotblasted surface with a minimum 3,000 psi pressure washer to clean and remove any loose or unsound material. If necessary, pressure wash shotblasted / scarified surface with a minimum 3,000 psi pressure washer to clean and remove any loose or unsound material.
K.	Remove any standing water prior to bonding agent or topping placement.
3.4	REBAR REPAIR / REPLACEMENT
A.	Repair or replace any missing or damaged primary structural reinforcement in the upper floor rebar mat that is exposed following the surface preparation.
B.	Do not proceed with bond coat or topping placement until all rebar work has been inspected and approved by Owner's engineering representative.
3.5	MECHANICAL ANCHORS AND KEYWAY
A.	Install two (2) staggered rows of headed stud perimeter fasteners as shown in the manufacturer's installation instructions, diagonally spaced at 12 to 18 inches (305-457 mm) at joints and the perimeter of the repair area where it abuts areas of the floor that are not being resurfaced.
B.	Install fasteners in pre-drilled holes.
C.	The perimeter of the repair area where it abuts areas of the floor that are not being resurfaced must be keyed to increase the mechanical bond between the base concrete and the topping material. The keyway will be a minimum of 1 inch (25 mm) deeper than the topping thickness.
3.6	EXAMINATION OF PREPARED FLOOR SLAB
A.	Verify by examination that surfaces are acceptable to receive the concrete topping. Obtain manufacturer's written approval of surface preparation before proceeding with topping placement. 
3.7	CONCRETE TOPPING APPLICATION
A.	Prior to the topping placement, coat the surface of the concrete substrate with an epoxy bonding agent aggregated with sand. Broadcast to refusal. Allow the epoxy and aggregate bed to cure. Mix and place the bond coat in accordance with the manufacturer's written instructions.
B.	Place screed bars for each area receiving topping mix.
C.	Mix prepackaged liquids and powder components in on-site mixers. Provide a back-up mixer.
D.	Screed the topping mix using a heavy-duty roller screed.
E.	Place and screed topping mix to the depths required to re-establish the floor drainage pattern of the original floor construction.
F.	Smooth any areas by bullfloating and power troweling as necessary and as recommended by the product manufacturer.
G.	Place only an area of topping which can be properly finished.
3.8	CURING
A.	Apply Seal N Kure 30 immediately after finishing to help retain moisture. Keep surface of overlay continually moist for a total of seven (7) days flowing placement and finishing.
B.	Use specified moisture curing compound and burlap and polyethylene moisture retaining cover.
C.	Temporarily remove cover and spray topping surface as necessary to keep wet, then recover throughout the initial curing period. If using thick mil plastic to cure the concrete topping, temporarily remove cover and spray topping surface as necessary to keep wet, then recover throughout the initial curing period.
3.9	CONTRACTION JOINTS
A.	Approximately (three) 3 days following completion of the topping mix finishing, while the concrete is still green, locate and cut contraction joints in the newly placed topping at the location of the existing contraction joints in the original floor slab.
B.	Adjust the timing of the joint cutting based on the condition and state of the topping cure.
3.10	JOINT FILLING
A.	After cutting of joints is complete and before turning the floor over to the Owner, fill all freshly cut joints with Jointfill 302.
3.11	QUALITY CONTROL
A.	The Owner will coordinate field quality control tests of the topping material as needed.
3.12	CLEANING AND PROTECTION
A.	Clean floor surface in accordance with the manufacturer's recommendations. 
B.	Touch-up, repair or replace damaged floor surfaces before Substantial Completion.

END OF SECTION