SECTION 03 35 16
HEAVY DUTY CONCRETE FLOOR FINISHING, HARDENING, AND REINFORCING
** NOTE TO SPECIFIER ** ABC Polymer Industries, LLC; Extruded Polypropylene Products.
This section is based on the products of ABC Polymer Industries, LLC, which is located at:
Helena Industrial Park, 545 Elm St.
Helena, AL 35080
Tel: 205-620-9889
Fax: 205-620-9882
Email: request info (sales@alabag.com)
Web: https://abcpolymerindustries.com
[ Click Here ] for additional information.
We are a fully integrated, leading manufacturer of many types of synthetic microfibers, synthetic macrofibers and steel macrofibers for the Ready-Mix Concrete Manufacturing industry. Since 1994, our concrete-fiber performance has been proven in over 200+ million cubic yards of concrete.
Our in-house registered elite engineers are always available to help you evaluate specific applications and recommend the best Fiber Reinforced Concrete (FRC) solution including fiber type, dosage rate, mix design, value engineering, and finishing methods.
Polypropylene is one of the most important and readily available plastics in the manufacturing industry. We are the leading producer of extruded polypropylene products, including microsynthetic and macrosynthetic concrete fibers. We are also a major distributor of bulk bags, fibrillated yarns, synthetic snow, and more. We are proud to repeat over and over again that we have consistently maintained a 99% on-time delivery record.
GENERAL
** NOTE TO SPECIFIER ** The section must be carefully reviewed and edited by the Engineer of Record to meet the requirements of the project and local building code. Coordinate this section with the concrete section. This section covers FullForce Fibers for use as secondary reinforcement in concrete. Consult FullForce for assistance in editing this section for the specific application.
SECTION INCLUDES
Fiber reinforced, abrasion resistant concrete slab system.
Synthetic macrofiber reinforcement for enhancement of concrete properties such as temperature-shrinkage crack reduction, secondary/post-first crack toughness, impact resistance, fatigue strength, and reduced permeability.
Integral liquid concrete hardening admixture.
RELATED SECTIONS
Section 03 30 00 - Cast-In-Place Concrete.
Section 03 39 00 - Concrete Curing.
REFERENCES
American Concrete Institute (ACI):
ACI 211.1 - Standard practices for selecting proportions for normal weight, heavyweight, and mass concrete.
ACI 302 - Guide for Concrete Floor and Slab Construction.
ACI 360 - Design of Slabs on Grade.
ACI 544.1R - State-of-the-Art Report on Fiber Reinforced Concrete.
ACI 544.3R - Proportioning, Mixing, Placing, and Finishing Steel Fiber Reinforced Concrete.
ACI 544.4R - Guide for Design with Fiber Reinforced Concrete.
American Society of Testing and Materials (ASTM):
ASTM C31 - Standard Practice for Making and Curing Concrete Test Specimens in the Field.
ASTM C78 - Test method for flexural strength of concrete.
ASTM C94 - Standard Specification for Ready Mixed Concrete.
ASTM C1116 - Specification for fiber reinforced concrete and shotcrete.
ASTM D7508 - Standard Specification for Polyolefin Chopped Strands for Use in Concrete.
ASTM C1609 - Flexural Performance of Fiber Reinforced Concrete (Using Beam with Third-Point Loading).
ASTM C1812 - Standard Practice for Design of Journal Bearing Supports to be Used in Fiber Reinforced Concrete Beam Tests.
ASTM C944 - Standard Test Method for Abrasion Resistance of Concrete Surfaces by Rotating Cutter Method.
International Code Council Evaluation Services (ICC-ES):
ICC-ES AC383 - Polyolefin Chopped Strands for Use in Concrete.
SUBMITTALS
Product Data:
Manufacturer's data sheets on each product to be used.
Product data and application rate.
Storage and handling requirements and recommendations.
Mixing and placing recommendations.
Test Reports:
Manufacturer must furnish an Engineering Report from a qualified, independent laboratory which provides ASTM C1609 test data showing that the proposed addition rate will meet or exceed the specified residual flexural strength values (fe,3) required for the subject project.
Manufacturer must furnish an Engineering Report from a qualified, independent laboratory which provides ASTM C944 test data showing that the slab system will meet or exceed the specified abrasion resistance for the subject project.
Manufacturer must furnish an ICC Evaluation Service Report (ESR) showing compliance with the requirements of ICC AC-383 Acceptance Criteria for Polyolefin Chopped Strands for Use in Concrete.
Manufacturer must furnish an Environmental Product Declaration (EPD).
QUALITY ASSURANCE
Manufacturer Qualifications: Company specializing in manufacturing products specified in this section with a minimum of five years of experience.
Installer Qualifications: Company specializing in performing work of this section with minimum two years of documented experience with projects similar in scope and size.
Source Limitations: Provide each type of product from a single manufacturing source to ensure uniformity.
Prior to pre-installation conference, prepare pre-construction trial mix or mixes, using proposed ingredients, be fabricated to ensure targeted engineering properties are met and the mix workability is within standard parameters. For fiber-reinforced concrete, prepare test specimens with the following modifications to ASTM C31/C31M:
Prepare test specimens using external vibration (or rubber mallet) to consolidate the specimens. Do not use rodding since it may produce preferential fiber alignment and nonuniform fiber distribution that may cause variance in the results.
Cast test specimens in a single layer (i.e., a single dump, not lifts) to avoid the reorientation of the fibers or fiber-free planes.
Use a cylinder mold with a diameter at least three times larger than the fiber length.
PRE-INSTALLATION CONFERENCE
Convene a conference approximately two weeks before scheduled commencement of the Work. Attendees shall include Architect, Contractor and trades involved. Agenda shall include schedule, responsibilities, critical path items and approvals.
DELIVERY, STORAGE, AND HANDLING
Deliver products in manufacturer's original unopened containers.
Product Labeling: Minimum Information.
Material name.
Manufacturer.
Weight of material.
Damaged containers will not be accepted.
Storage:
Synthetic Macrofibers:
Keep material in a dry environment.
Do not store in direct sunlight.
Keep containers sealed until ready for use.
Handling: Handle materials to avoid damage.
PROJECT CONDITIONS
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.
SEQUENCING
Ensure that products of this section are supplied to affected trades in time to prevent interruption of construction progress.
WARRANTY
Manufacturer's standard limited warranty unless indicated otherwise.
PRODUCTS
MANUFACTURERS
Acceptable Manufacturer: ABC Polymer Industries, LLC, which is located at:
Helena Industrial Park, 545 Elm St.
Helena, AL 35080
Tel: 205-620-9889
Fax: 205-620-9882
Email: request info (sales@alabag.com);Web: https://abcpolymerindustries.com
** NOTE TO SPECIFIER **
Delete one of the following two paragraphs: coordinate with requirements of Division 1 section on product options and substitutions.
Substitutions: Not permitted.
Requests for substitutions will be considered in accordance with provisions of Section 01 60 00.
FIBROUS REINFORCING - MACRO SYNTHETIC FIBER REINFORCEMENT
Basis of Design: FiberForce 750 Synthetic Macrofiber Reinforcement as manufactured by FullForce. A blend of synthetic macrofibers that combines a mechanically embossed tape macrofiber with a modified fibrillated macrofiber. The modified fibrillated portion has been engineered so the main fibrils are enlarged to increase performance. Excellent distribution and finishing properties.
Standards Compliance:
ANSI/SDI C-2017 - Shrinkage and temperature reinforcement alternative to welded wire reinforcing.
ASTM C1116 Section 4.1.3 Type III and Note 2 - For synthetic reinforced concrete.
ASTM D7508.
ICC ES AC383.
ICC ESR-4335.
Listed by UL in CBXQ.R19202 - Fiber Reinforcement and Concrete Additives. For use as an alternate or in addition to the welded wire fabric used in Floor-Ceiling Design No. D700, D800, and D900.
Material Properties:
Material: Polypropylene/Polyethelene Blend.
Absorption: None.
Specific Gravity: 0.91.
Alkali, Salt, and Acid Resistance: High.
Melting Point: 320 degrees F (160 degrees C).
Electrical Conductivity: Low.
Tensile Strength: 70 ksi (483 MPa).
Aspect Ratio: 2.0 inches - 93; 1.5 inches - 70.
Standard Length: 2.0 inches (50 mm).
Other Available Length: 1.5 inches (38 mm).
Dosage Rate: Between 3 to 11 lbs per cu yard.
Add project specifications or engineer's instructions.
Specific Dosage Rate: To be established by the project engineer or government agency for a given application based on project conditions and requirements.
Dosage rates for Synthetic Macrofiber: Determine according to ASTM 1609 flexural beam testing to determine the residual flexural strength.
See ACI 544.4R-18 Guide for Design with Fiber Reinforced Concrete or contact the Manufacturer for more information.
For Slabs on Composite Metal Deck: The Steel Deck Institute's provision requires a minimum of 4 lbs per cu yard.
** NOTE TO SPECIFIER ** Below is a correlation of steel reinforcement ratios of traditionally reinforced concrete to the required fFe3 value for fiber reinforced concrete and the macrofiber dosage required:
<=0.14%-> Fe3 = 135 psi (~3.0 pcy).
0.16% -> Fe3 = 150 psi (~3.5 pcy).
0.18% -> Fe3 = 170 psi (~4.0 pcy).
0.19% -> Fe3 = 185 psi (~4.5 pcy).
0.21% -> Fe3 = 200 psi (~5.0 pcy).
Submit manufacturer's data indicating that the proposed fiber dosage that achieve a minimum residual flexural strength, Fe3 of _____ psi (_____ MPa).
Mixing: Product is packaged in preweighed water-soluble bags.
Preload in empty ready-mix drums or add anytime during or after concrete is batched.
After Proper Dosage: Mix for a minimum of 5 minutes at full charging speed; 75 - 100 revolutions per minute, to ensure complete dispersion of fibers.
Use appropriate water reducing chemical admixture for any slump modification that may be necessary.
INTEGRAL LIQUID CONCRETE HARDENING ADMIXTURE PRODUCT
** NOTE TO SPECIFIER ** DuraForce (i) is a chloride-free, water-based liquid integral concrete hardener that increases the abrasion resistance of concrete flooring.
Basis of Design: DuraForce(i) as manufactured by FullForce. A chloride-free, water-based liquid integral concrete hardener that increases the abrasion resistance of concrete flooring. Its reactive ingredients create additional hydration products within the multitude of capillaries resulting in 3-Dimensional performance throughout the entire slab. DuraForce(i) is non-toxic and volatile organic compound (VOC) free.
Closed capillaries restrict bleed water pass through.
Helps retain moisture promoting internal curing and early strength gain with decreased set time.
Reduces hydrostatic permeability.
Standards Compliance:
Increased Wear Resistance: Per ASTM C779 and ASTM C944.
Reduced Long Term Shrinkage: Up to 35 percent based on ASTM C494 in compliance with ASTM C157.
Type S Admixture: Per ASTM C494/C494M.
Physical Properties:
Physical State: Liquid.
Toxicity: None.
Flammability: None.
Odor: Odorless.
Color: Hazy Whitish Liquid.
Turbidity: 60-70.
Freezing Point: 32 degrees F (0 degrees C).
Boiling Point: 212 degrees F (100 degrees C).
VOCs: 0.0 grams per L.
Active Solids: 20 to 25 percent.
pH: 11.0 to 12.0.
Specific Gravity: 1.19 to 1.23.
Dosage Rate: Nominal 10 oz (295 mL) per 100 lbs (45 kg) total cementitious material when used as part of the FullForce(HP) slab system.
Specific Dosage Rate: To be established by the Project Engineer of Record or government agency for a given application based on project conditions and requirements.
Mixing:
For best results, add to the freshly batched ready-mixed concrete at the end of the batch process with the tail water.
Mix for a minimum of 7 minutes at full charging speed (75 - 100 revolutions per minute) to ensure complete and uniform dispersion of integral liquid hardener.
EXECUTION
EXAMINATION
Use the packing slip and product labels to verify that product is the product specified for the project per the engineer.
Verify the concrete producer has allotted sufficient mixing time to ensure proper distribution of the Macrosynthetic Fibers and Liquid Integral Concrete Hardening Admixture.
Do not begin installation until substrates have been properly constructed and prepared as stated in the construction documents.
If substrate preparation is the responsibility of another installer, notify Architect in writing of unsatisfactory preparation before proceeding.
INSTALLATION
Install in accordance with manufacturer's instructions, approved submittals, and in proper relationship with adjacent construction.
Measure, batch, mix, and deliver concrete in accordance with ASTM C94/C94M and the requirements of section 03 30 00.
Fiber reinforcement product:
Add fibers to concrete mix at dosage rate in accordance with manufacturer's instructions and approved submittals.
Add pre-weighed water-soluble fiber bags at the end of the batching sequence. Do not add the fiber bags with the cement. Add the bags while the drum is rotating at charging speed and mix for the time required by ASTM C1116. Mix for an additional 70 drum revolutions minimum at mixing speed after adding fiber (about 5 minutes).
Integral liquid hardener:
Add integral liquid harder to concrete mix at dosage rate in accordance with manufacturer's instructions and approved submittals.
PLACING AND FINISHING
As specified in Section 03 30 00.
To ensure the fibers at the surface of the slab are encapsulated in the concrete matrix, and to improve the quality of consolidation of the concrete, utilize a laser or vibrating screed.
FullForce(HP) High Performance Slab System shall receive a mirrored/burnished finish.
If fibers are visible at the surface of the concrete, they may be removed with a torch burner.
JOINTING
Sawcut contraction joints should be implemented shortly after final set when cutting will not pull up fibers or damage the surface through raveling or tearing . The sawcut depth should be one-third the slab thickness.
FIELD QUALITY CONTROL
Field Inspection: Coordinate field inspection in accordance with appropriate sections in Division 01.
** NOTE TO SPECIFIER ** Include if manufacturer provides field quality control with onsite personnel for instruction or supervision of product installation, application, erection, or construction. Delete if not required.
Manufacturer's Field Services: Manufacturer's representatives shall provide technical assistance as required.
Project team: Upon request, provide batch tickets indicating presence and dosage of fiber reinforcement.
Project team: Upon request, provide batch tickets indicating presence and dosage of integral liquid hardener.