SECTION POLISHED CONCRETE FLOOR FINISHES EXISTING FLOORS

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SECTION POLISHED CONCRETE FLOOR FINISHES EXISTING FLOORS Powered By Docstoc
					 1         9-10-10 PR #1

UniSpec II-Store Planning                                                                                                          073109
SPCI S-5212 (Increase allowable minimum Specified Overall Gloss Value (SOGV) from 45 to 60 and allowable Minimum Local Gloss Value (MLGV)
from 30 to 45.)
Rev 4: (07/31/09) SPCI S-5245 (Multiple changes throughout section.)


SECTION 03363 - POLISHED CONCRETE FLOOR FINISHES (EXISTING FLOORS)                                          1

PART 1 - GENERAL

1.1          SUMMARY

      A.     Section Includes:
             1.     Removal of all existing floor finishes (sealers, coatings, tile, etc.) and underlayments, as necessary.
             2.     Grinding of slab surface to receive densifier treatment.
             3.     Application of reactive surface densifier.
             4.     Applications of stain guard surface treatment.
             5.     Progressive polishing and burnishing of slab surface to achieve required gloss values.

      B.     Related Sections:
             1.     Section 01330 – Submittal Procedures
             2.     Section 01458 – Testing Laboratory Services: Procedures for inspection, testing, and documentation by
                    Owner-furnished Construction Testing Laboratory.
             3.     Section 03905 - Interior Concrete Slab Repairs and Joint Filler Replacement.

      C.     Furnish all labor, materials, equipment and services for the Work of this Section.

1.2          SUBMITTALS

      A.     Section 01330 - Submittal Procedures: Procedures for Submittals.

      B.     Product data for:
             1.    Manufacturer and model of equipment to be used, including all types of grinding heads, saws and dust
                   extraction systems for polishing, joint filler replacement and slab defect repairs.
             2.    Reactive surface densifying system including stain guard treatment.

      C.     Certifications:
             1.      Provide list of a minimum of 5 projects performed within last three years of similar type, size, and
                     complexity. Submit project names, addresses, contacts, and phone numbers for each project.
             2.      Applicator Qualifications: Submit letter of certification, identifying the individuals that are currently
                     certified applicators of the system and are familiar with proper procedures and installation methods as
                     required by the manufacturer for:
                     a.      Surface densifier system.
                     b.      Joint filler replacement materials (specified in section 03905).
                     c.      Surface defect repair materials (specified in section 03905).
             3.      A minimum of one installer for work requiring certification, possessing manufacturer’s documents that
                     state this individual has been specifically trained and certified, must be present during all installations of
                     such work.

      D.     Floor Polishing Plan:
             1.     Prior to commencement of work, submit a Floor Polishing Plan (developed from Sheet A-1 “Floor Plan”)
                    including:
                    a.      Size, location and anticipated progression of individual nightly work areas.
                    b.      Location of all cracks, spalls and other surface defects requiring repairs.
                    c.      Electrical supply locations, including exterior access if generators are utilized.


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           2.     Use plan to document gloss value measurements, as reported weekly from CTL.
           3.     Plan shall be reviewed and accepted by Wal-Mart Construction Manager and Store Manager prior to start
                  of work.

      E.   Test Results:
           1.     Submit final floor gloss and slip resistance test reports produced by the Construction Testing Laboratory to
                  Wal-Mart’s Concrete Consultant and the Wal-Mart Construction Manager.

      F.   Closeout Documents: Submit in accordance with Section 01770.
           1.    Maintenance Data: Submit 7 sets of maintenance data as follows:
                 a.     Manufacturer’s technical product data and literature.
                 b.     Storage and handling requirements and recommendations.
                 c.     Testing.
                 d.     Manufacturer’s safety data sheets and related safety requirements.
                 e.     As-built Floor Polishing Plan.

1.3        QUALITY ASSURANCE

      A.   Regulatory Requirements:
           1.    Accessibility Requirements: Comply with applicable requirements of the Americans with Disabilities Act
                 Accessibility Guidelines (ADAAGs) for Buildings and Facilities; Final Guidelines, revisions, and updates
                 for static coefficient of friction for walkway surfaces.
           2.    Environmental Requirements: Comply with current Federal and local toxicity and air quality regulations
                 and with Federal requirements on content of lead, mercury, and other heavy metals. Do not use solvents in
                 floor polish products that contribute to air pollution.

      B.   Wal-Mart Concrete Consultant
           1.   Structural Services, Inc.: 214-522-6438

      C.   Technical Representative: At the request of the Wal-Mart Construction Manager or Concrete Consultant, a manu-
           facturer’s technical representative shall be on site to oversee the installation of the surface densifier system, joint
           filler or surface defect repairs to verify proper installation of product.

      D.   Mock Up: Prior to commencement of work, prepare mock up for evaluation of surface preparation techniques and
           application workmanship.
           1.     Designate 250 square feet for mock up of system specified, using same materials, tools, equipment, and
                  procedures intended for actual surface preparation in Sales floor at location determined by the Wal-Mart
                  Construction Manager. Include properly prepared slab joints, surface spalls and crack repairs if available.
                  Include slab edges adjoining existing partitions/walls.
           2.     Notify Wal-Mart Construction Manager minimum 7 days prior to date and time when mockups will be
                  performed and completed.
           3.     Choose mockup location that demonstrates proposed range of aesthetic effects and workmanship.
           4.     Obtain Wal-Mart Construction Manager’s approval of mockups before proceeding with work.
           5.     Maintain mockups during construction in undisturbed condition as a standard for judging completed work.
           6.     Approved mockups installed in sales areas may become part of the completed work if acceptable to Wal-
                  Mart Construction Manager.

      E.   Mandatory Pre-Installation Meeting:
           1.   Schedule meeting to be conducted a minimum of one day prior to first polishing of existing concrete slab
                and after installation of mockup and all required submittals have been approved.
           2.   Obtain meeting agenda from Wal-Mart Concrete Consultant.
           3.   Notify all required attendees in writing of scheduled time and meeting location a minimum of 14 days in
                advance of pre-installation meeting. Include copy of agenda with invitation.
           4.   Attendees shall include all personnel directly involved in overseeing and who have authority to control the
                work, including but not limited to the following:
                a.      Wal-Mart Construction Manager


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                  b.     Wal-Mart Store Manager
                  c.     Wal-Mart Concrete Consultant
                  d.     General Contractor
                         1)     Project Manager
                         2)     Superintendent (overseeing polish work)
                  e.     Concrete Polishing Subcontractor
                         1)     Project Manager
                         2)     Foreman (Representative that will be present during all phases of work)
                  f.     Joint Filler Replacement and Slab Repair Subcontractor (if separate)
                  g.     Wal-Mart Construction Testing Laboratory representative
                  h.     Manufacturers’ representatives for all products specified in this section.
           5.     Convene meeting only when all required parties are in attendance.
           6.     Review the following:
                  a.     Expectations of finished work specified.
                  b.     Scheduling and phasing of work.
                  c.     Environmental requirements (store working conditions).
                  d.     Existing joint filler replacement.
                  e.     Repair of existing slab defects.
                  f.     Grinding and polishing procedures, including application of liquid densifier system.
                  g.     Field quality control requirements.
                  h.     Slab protection after completion of work.
           7.     Record and distribute minutes to all parties in attendance within 2 days of the meeting via e-mail in .pdf
                  format. Completed pre-installation meeting agenda is acceptable.

1.4        DELIVERY, STORAGE, AND HANDLING

      A.   Deliver materials to site in original, factory sealed, unopened, new containers (drums) bearing manufacturer’s
           name and label intact and legible, with the following information:
           1.     Name or title of material.
           2.     Manufacturer’s standard container (drum) numbers.
           3.     Application instructions.

      B.   Storage:
           1.     Store materials in protected and well-ventilated area at temperatures between 40 and 90 degrees F unless
                  otherwise required by manufacturer.
           2.     Keep containers sealed until ready for use.
           3.     Do not use materials beyond manufacturer’s shelf life limits.

      C.   Handling: Protect materials during handling and application to prevent damage or contamination.
           1.    Dispense penetrating liquid densifier only from factory sealed and numbered containers (drums).
           2.    Maintain record of container (drum) numbers received and used during floor treatment.

1.5        ENVIRONMENTAL REQUIREMENTS

      A.   Limit and control damage from excessive dust and moisture caused by surface preparation and polishing.

      B.   Comply with manufacturer's written instructions for substrate temperature and moisture content, ambient tempera-
           ture and humidity, ventilation and other conditions affecting product performance.

      C.   All replaced concrete shall be cured a minimum of 28 days or until such point equipment can be put on slab with-
           out displacing aggregate.

1.6        SEQUENCING AND SCHEDULING

      A.   Floor Polishing Plan schedule: Provide detailed written schedule for sequence of work to ensure uninterrupted
           progress of Owner's on-site operations.


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      B.   Coordinate project phasing and relocation of racking, shelving, or merchandise to ensure minimum interference
           with other aspects of the Work. This may require multiple visits to job site on a given project.

      C.   Conduct grinding and polishing work in manner to minimize disruption of Owner's normal operations. Work shall
           be performed after normal hours of operation and shall be completed (including cleanup) each day prior to start of
           normal store operations.

PART 2 - PRODUCTS

2.1        MANUFACTURERS

      A.   Subject to compliance with project requirements, provide products and equipment by the following:
           1.     3M (888) 364-3577 www.3m.com
           2.     Concrete Polishing Solutions (877) 472-8200 www.go2cps.com
           3.     Convergent Concrete Technologies (866) 375-2280 www.convergentconcrete.com
           4.     Eagle Solutions (800) 633-0519 www.eaglefloorsolutions.com
           5.     HTC (877) 482-8700 www.htc-america.com
           6.     Innovatech (800) 267-6682 www.innovatechproducts.com
           7.     Norton Abrasives (800) 331-3604 www.nortonprocleaning.com
           8.     Pioneer Eclipse (800) 367-3550 www.pioneer-eclipse.com
           9.     Prosoco (800) 255-4255 www.prosoco.com
           10.    Pullman-Ermator (800) 232-2635 www.pullman-ermator.com
           11.    Rubbermaid Commercial Products (540) 667-8700.
           12.    SASE Company, Inc. (800) 522-2606 www.sasecompany.com
           13.    Seal Source (800) 305-9144 www.sealsource.com
           14.    Substrate Technology, Inc. (815) 941-4800 www.substratetechnology.com
           15.    VIC International Corporation (800) 423-1634 www.vicintl.com
           16.    VMC Technical Assistance Corp (800) 460-4862 www.vmctac.com

      B.   Substitutions: Not permitted.

2.2        EQUIPMENT

      A.   Contractor to furnish minimum three grinding/polishing machines in full operating condition during the duration
           of work.
           1.    Planetary, counter rotating variable speed floor grinder (3 or 4 head).
           2.    Minimum 600 pounds of downward pressure.

      B.   Dust extraction system and pre-separator for grinding and polishing.
           1.     Heavy-duty industrial HEPA filtration vacuum system, suitable for extracting and containing large
                  quantities of fine concrete dust (minimum 350CFM air flow) in conjunction with manufacturer
                  recommended pre-separator.
           2.     Provide one of the following:
                  a.     86D, by HTC.
                  b.     T8600, by Pullman-Ermator.
                  c.     Bull 1250, by SASE Company, Inc.
                  d.     Approved equal.

      C.   Three-phase 480-volt electrical supply to be provided by the General Contractor within 200 feet of the work area.
           1.    If generators are required due to site constraints, coordinate security at all access points for cables.
           2.    All fuel powered generators must be used outside the building, and in compliance with Authorities Having
                 Jurisdiction (if applicable).




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      D.   Hand grinder with dust extraction attachment and pads for edge grinding/polishing.

      E.   High speed propane burnisher:
           1.     Minimum 27 inch head generating pad speeds of 1,500 RPM or higher, as verified with tachometer.

      F.   Diamond Grinding Heads:
           1.   Use diamond grinding heads from approved manufacturers only.
           2.   Grinding Diamonds (or approved equivalents):
                a.     Metal Bonded Diamond Grit Sizes 40, 80, and 150.
                b.     Resin Bonded, Phenolic Diamond Grit Sizes: 100, 200, 400, 800 and 1,500.
           3.   Grinding/Polishing Pads for Edges (or approved equivalents):
                a.     Grit Size: 60, 100, 120, 200, 400, 800, 1500, and 3000.

      G.   Diamond Impregnated Pads (800 and 1500 grit)
           1.   Twister Diamond Cleaning System Pads, by HTC.
           2.   Diamond Polishing Pads, by Norton.
           3.   SpinFlex Diamond Polishing Pads, by CPS.
           4.   Scotch-Brite Diamond Floor Pads Plus, by 3M.

      H.   Natural Hair Pads:
           1.     Niagra Super Hogs Hair Floor Pad 3700N by 3M.
           2.     Ultra Grizzly Bear by Norton.
           3.     Consolideck Heat Pad by Prosoco.

      I.   Applicator pad:
           1.    Minimum 24" Microfiber Wet Room Pad, by Rubbermaid.

2.3        PRODUCTS

      A.   Joint Filler
           1.     Polyurea joint filler as specified in Section 03905.
           2.     Color: Match polished slab surface. Dry sample shall be approved by Wal-Mart Construction Manager.

      B.   Reactive Surface Densifier: Clear, lithium-silicate based liquid.
           1.     Pentra-Sil (NL), by Convergent Concrete Technologies.
           2.     Consolideck LS, by Prosoco.
           3.     SS Harden X, by SealSource.

      C.   Protective Surface Treatment (Stain Guard):
           1.     Pentra-Guard (HP), by Convergent Concrete Technologies.
           2.     Consolideck LS Guard, by Prosoco.
           3.     SS Duraguard, by SealSource.

PART 3 - EXECUTION

3.1        EXAMINATION

      A.   Examine concrete slab in the presence of the certified applicator and Wal-Mart Construction Manager. Identify
           and note all joint filler replacement and repairs required for existing slab defects on as-built Floor Polishing Plan.

3.2        PREPARATION

      A.   Close areas to traffic during and after floor finish application for time period recommended by product manufac-
           turer(s).




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      B.   Cover and protect merchandise and racking to prevent damage or contamination of stored products. Provide dust
           drapes as required to protect merchandise from dust or debris.

      C.   Clean Substrate: Remove surface contaminants to ensure penetration of reactive surface densifier. No hazardous,
           flammable, toxic or solvent based cleaning materials are permitted.
           1.     Remove all curing or sealing compounds, coatings (including epoxy resins), and wax by mechanical means
                  that will not expose concrete slab coarse aggregate.
           2.     Remove deep-set oil and grease stains.
           3.     Remove paint residue.
           4.     Remove grease and general soiling with cleaner/degreaser diluted as recommended by manufacturer in an
                  auto scrubber.
           5.     Remove mildew by scrubbing with solution of trisodium phosphate and bleach. Rinse with clean water.
           6.     Thoroughly rinse floor surface to remove soap residue and contaminants.
           7.     Squeegee dry.

      D.   Remove and replace filler at all slab joints within the limits of required slab polishing, in accordance with Section
           03905.

      E.   Repair all slab defects within the limits of required slab polishing, in accordance with Section 03905, including all
           previously repaired defects that do not conform to 03905 requirements.

3.3        SURFACE POLISHING AND DENSIFIER APPLICATION

      A.   Ensure surfaces are clean (free of oil, grease, dirt, dust, contaminants, etc.) and dry.

      B.   Complete all joint replacement and slab repair work prior to commencement of any grinding or polishing,

      C.   Open slab surface by progressively grinding with 40, 80, or 150-grit metal-bonded diamond heads. Start with ini-
           tial grinding grit necessary to produce required gloss values in a surface free of pits and scratches. Do not expose
           coarse aggregate.
           1.      Use of more aggressive metal bonded diamond grits for removal of existing surface imperfections, sealers
                   or coatings must be approved in writing by the Wal-Mart Construction Manager prior to use. Include all
                   work necessary for proper initial grinding and removals.
           2.      Sequential progression of diamond grinding shall be required and limited to no more than double the grit
                   value of the previous diamonds used.

      D.   Clean slab with wet auto scrubber between grinding passes.

      E.   Apply reactive surface densifier at 500 sq. ft. per gallon, one time after 150-grit metal or 100-grit resin diamond
           pass, according to manufacturer's instructions. Allow to dry 30 to 60 minutes.

      F.   Progressively polish slab surface with 100, 200, 400 and 800-grit (and 1,500-grit as needed) resin-bonded, phenol-
           ic diamond heads. Clean slab with wet auto scrubber between polishing passes. Use of 100/200 combination di-
           amond heads will be acceptable if required to produce less scratching in the slab surface.

      G.   Progressively diamond grind and polish edges along and around all vertical abutments, including walls, columns,
           cases, and racking systems as shown on Drawings. Use same progression of grinding/polishing diamonds as noted
           above and include application of reactive surface densifier after initial grinding.

3.4        PROTECTIVE SURFACE TREATMENT (STAIN GUARD) APPLICATION

      A.   Area to be treated: Subsequent to densifier application, apply protective treatment over surfaces to which densifier
           has been applied and has dried.

      B.   Use proper Personal Protective Equipment (PPE) when applying lithium stain guard and/or burnishing.


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#6260 Bartlett, Tennessee                                                                                             8/19/10
      C.   Apply Stain Guard:
           1.    Apply in accordance with manufacturer’s published instructions.
           2.    Apply first coat at the rate of 2,000-2,500 sq. ft. per gallon, per manufacturer’s recommendation (DO NOT
                 OVER APPLY).
           3.    Use applicator pad, pre-wetted with stain guard, to pull material out to create a thin film prior to drying.
           4.    Remove product completely from areas of over application, as evidenced by surface streaking, and replace
                 with unused stain guard.
           5.    Apply second coat of stain guard at all high traffic areas identified on the drawings at the rate of 2,500 sq.
                 ft. per gallon.

      D.   High speed burnish:
           1.     After each application of stain guard is dry, burnish surface.
           2.     Burnish at a slow movement pace using high speed machine with 800 grit diamond impregnated or hog’s
                  hair burnishing pads.
           3.     Burnish with several passes. Make each progressive pass at 90 degrees from previous pass.
           4.     Burnishing, pad type, and pace of forward movement shall combine to develop a minimum floor surface
                  temperature of 91-degrees F directly below the burnishing pad as continuously measured by the operator
                  during installation.

      E.   Continue burnishing operations until the specified gloss is attained. Achieve specified gloss no later than two
           weeks prior to Grand Opening and maintain specified gloss until Grand Opening.

      F.   Provide final burnishing prior to Grand Opening as required to eliminate damage from subsequent work.

3.5        FINISH REQUIREMENTS:

      A.   Gloss: Final surface gloss shall be a Specified Overall Gloss Value (SOGV) of not less than 50 and Minimum Lo-
           cal Gloss Value (MLGV) of 40 as measured using a Horiba IG-320 Gloss Checker.

      B.   Slip Resistance: Measured static coefficient of friction (SCOF) shall be not less than 0.50 at time of Re-Grand
           Opening as measured using an American Slip Meter ASM 825 Digital Meter, Regan Scientific Instruments BOT-
           3000 Tribometer, or approved equal.

      C.   Leave work complete and ready for final inspection by Wal-Mart Construction Manager.

3.6        PROTECTION

      A.   General Contractor shall protect areas to receive polished concrete finish at all times during construction to pre-
           vent oils, dirt, metal, excessive water, paint and other potentially damaging materials from affecting the finished
           concrete surface. Protective measures listed below shall begin immediately after completion of grinding and po-
           lishing.
           1.      Communicate to all subcontractors, vendors, and trades importance of maintaining slab protection at all
                   times. Damage to finished slab resulting from lack of protection shall be repaired at no additional cost to
                   Walmart.
           2.      Protect slab surface from moisture for 72 hours to prevent re-emulsification of surface treatment prior to
                   cure. Verify that all wood pallets are dry prior to placing on finished slab.
           3.      Each day, inspect all equipment used over completed slab surface, to insure:
                   a.       Equipment is without leaking hydraulic lines and is diapered to avoid staining. Remove all equip-
                            ment with hydraulic fluid leaks from store site.
                   b.       No tire embedments (rocks, nails, screws, etc.) that will scratch or pit slab surface.
           4.      Cutting pipe on the finished slab is not allowed.
           5.      Do not place steel on the finished slab to avoid rust staining.
           6.      Prevent contact with acids and acidic detergents.
           7.      Use breathable surface protective materials for high traffic areas.
                   a.       EZ-Cover, by McTech Group, (866) 913-8363.
                   b.       Ram Board, by Ram Board, (818) 848-0400.


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           8.     Use breathable drop cloths during all painting. Immediately wipe clean spilled paint.

3.7        QUALITY ASSURANCE TESTING

      A.   Testing will be performed by the Wal-Mart Construction Testing Laboratory (CTL) at no expense to the Contrac-
           tor. A test report of all measurements and a plan and table of the measurements taken shall be prepared by the
           CTL for submittal.

      B.   General Contractor shall notify CTL when slab is ready for testing.

      C.   Take gloss measurements once weekly. Gloss shall be considered as a quantitative value that expresses the degree
           of reflection when light hits the concrete floor surface. Gloss measurements will be taken independent of ambient
           lighting and within a sealed measurement window located beneath the testing equipment. Measurement and re-
           porting of SOGV and MLGV by CTL shall be as follows:
           1.      Collect a minimum of five samples per each bay, in random, evenly distributed locations. Record
                   measurement locations on copy of Floor Polishing Plan. Discard the high and low values measured in each
                   bay.
           2.      The average of all samples collected in each bay shall meet SOGV.
                   a.     If the average of samples collected do not meet the SOGV, collect an additional 3 samples in each
                          bay for each deficient result unless the individual samples fail to meet the MLGV or the average of
                          all collected samples in each bay fail to meet the SOGV.
                   b.     If samples fail to meet the SOGV, Contractor shall continue sweeping, scrubbing and polishing until
                          the SOGV is achieved.
           3.      No single measured value shall be less than MLGV.
                   a.     If one or more samples fall below the MLGV, Contractor shall continue sweeping, scrubbing and
                          polishing until all samples comply with Specified MLGV and SOGV.
           4.      Collect and certify final gloss measurements.

      D.   Slip Resistance Measurements:
           1.     Take slip resistance measurements 2 weeks prior to Re-Grand Opening and at time of Re-Grand Opening.
                  Contractor shall notify CTL when floors are ready for testing.
           2.     Four slip resistance measurements will be required within the areas of the two highest and two lowest
                  SOGV measurements.
           3.     Correlate single re-measured gloss value at each location in floor slab where slip resistance is measured.

END OF SECTION




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#6260 Bartlett, Tennessee                                                                                          8/19/10

				
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