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)*

(Reapproved 1997,2003) Reported by ACI 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 Secretary Richard Montani 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 G.M. Scales Raymond J. Schutz George W. Whitesides

This specification describes the work of bonding hardened concrete. steel, wood, b r i c k 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 and preparation 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.

This foreword is included for explanatory purposes o n l y ; it does not form a part of Standard Specification ACI 503.1. This specification is a reference standard which the Architect/Engineer may cite in the project specifications, together with the supplemental requirements for the specific project. It is written in terse, imperative language and is
ACI 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. I t was revised according to the expedited procedure effective October 1986 and March 1992. Copyright 1978 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-l
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FOREWORD

divided into two sections: general requirements and materials and applications, including a section on the allimportant surface preparation. This document covers materials 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 of, Standard Specification ACI 503.1. The purpose of this guide and checklist is to assist the Architect/Engineers' designer(s) and specifier(s) to properly choose and specify, the necessary supplemental requirements for the project specifications.

503.1-2

ACI STANDARD

CONTENTS

SPECIFICATION GUIDE SGl-Standard Specification ACI 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 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 ACI 503.1. Or exceptions shall be taken to Standard Specification ACI 503.1 if required. SG4-A statement such as the following will serve to make Standard Specification ACI 503.1 an official part of the contract requirements:

Specification guide, pg. 503.1-2 Specification checklist, pg. 503.1-3 Section 1-General requirements, pg. 503.1-3 1 .1-Scope

1.2-Notation 1.3-Specification wording 1.4-Reference standards

Section 2-Materials and application, pg. 503.1-4 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-Execution, pg. 503.1-4

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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 2.3.8-Adhesive mixes 2.3.9-Adhesive application and placing of elements to be bonded 2.3.10-Cleanup 2.3.11-Safety

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 (ACI 503.1), published by the American Concrete Institute, Detroit, Mich., except as modified by the requirements of this project specification. SG5-The specification checklist that follows is addressed to each item of ACI 503.1 that requires the designer/specifier to make a choice where alternates are indicated, or to add provisions where they are not indicated in ACI 503.1, or to take exceptions to ACI 503.1. The checklist consists of section, part, and article heads of ACI 503.1, and accompanying notes to the designers/ specifiers to indicate the action required of them.

EPOXY RESINS

503.1-3

SPECIFICATION CHECKLIST
Section/Part/Article of ACI 503.1 Section l-General requirements 1.1 Scope 1.4 Reference standards Section 2-Materials and applications Part 2.1-General 2.1.2 Submittals Notes to the Designer/Specifier

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

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

2.1.3.2 Application control 2.1.5 Project conditions

Part 2.2-Products

2.2.1 Epoxy adhesive

Specify Class and Grade as indicated. Also specify additional performance requirements and/or 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

Specify limitations, if any, on use of mechanical abrasion and on disposal of waste products. If sand abrasive not suitable, specify 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.
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SECTION l-GENERAL REQUIREMENTS

l.l-Scope 1.1.1 This standard specification covers the bonding of 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:

1.2.3 SSPC:

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 48219 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 ACI 503.1 are listed in Articles 1.4.2 and 1.4.3

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503.1-4

ACI 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 ACI 503.1 the same as if fully set forth herein, unless otherwise indicated in the contract documents. 1.4.2 ASTM standard C 881-87 Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete

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 adhesive-ASTM C 881 Type I for non-

1.4.3 SSPC standards Vis l-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, Surface Preparation Specification No. 3, SP3-63 Power Tool Cleaning Surface Preparation Specification No. 6, SP6-63 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. Part 2.3-Execution 2.3.1 Preparation of concrete surfaces 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 of carbon steel surfaces 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 SPl, 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 of galvanized steel surfaces 2.3.3.1 Scrub galvanized steel surfaces thoroughly in accordance with SSPC SPl, 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 of aluminum surfaces 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 of copper and copper-alloy surfaces 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 of wood surfaces 2.3.6.1 Clean wood surfaces of all visible loose or foreign particles or contaminants by sanding. Remove
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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 control-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 breaking container seals. 2.1.5 Project conditions
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EPOXY RESINS

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 within 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 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. 2.3.8 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 (16-38C), 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 within 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 first 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 (ACI 503.2-92, reapproved 1997, 2003)*
Reported by ACI 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 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 of bonding plastic concrete 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 and preparation as well as inspection and quality control.

FOREWORD This foreword is included for explanatory purposes only; it does not form a part of Standard Specification ACI 503.2. Standard Specification 503.2 is a reference standard

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

which the Architect/Engineer may cite in the project specification(s) 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 ACI requirements. The language is generally imperative and terse. A specification guide is included as a preface to, but not forming apart of; Standard Specification ACI 503.2. The purpose of this guide is to assist the Architect/Engineers' designer(s) and specifier(s) to property choose and specify the necessary supplementary requirements for the project specification(s).

503.2-2

ACI STANDARD

CONTENTS
Specification guide, pg. 503.2-2 Specification checklist, pg. 503.2-2

SPECIFICATION GUIDE

Section l-General requirements, pg. 503.2-4

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

Section 2-Materials and application, pg. 503.2-4 Part 2.1-General, pg. 503.2-4

2.1.1-Description 2.1.2-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

SGl -Standard Specification ACI 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 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 ACI 503.2. Or exceptions shall be taken to Standard Specification ACI 503.2 if required_ SG4 -A statement such as the following will serve to make Standard Specification ACI 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 (ACI 503.2)," published by the American Concrete Institute, Detroit, Mich., except as modified by the requirements of this project specification. SG5 -The specification checklist that follows is addressed to each item of ACI 503.2 that requires the designer/specifier to make a choice where alternates are indicated, or to add provisions where they are not indicated in ACI 503.2, or to take exceptions to ACI 503.2. The checklist consists of section, part, and article heads of ACI 503.2, with accompanying notes to the designer/ specifier to indicate the action required of them.

2.2.2-Plastic concrete
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

SPECIFICATION CHECKLIST Section/Part/Article of ACI 503.2 Section l-General requirements Notes to the Designer/Specifier

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.

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503.2-3

SPECIFICATION CHECKLIST (cont.)

Section/Part/Article of ACI 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. Specify 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 Specify Class and Grade as indicated. Also specify additional performance requirements and/or approved suppliers, as advisable. Specify 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

Specify limitations, if any, on use of mechanical abrasion and on disposal of waste products. Specify 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

ACI STANDARD

SPECIFICATION CHECKLIST (cont.) Section/Part/Article of ACI 503.2 2.3.4.3 Consolidation of concrete I Notes to the Designer/Specifier

Review applicability of referenced standard and take exceptions if required. Specify procedure to be used. Also specify additional performance requirements and/or 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.

2.3.4.4 Curing

2.3.7 Field quality performance requirements

SECTION l-GENERAL REQUIREMENTS l.l-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 48219 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 ACI 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 ASTM standard C 831-87 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 breaking 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

application of epoxy adhesives and concrete placement. Work shall be performed in accordance with Chapters 7 load bearing or Type V for load bearing applications. and 3 of ACI 301. Curing temperature requirements (Class) and viscosity 2.3.4.2 Apply epoxy adhesive to concrete surface by (Grade) shall be determined by supplier and contractor brush, roller, broom, squeegee, or spray equipment, Apafter project conditions have been established. ply epoxy compound at a thickness not less than that re2.2.2 Plastic concrete-As required by the project commended by manufacturer. specification. 2.3.4.3 Place fresh plastic concrete while adhesive is still tacky. If epoxy adhesive cures to extent of losing its Part 2.3-Execution tack before plastic concrete is placed, remove or slightly abrade first coal before placing second coat. 2.3.1 Preparation of concrete surfaces 2.3.4.4 Consolidate freshly placed plastic concrete 2.3.1.1 Concrete surfaces to which epoxies are to be applied shall be exposed parent concrete free of loose in accordance with ACI 301 to insure full bonding of new and unsound materials. Prepare surfaces by mechanical concrete. 2.3.4.5 Upon completion of finishing operations, abrasion. cure concrete in accordance with procedures defined in 2.3.1.2 Mechanical abrasion-Use sandblasting, Chapter 12 of ACI 301 and as indicated in the project scarifying, waterblasting, or other approved means. 2.3.2 Inspection of concrete surfaces prior to adhesive specification. application 2.3.5 Cleanup 2.3.5.1 Protect concrete surfaces, beyond limits of 2.3.2.1 Inspect all concrete surfaces prior to application of adhesive to insure that requirements of this surface receiving adhesive, against spillage. Article 2.3.2 are met. 2.3.5.2 Immediately remove any epoxy compound 2.3.2.2 Surfaces shall be sound concrete which ex- applied or spilled beyond desired areas. Perform cleanup hibits a minimum 100 psi pullout strength when tested in with material designated by epoxy adhesive manufacturer. accordance with Appendix A of Use of Epoxy Com- Avoid contamination of work area. 2.3.6 Safety-Epoxy materials are skin irritants or pounds with Concrete, reported by ACI Committee 503. 2.3.2.3 Surfaces shall be free of any deleterious sensitizers to many people. Accordingly, advise applimaterials such as laitance, curing compounds, dust, dirt, cators to avoid contact with eyes and skin, inhalation of and oil. Materials resulting from surface preparation spe- vapors, and ingestion. Make protective and safety equipment available on site. Heed all label warnings by manucified in Article 2.3.1 shall be removed. 2.3.2.4 All concrete surfaces shall have a moisture facturer. 2.3.7 Field quality performance requirements content not exceeding saturated surface dry condition. 2.3.7.1 The Architect/Engineer shall evaluate bondSurface temperature shall be at least 40 F to permit weting of fresh concrete to existing concrete after the fresh ting of concrete surface by epoxy adhesive. 2.3.2.5 Evaluate moisture content for concrete by concrete has cured for not less than 28 days. 2.3.7.2 The evaluation shall be performed by sounddetermining if moisture will collect at bond lines between ing, using one of the following, or similar, methods: old concrete and epoxy adhesive before epoxy has cured. This may be accomplished by taping a 4 x 4 ft polya) Tapping fresh concrete with a blunt metal ethylene sheet to concrete surface. If moisture collects on instrument underside of polyethylene sheet before epoxy would cure, b) Dragging a heavy steel chain across the surface then allow concrete to dry sufficiently to prevent the pos(for horizontal surfaces only) sibility of a moisture barrier between old concrete and new epoxy. 2.3.7.3 Detection of a hollow sound in any area 2.3.3 Adhesive mixes 2.3.3.1 Mix epoxy components in a clean container shall be reason to suspect inadequate bonding, and contractor shall then core each such area, as requested by Free of harmful residue or foreign particles. 2.3.3.2 Condition epoxy compound components to the Architect/Engineer, to determine bonding adequacy. 2.3.7.4 Coring shall be through the new concrete be at a temperature between 60-100 F (16-38 C), unless and into the existing concrete. Core diameter shall be as otherwise recommended by manufacturer. 2.3.3.3 Thoroughly blend epoxy components with a required by the Architect/Engineer. Length of cores shall mechanical mixer to a uniform and homogeneous mix- be twice the core diameter, or twice the thickness of new concrete, or as requested by the Architect/Engineer. ture. Mix small batches (up to 1 qt) by use of spatulas, 2.3.7.5 Cores will be visually inspected, and further palette knives, or similar devices. testing required, if any, will then be determined by the 2.3.4 Adhesive application and concrete placement 2.3.4.1 Ambient temperature is critical during Architect/Engineer.
Part 2.2-Products 2.2.1 Epoxy adhesive-ASTM C 881 Type II for nonCopyright American Concrete Institute Provided by IHS under license with ACI No reproduction or networking permitted without license from IHS Licensee=Aramco HQ/9980755100 Not for Resale, 01/23/2006 00:11:01 MST

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Standard Specification for Producing a Skid-Resistant Surface on Concrete by the Use of a Multi-Component Epoxy System ( ACI 503.3-92,reapproved 1997, 2003)*
Reported by ACI 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 Montani 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 G.M. Scales Raymond J. Schutz George W. Whitesides

This specification describes rhe work of producing a skid-resistant surface on hardened concrete by the application of a multi-component epoxy adhesive such as defined for this purpose in ASTM C 881. It includes controls for adhesive labeling, storage, handling, mixing nnd application, surface evaluation and preparation as well as inspectron nnd quality control. In addition, it describes an aggregate to be used with the coating.

Standard Specification 503.3 is a reference standard which the Architect/Engineer may cite in the project specification(s) 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 ACI requirements. The Keywords: aggregates; coatings; concrete pavements; epoxy resins; language is generally imperative and terse. hardened concrete; quality control; skid resistance; specifications; A specification guide and checklist are included as a standards. preface to, but not forming a part of, Standard Specification ACI 503.3. The purpose of this guide is to assist the Architect/Engineers designer(s) and specifier(s) to properly FOREWORD choose and specify the necessary supplementary requirements for the project specification(s). This foreword is included for explanatory purposes only; it does not form a part of Standard Specification ACI 503.3.
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ACI 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 March 1992. Copyright @ 1978 American Concrete 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 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-I
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503.3-2

ACI STANDARD

SPECIFICATION GUIDE Specification guide, pg. 503.3-2 Specification checklist, pg. 503.3-2 Section l-General requirements, pg. 503.3-4 l.l-Scope 1.2-Notation 1.3-Specification wording 1.4-Reference standards Section 2-Materials and application, pg. 503.3-4 Part 2.1-Genera1, 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. l-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 SGl-Standard Specification ACI 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 ACI 503.3. Or exceptions shall be taken to Standard Specification ACI 503.3 if required. SG4-A statement such as the following will serve to make Standard Specification ACI 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 (ACI 503.3), published by the American Concrete Institute, Detroit, Mich., except as modified by the requirements of this project specification. SG5-The specification checklist that follows is addressed to each item of ACI 503.3 that requires the designer/specifier to make a choice where alternates are indicated, or to add provisions where they are not indicated in ACI 503.3, or to take exceptions to ACI 503.3. The checklist consists of section, part, and article heads of ACI 503.3, with accompanying notes to the designer/ specifier to indicate the action required of them.

SPECIFICATION CHECKLIST Section/Part/Article of ACI 503.3 Section l-General requirements 1.1 Scope 1.4 Reference standards
Section 2-Materials and application
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Notes to the Designer/Specifier

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

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EPOXY RESINS

503.3-3

SPECIFICATION CHECKLIST (cont.) Section/Part/Article of ACI 503.3 Notes to the Designer/Specifier

2.1.2 Submittals 2.1.3.2 Application control 2.1.4.2 Storage of materials

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 grinding 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

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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

ACI STANDARD

SPECIFICATION CHECKLIST (cont.) Section/Part/Article of ACI 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.
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2.3.4.2 Aggregate application

2.3.5 Field quality control

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.

SECTION l-GENERAL REQUIREMENTS l.l-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 48219 American Society for Testing and Materials 1916 Race Street Philadelphia, PA 19103

1.4.1 The standards referred to in this Standard Specification ACI 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 ACI 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 C 881-87 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:

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 speLicensee=Aramco HQ/9980755100 Not for Resale, 01/23/2006 00:11:01 MST

EPOXY RESINS

503.3-5

cifications 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

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 breaking 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 coating-ASTM C 881. Curing temperature requirements (Class) and viscosity (Grade) shall be determined by supplier and contractor and approved by architect/engineer after project conditions have been established. 2.2.2 Skid-resistant aggregate 2.2.2.1 Aggregate shall meet the following gradation when tested in accordance with ASTM C 136: Sieve size
Y4

Percent passing 100 97-100 55-75 0-3

6 8 16

2.2.2.2 When tested in accordance with ASTM C 131, aggregate shall have a maximum weight loss of 20 percent at 500 revolutions. 2.2.2.3 Moisture content of the aggregate shall not exceed 0.15 percent when tested in accordance with ASTM C 566, Standard Test Method for Total Moisture Content of Aggregate by Drying. Part 2.3-Execution 2.3.1 Preparation of surfaces 2.3.1.1 Concrete surfaces to which epoxies are to
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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 Inspection of surface prior to coating application 2.3.2.1 Inspect all concrete surfaces prior to application of coating 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 Use of Epoxy Compounds with Concrete, reported by ACI Committee 503. 2.3.2.3 Surface shall be free of any deleterious materials such as laitance, curing compounds, dust, dirt, and oil, and materials resulting from surface preparation, as 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 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 moisture between old concrete and new epoxy. 2.3.3 Coating mixes 2.3.3.1 Mix epoxy components in a clear 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 Coating application 2.3.4.1 Apply epbxy coating to concrete surface by brush, roller, broom, squeegee, or spray equipment. Apply epoxy compound at a uniform thickness of 60 + 10 mils. 2.3.4.2 Apply skid-resistant aggregate while coating is still fluid at the rate of 12 + 1 lb&d-. 2.3.5 Field quality control-The inspector shall determine that coating and skid-resistant aggregate are applied at a rate at least equal to that specified and that aggregate and coating are securely bonded. The pullout strength of the cured skid-resistant surface to the concrete shall be a minimum 100 psi when tested in accordance with Appendix A of Use of Epoxy Compounds with Concrete, reported by ACI Committee 503. The failure shall be cohesive within the concrete. There shall be no failures in adhesion. 2.3.6 Cleanup
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503.3-6

ACI 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.
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2.3.7 Safety-Epoxy materials are skin irritants or sensitizers to many people. Accordingly, advise applicaors 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 Repairing Concrete with Epoxy Mortars (ACI 503.4-92, Reapproved 1997, 2003)
Reported by ACI 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. 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 of repairing defects in hardened portland cement concrete with a sand-filled mortar using an adhesive binder such as defined in ASTM C 881. It includes controls for adhesive labeling storage, handling, 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.
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FOREWORD

fication(s) 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 ACI requirements. The language is generally imperative and terse. A specification guide and checklist are included as a preface to, but not forming a part of Standard Specification ACI 503.4. The purpose of this guide and checklist is to assist the Architect/Engineers' d e s i g n e r ( s ) a n d specifier(s) to properly choose and specify the necessary supplementary requirements for the project specification(s).

This foreword is included for explanatory purposes only; it does not form a part of Standard Specification ACI 503.4. Standard Specification 503.2 is a reference standard which the Architect/Engineer 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.

* 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 8 1978 and 1986 American Concrete 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 anv knowledge or retrieval system or device, unless permission in writing is obtained from the copyright proprietors.

503.4-l
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503.4-2

CONTENTS Specification guide, pg. 503.4-2 Specification checklist, pg. 503.4-2 Section l-General requirements, pg. 503.4-4 1.1-Scope 1.2-Notation 1.3--Specification wording 1.4-Reference standards
Section 2-Materials and application, pg. 503.4-4

SPECIFICATION GUIDE SGl-Standard Specification ACI 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 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 ACI 503.4. Or exceptions shall be taken in Standard Specification ACI 503.4 if required. SG4-A statement such as the following will serve to make Standard Specification ACI 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 (ACI 503.4), published by the American Concrete Institute, Detroit, Mich., except as modified by the requirements of this project specification. SG5-The specification checklist that follows is addressed to each item of ACI 503.4 that requires the designer/specifier to make a choice where alternates are indicated, or to add provisions where they are not indicated in ACI 503.4, or to take exceptions to ACI 503.4. The checklist consists of one column identifying sections, parts, and articles of ACI 503.4, and a second column of notes to the designer/specifier to indicate the action required of them.

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

SPECIFICATION CHECKLIST Section/Part/Article of ACI 503.4 Section l-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

503.4-3

SPECIFICATION CHECKLIST (cont.) Section/Part/Article of ACI 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. Specify limitations, if any, on use of mechanical abrasion, and on disposal of waste products. Specify 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

ACI STANDARD

SPECIFICATION CHECKLIST (cont.)

Section/Part/Article of ACI 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 l-GENERAL REQUIREMENTS l.l-Scope 1.1.1 This standard specification covers repairing of

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

2.1.1 Description - 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) b) c) d) Name of manufacturer Manufacturers product identification Manufacturers instructions for mixing Warning for handling and toxicity

1.2.1 ACI:

American Concrete Institute P.O. Box 19150 Detroit, MI 48219

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 ACI 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 ACI 503.4 the same as if fully set forth herein, unless otherwise indicated in the contract documents. 1.4.2 ASTM standard C 881-87 Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete
SECTION 2-MATERIALS AND APPLICATION
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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 breaking 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 surfaces 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, scarifying, waterblasting, or other approved means. 2.3.2 Inspection of concrete surfaces prior to mortar application 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 ACI 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 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 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 2.3.4.1 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 finishing 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 skin, 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 American Concrete Institute Provided by IHS under license with ACI No reproduction or networking permitted without license from IHS

Licensee=Aramco HQ/9980755100 Not for Resale, 01/23/2006 00:11:01 MST