ACI 503.1-503.4 (R2003) Four Epoxy Standards

7/30/2019 ACI 503.1-503.4 (R2003) Four Epoxy Standards

1/21

Standard Specification for Bonding HardenedConcrete, Steel, Wood, Brick, and Other

Materials to Hardened Concrete with aMulti-Component EpoxyAdhesive(AC1 503.1-92, reapproved 1997

R.W. Gaul George SeldenChairman Secretary

Russell H. Brink

George HoreczkoHarold C. KlassenJoseph A. McElroy

Leonard J. MitchellMyles A. Murray

Leonard Pepper

G.M. ScalesRaymond J. SchutzGeorge W. Whitesides

Reported by ACI Committee 503

Committee voting on the 1992 revisions:

Raymond J. SchutzChairman

Milton D. Anderson David P. Hu

Myles A. MurraySecretary

Richard MontaniRoger W. BlackJohn P. CookFloyd E. DimmickWolfgang D. EisenhutJack J. FontanaRobert W. GaulPaul R. Hollenbach

T. Michael JacksonTroy D. Madeley

Albert MayerJoseph A. McElroyPaul F. McHalePctcr Mendis

Joseph M. PlecnikHamid SaadatmaneshW. Glenn SmoakJoe SolomonMichael M. SprinkelDouglas G. Walters

This specification describes the work ofbo nd in g hardened concrete. ste el,

wood, br i ck and other ma te ri al sto hardenedconcrete with a multi-com-

ponent epoxy adhesive such as defined for this purpose in ASTM C 881.

It includes controls for adhesive labeling, sto rag e, 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.

FOREWORD

This foreword is included for explanatory purposes o n l y ; it

does not forma

part of Standard Specification ACI 503.1.Th is specification is a reference standard wh ich the

Arch it ect / Engineer m ay cite in the project specifications,

together with the sup plem ental requirements for the specific

project. It is w ritten in t erse, i m p er a t i v el a n g u a g e and is

AC I Committee Reports, Guides, Standard Practices, and

Commentaries are intended for guidance in designing, plan-

ning, 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 Doc-

uments, they should be phrased in mandatory language and

incorporated into the Project Documents.

divided into two sections: general requirements and materi

als and applications, including a section on the allimportant surface preparation.

This documentcovers materials and methods for bond

ing concrete, steel, wood, brick, aluminum, copper, and

other materials to hardened concrete.

This specification is written in the section and three-pa

form at of th e Con stru ction S pecifications Institute, but with

the numbering system modified to ACI requirements.

A sp ecifi cation gu id e andchecklistare includ ed as a

preface to, but not form in g a pa rt of, S ta ndard S pecificat ion

ACI 503.1. T he purpose of this guide and checklist is to

assist th eArch it ect / E n gi n eers' designer(s) and specifier(s) to

p ro p er l y choose and specify, th e necessary su ppl em entarequirem ent s for the project specifications.

Adopted` asa standard of theAmerican Concrete Institute effective June 1

in accordance with the Institutes standardization procedure. I t was revis

accordingto theexpedited procedure effective October 1986 and March 1992

Copyright 1978and 1986 American Concrctc Institute.

All rights reserved including rights of reproduction and use in any form or b

any means. including the making of copies by any photo process. or by any elec

tronic 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 writ ing is obtained from the copyright proprietors.

503.1-l

(Reapproved 1997,2003)


2/21

503.1-2 ACI STANDARD

CONTENTS

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-Notation1.3-Specification wording1.4-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-Submittals2.1.3-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

2.3.1-Preparation of concrete surfaces

2.3.2-Preparation of carbon steel surfaces2.3.3-Preparation of galvanized steel surfaces2.3.4-Preparation of aluminum surfaces2.3.5-Preparation of copper and copper-alloy

surfaces2.3.6-Preparation of wood surfaces2.3.7-Inspection of concrete surfaces prior to

adhesive application2.3.8-Adhesive mixes2.3.9-Adhesive application and placing of

elements to be bonded2.3.10-Cleanup

2.3.11-Safety

SPECIFICATION GUIDE

SGl-Standard Specification ACI 503.1 is intended tobe used essentially in its entirety, by citation in theproject specification, to cover all usual requirements forbonding hardened concrete, steel, wood, brick, and othermaterials to hardened concrete with a multi-component

epoxy adhesive. Individual sections, parts, or articlesshould not be copied into project specifications sincetaking them out of context may change their meanings_

SG2-However, adjustments to the needs of a parti-cular project shall be made by the Architect/Engineersdesigners and specifiers by reviewing each of the itemsindicated in this specification guide and checklist andthen including their decisions on each as mandatory re-quirements in the project specification.

SG3-These mandatory requirements shall designatespecific qualities, procedures, materials, and performancecriteria for which alternatives are permitted or for which

provision is not made in Standard Specification AC I503.1. Or exceptions shall be taken to Standard Spe-cification AC I 503.1 if required.

SG4-A statement such as the following will serve tomake Standard Specification AC I 503.1 an official part ofthe contract requirements:

The use of an epoxy adhesive for bonding hardenedconcrete, steel, wood, brick, and other materials tohardened concrete shall conform to all requirementsof Standard Specification for Bonding HardenedConcrete, Steel, Wood, Brick, and Other Materials to

Hardened Concrete with a Multi-Component EpoxyAdhesive (ACI503.1), published by the AmericanConcrete Institute, Detroit, Mich., except as modifiedby the requirements of this project specification.

SG5-The specification checklist that follows is ad-dressed to each item of AC I 503.1 that requires thedesigner/specifier to make a choice where alternates areindicated, or to add provisions where they are not in-dicated in AC I 503.1, or to take exceptions to AC I 503.1.The checklist consists of section, part, and article headsofAC I 503.1, and accompanying notes to the designers/

specifiers to indicate the action required of them.yright American Concrete Institute

vided by IHS under license with ACI Licensee=Aramco HQ/9980755100Not for Resale, 01/23/2006 00:11:01 MSTeproduction or networking permitted without license from IHS

--`,,

,,,,,

`,

`,,,,

`,,

``,,

``,,,,,-`-`,,

`,,

`,

`,,

`---


3/21

EPOXY RESINS

SPECIFICATION CHECKLIST

503.1

1 .1

1 .4

Part

Section/Part/Article ofACI503.1 Notes to the Designer/Specifier

Section l-General requirements

Scope

Reference standards

Section 2-Materials and applications

2.1-General

2.1.2 Submittals

2.1.3.2 Application control

2.1.5 Project conditions

Part 2.2-Products

2.2.1 Epoxy adhesive

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

Indicate specific scope.

Review applicability of cited references and take ex-ceptions if required.

To whom sent?

To whom sent?

Specify any which would specifically affect this work.

Specify Class and Grade as indicated. Also specify ad-ditional performance requirements and/or approved

suppliers, as advisable.

Specify limitations, if any, on use of mechanical abra-sion and on disposal of waste products.

If sand abrasive not suitable, specify grit or shot.

A commercially available probe type moisture metershould be used except for plywood which will require aflat plate type with a depth of field suitable forplywood.

For a durable adhesive bond to wood the woodshould be sealed on all exposed sides to reduce ab-sorption of moisture which will swell the wood andstress (to rupture) the wood fibers which are re-strained by the cured adhesive.

SECTION l-GENERAL REQUIREMENTS

l . l -Scope

1.1.1 This standard specification covers the bonding ofhardened concrete, steel, wood, brick, and other ma-terials to hardened concrete with a multi-componentepoxy adhesive.

1.1.2 The provisions of this standard specification shallgovern unless otherwise specified in the contract doc-uments. In case of conflicting requirements, the contractdocuments shall govern.

1.2-Notation

1.2.1 ACI: American Concrete InstituteP.O. Box 19150Detroit, MI 48219

1.2.2 ASTM: American Society for Testing andMaterials

1916 Race StreetPhiladelphia, PA 19103

1.2.3 SSPC: Steel Structures Painting Council4400 Fifth AvenuePittsburgh, PA 15213

1.3-Specification wording

1.3.1 The language of this standard specification igenerally imperative and terse, and may include incomplete sentences. Omissions of phrases and of words sucas the contractor shall, in accordance with, shall beas indicated, a, an, the, all, etc., are intentionaOmitted phrases and words shall be supplied by inference.

1.4-Reference standards

1.4.1 The standards referred to in this Standard Specification AC I 503.1 are listed in Articles 1.4.2 and 1.4.

yright American Concrete Institute

ded by IHS under license with ACI Licensee=Aramco HQ/9980755100

Not for Resale, 01/23/2006 00:11:01 MSTeproduction or networking permitted without license from IHS

--`,,,,,,,

`,

`,,,,

`,,

``,,

``,,,,,-`-`,,

`,,

`,

`,,

`---


4/21


of this section, with their complete designation and titleincluding the year of adoption or revision and are de-clared to be a part of this Standard Specification AC I503.1 the same as if fully set forth herein, unlessotherwise indicated in the contract documents.

1.4.2ASTM standard

C 881-87 Standard Specification for Epoxy-Resin-BaseBonding Systems for Concrete

1.4.3SSPC standards

Vis l-67T Surface Preparation Standard No. 1-Pic-torial Surface Preparation. Standards forPainting Steel Surfaces

SP1-63 Surface Preparation Specification No. 1,Solvent Cleaning

SP2-63 Surface Preparation Specification No. 2,

Hand Tool Cleaning,SP3-63 Surface Preparation Specification No. 3,Power Tool Cleaning

SP6-63 Surface Preparation Specification No. 6,Commercial Blast Cleaning

SECTION 2-MATERIALS AND APPLICATION

Part 2.1-General

2.1.1 De scrip tio n-This section covers the re-quirements for surface preparation of specified materials

and for application of the multi-component epoxyadhesive.2.1.2Submit tals

2.1.2.1 Contractor shall submit manufacturerscertification verifying conformance to material spe-cifications specified in Part 2.2.

2.13 Quality assurance2.1.3.1 Labeling-Clearly mark all containers with

the following information:

a) Name of manufacturerb) Manufacturers product identification

c) Manufacturers instructions for mixingd) Warning for handling and toxicity

2.1.3.2 Application control-Submit mixing andapplication procedures for approval prior to USC.

2.1.4 Product delivery, storage, and handling2.1.4.1Delivery ofmaterials-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 otherwiserecommended by manufacturer.

2.1.4.3Handling ofmaterials-Handle all materials

in a safe manner and in a way to avoid breaking con-tainer seals.2.1.5Project conditions

2.1.5.1 Environmental requirements-Contractorshall comply with manufacturers recommendations as toenvironmental conditions under which the epoxy com-pound may be applied.

Part 2.2-Products

2.2.1 Epoxy adhesive-ASTM C 881 Type I for non-load bearing or Type IV for load bearing applications.Curing temperature requirements (Class) shall be deter-mined by supplier and contractor after project conditionshave been established. Use Grade 2 (medium viscosity)for bonding mating surfaces. Use Grade 3 (nonsagging)for overhead, or vertical, or sloping, surfaces, and fornonmating surfaces.

Part 2.3-Execution2.3.1 Preparation of concrete surfaces

2.3.1.1Concrete surfaces to which epoxies are to beapplied shall be newly exposed parent concrete free of

loose and unsound materials. Prepare surfaces by mech-anical abrasion.2.3.1.2Mechanical 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, usingSSPC SP6, to give a surface condition corresponding toASa2, BSa2, CSa2 of SSPC Vis 1, depending on the ini-tial surface condition of the steel surface. Use sandabrasive.

2.3.2.2 Prior to blast-cleaning, clean surfaces withSSPC SPl, SP2, and SP3, as required.

2.3.2.3Remove blast-cleaning residue with com-pressed air from an oil-and-water-free compressed air

source.2.3.3Preparation of galvanized steel surfaces

2.3.3.1 Scrub galvanized steel surfaces thoroughlyin accordance with SSPC SPl, wash well with lime water,and dry.

2.3.3.2 For galvanized steel surfaces showing signsof subsurface corrosion, blast-clean as specified in Article2.3.2 for carbon steel.

2.3.4Preparation of aluminum surfaces23.4.1Scrub aluminum surfaces thoroughly with a

nonchlorinated cleaner and then etch with proprietarychromate treatment in strict compliance with manu-facturers application instructions and safety warnings.

2.3.4.2 After etching, wash surface with distilledwater and then dry thoroughly.

2.3.5Preparation of copper and copper-alloy surfaces2.3.5.1 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 house-hold ammonia, wash surfaces with distilled water, and

then dry thoroughly.2.3.6Preparation of wood surfaces

2.3.6.1Clean wood surfaces of all visible loose orforeign particles or contaminants by sanding. Remove


--`,,,,,,,`,`,,,,`,,``,,``,,,,,-`-`,,`,,`,`,,`---


5/21

EPOXY RESINS 503.1-5

sanding or filling dust by wiping with an alcohol-soakedrag, or clean with oil-and-water-free compressed air.

2.3.6.2 For use with moisture-sensitive epoxyadhesives, reduce moisture content of wood to below 12percent by weight, or the wood should appear dry totouch.

2.3.7Inspection of concrete surfaces prior to adhesiveapplication

2.3.7.1 Inspect all concrete surfaces prior toapplication of adhesive to insure that requirements ofthis Article 2.3.7 are met.

2.3.7.2 Surfaces shall be sound and have coarseaggregate exposed. Coarse aggregate requirement may bewaived 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 spe-cified 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 ofthe concrete shall be within the limits recommended bythe adhesive manufacturer.

2.3.7.5 Evaluate moisture content for concrete bydetermining if moisture will collect at bond lines betweenold concrete and epoxy adhesive before epoxy has cured.This may be accomplished by taping a 4 x 4 ft poly-ethylene sheet to concrete surface. If moisture collects onunderside of polyethylene sheet before epoxy would cure,then allow concrete to dry sufficiently to prevent the

possibility of a moisture barrier between old concrete andnew epoxy.

2.3.8Adhesive mixes23.8.1Mix epoxy components in a clean container

free of harmful residue or foreign particles.

2.3.8.2 Condition epoxy compound components tobe at a temperature between 60-100 F (16-38C), unless

otherwise recommended by manufacturer.2.3.8.3 Thoroughly blend epoxy components with a

mechanical mixer to a uniform and homogeneous mix-ture. Mix small batches (up to 1 qt) by use of spatulas,palette knives, or similar devices.

2.3.9Adhesive application and placing of elements tobonded

2.3.9.1Apply epoxy adhesive to concrete surface b

brush, roller, broom, squeegee, or spray equipment. Ap-ply epoxy adhesive at a thickness sufficient to fill, withslight excess, the gap between substrate and the element

to be bonded.2.3.9.2 Position elements to be bonded within con-

tact time of adhesive as recommended by manufacturer.2.3.9.3 If movement of elements to be bonded ma

occur on sloping, vertical, or overhead positions, tem-porarily fasten or shore these elements.

2.3.9.4 If epoxy adhesive cures to extent of losingits tack before elements are in contact with adhesive, re-move 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 cleanupwith material designated by epoxy adhesive manufacturer.Avoid contamination of work area.

2.3.11Safety-Epoxy materials may be skin irritants orsensitizers to many people. Accordingly, adviseapplicators to avoid contact with eyes and skin, inhalationof vapors, and ingestion. Make protective and safetyequipment available on site. Heed all label warnings bymanufacturer.

yright American Concrete Institutevided by IHS under license with ACI Licensee=Aramco HQ/9980755100


--`,,,,,,,`,`,,,,`,,``,,``,,,,,-`-`,,`,,`,`,,`---


6/21

Standard Specification for Bonding Plastic Concreteto Hardened Concrete with a Multi-Component

Epoxy Adhesive (ACI 503.2-92, reapproved 1997, 200Reported by ACI Committee 503


Russell H. BrinkGeorge HoreczkoHarold C. KlassenJoseph A. McElroy

Leonard J. Mitchell

Myles A. MurrayLeonard Pepper

G.M. Scales

Raymond J. SchutzGeorge W. Whitesides


Raymond J. SchutzChairman


Milton D. AndersonRoger W. BlackJohn P. CookFloyd E. Dimmick

Wolfgang D. EisenhutJack J. FontanaRobert W. Gaul

Paul R. Hollenbach

David P. HuT. Michael JacksonTroy D. MadeleyAlbert MayerJoseph A. McElroyPaul F. McHalePeter Mendis

Richard MontaniJoseph M. PlecnikHamid SaadatmaneshW. Glenn Smoak

Joe SolomonMichael M. SprinkelDouglas G. Walters

Th i s specification describes the work of bonding plastic concrete to

hardened concrete with a multi-component epoxy adhesive such as defined which the Architect/Engineer may cite in the projectspeci-

forthis purpose in ASTM C881.It includes controlsfor adhesive labeling,fication(s) for any building project, together with supple-

storage, handling, mixing and application, surface evaluation and pre-mentary requirements for the specific project.

paration as well as inspection and quality control. This specification is written in the section and three-part

format of the Construction Specifications Institute, but withKeywords:adhesives;bond (concrete to concrete); bonding; concreteconstruction; epoxy resins; fresh concretes; hardened concrete; quality

the numbering system modified toACIrequirements. The

control; repairs; specifications;standards. 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'FOREWORD designer(s) and specifier(s) to property choose andspecify

the necessary supplementary requirements for the project

This forewordis included forexplanatory purposes only; it specification(s).

does not form a partof Standard Specification ACI 503.2.

Standard Specification 503.2 is a reference standard

ACI Committee Reports, Guides, Standard Practices, and





documents are desired to be a part of the Project Doc-

uments, they should be phrased in mandatory language and


*Adopted as a standard of the American Concrete Institute effective June 1979.

In accordance with the Institutes standardization procedure. It was revisedaccording to the expedited procedure effective October 1986 and March 1992.

Copyright 1978 and 1986 AmericanConcrete 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 elec-

tronic or mechanical device, printed or written or oral or recording for sound orvisual reproduction or for use in any knowledge or retrievalsystem or devic

unless permission in writing is obtained from the copyright proprietors.

503.2-lyright American Concrete Institutevided by IHS under license with ACI Licensee=Aramco HQ/9980755100

Not for Resale 01/23/2006 00:11:01 MSTeproduction or networking permitted without license from IHS


7/21


CONTENTS



Section l-General requirements, pg. 503.2-4

l.l-Scope1.2-Notation1.3-Specification wording1.4-Reference standards



2.1.1-Description2.1.2-Submittals2.1.3-Quality assurance2.1.4-Product delivery, storage, and handling2.1 S-Project conditions


2.2.1-Epoxy adhesive

2.2.2-Plastic concrete


2.3.1-Preparation of concrete surfaces2.3.2-Inspection of concrete surfaces prior to

adhesive application2.3.3-Adhesive mixes

2.3.4-Adhesive application and concrete placement2.3.5-Cleanup2.3.6-Safety2.3.7-Field quality performance requirements

SPECIFICATION GUIDE

SGl -Standard Specification ACI 503.2 is intended be used essentially in its entirety, by citation in thproject specification, to cover all usual requirements fobonding plastic concrete to hardened concrete with multi-component epoxy adhesive. Individual sectionparts, and articles should not be copied into projec

specifications since taking them out of context machange their meanings.

SG2 -However, adjustments to the needs of a partcular project shall be made by the Architect/Engineerdesigners and specifiers by reviewing each of the itemindicated in this specification guide and checklist anthen including their decisions on each as mandatory requirements in the project specification.

SG3 -These mandatory requirements shall designaspecific qualities, procedures, materials, and performanccriteria for which alternatives are permitted or for whicprovision is not made in Standard Specification AC

503.2. Or exceptions shall be taken to Standard Specification ACI 503.2 if required_

SG4 -A statement such as the following will serve tmake Standard Specification ACI 503.2 an official part othe contract requirements:

The use of an epoxy adhesive for bonding plastic concrete to hardened concrete shall conform to all requirements of Standard Specification For BondinPlastic Concrete To Hardened Concrete with a MultComponent Epoxy Adhesive (ACI503.2)," publisheby the American Concrete Institute, Detroit, Mich

except as modified by the requirements of this projecspecification.

SG5 -The specification checklist that follows addressed to each item of ACI 503.2 that requires thdesigner/specifier to make a choice where alternates arindicated, or to add provisions where they are not indicated in ACI 503.2, or to take exceptions to ACI 503.2The checklist consists of section, part, and article headofACI 503.2, with accompanying notes to the designespecifier to indicate the action required of them.


Section/Part/Article of AC I 503.2 Notes to the Designer/Specifier


1.1 Scope

1.4 Reference standards

Section 2-Materials and application



rightAmericanConcrete Instit te

--`,,,,,,,`,`,,,,`,,``,,``,,,,,-`-`,,`,,`,`,,`---


8/21

Section/Part/Article ofACI 503.2 Notes to the Designer/Specifier

Part 2.1-General

2.1.2 Submittals


2.1.5 Project conditions

2.1.5.1 Environmental requirements

Part 2.2-Products

2.2.1 Epoxy adhesive

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

2.3.2.4 Surface moisture content

2.3.4.1 Ambient temperature control

2.3.4.2 Coverage rate


SPECIFICATION CHECKLIST (cont.)

To whom sent?

Mixing and application procedures submitted must bein accordance with product manufacturers instruc-tions.

Specify any which would specifically affect this work.

Performance of epoxy systems may be affected by tern-perature, humidity, and surface water. Strict adherenceto the manufacturers recommendations should bemaintained. Where other unusual conditions are en-countered, the material manufacturer should be con-sulted before application.

Specify Class and Grade as indicated. Also specify ad-ditional performance requirements and/or approvedsuppliers, as advisable.

Specify concrete requirements.

Specify limitations, if any, on use of mechanicalabrasion 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 pipecap to the concrete surface with an epoxy adhesive. Ifthe test results not in failure of the concrete but incohesion of the epoxy resin adhesive or any failure inadhesion, the test shall be repeated. Repeated failuresin adhesion, or cohesion in the adhesive, indicate im-proper cleaning of the concrete, incorrect adhesive, orfaulty adhesive application techniques.

Some epoxy adhesives may be capable of wetting theconcrete surface at temperatures below 40 F. The spe-

cification should allow such use only if test data isavailable which conclusively demonstrates adequatebond at the actual concrete temperature expected.

Review applicability of referenced standards and takeexceptions if required. Also specify any unusualambient conditions.

The rate at which the epoxy should be applied is gen-erally a function of the surface texture and viscosity ofthe epoxy system. Therefore, the rate at which theepoxy should be applied should be in accordance withthe manufacturers recommendations.



--`,,,,,,,`,`,,,,`,,``,,``,,,,,-`-`,,`,,`,`,,`---


9/21



Section/Part/Article of ACI 503.2 I Notes to the Designer/Specifier

2.3.4.3Consolidation of concrete

2.3.4.4 Curing

2.3.7 Field quality performance requirements


l . l -Scope

1.1.1 This standard specification covers the bonding ofplastic concrete to hardened concrete with a multi-component epoxy adhesive.

1.1.2 The provisions of this standard specification shallgovern unless otherwise specified in the contract docu-ments. In case of conflicting requirements, the contractdocuments shall govern.

1.2-Notation

1.2.1 ACI:

1.2.2 ASTM:

American ConcreteP.O. Box 19150Detroit, MI 48219

Institute

for Testing andAmerican SocietyMaterials1916 Race StreetPhiladelphia, PA 19103


1.3.1 The language of this standard specification isgenerally imperative and terse, and may include incom-plete sentences. Omissions of phrases and words such asthe contractor shall, in accordance with, shall be, asindicated, a, an, the, all, etc., are intentional.Omitted phrases and words shall be supplied by in-

ference.


1.4.1 Thestandards referred to in this Standard Spe-cification ACI 503.2 are listed in Articles 1.4.2 and 1.4.3of this section, with their complete designation and titleincluding the year of adoption or revision and are de-clared to be a part of this Standard Specification AC1

503.2 the same as if fully set forth herein, unlessotherwise indicated in the contract documents.

1.4.2ASTM standardC 831-87 Standard Specification for Epoxy-Resin-Base

Bonding Systems for Concrete

Review applicability of referenced standard and takeexceptions 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) suit-able? Are additional requirements necessary? Specifytest methods that will be used, and size of cores.

1.4.3ACI standard301-89 Specifications for Structural Concrete fo

Buildings


Part 2.1-General

2.1.1Description -Th is section covers the requirments for surface preparation of the hardened concreteand 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 manufacturercertification verifying conformance to material specifications specified in Part 2.2.

2.1.3 Quality assurance2.1.3.1 Labeling-Clearly mark all containers withthe following information:

a) Name of manufacturerb) Manufacturers product identificationc) Manufacturers instructions for mixingd) Warning for handling and toxicity

2.1.3.2Application Control-Submit mixing and aplication procedures for approval prior to use.

2.1.4 Product delivery, storage, and handling

2.1.4.1

Delivery of materials-Deliver

all materiasealed containers with labels legible and intact.2.1.4.2 Storage of materials-Store all materials

temperatures between 40-100 F (5-38 C) unless otherwiserecommended by manufacturer.

2.1.4.3 Handling ofmaterials-Handle all materialin a safe manner and in a way to avoid breaking con-tainer seals.

2.1.5Project conditions2.1.5.1Environmental requirements-Contrac

shall comply with manufacturers recommendations as toenvironmental conditions under which the epoxycompound may be applied.



--`,,,,,,,`,`,,,,`,,``,,``,,,,,-`-`,,`,,`,`,,`---


10/21


Part 2.2-Products

2.2.1Epoxy adhesive-ASTM C 881 Type II for non-load bearing or Type V for load bearing applications.Curing temperature requirements (Class) and viscosity(Grade) shall be determined by supplier and contractorafter project conditions have been established.

2.2.2 Plastic concrete-As required by the projectspecification.

Part 2.3-Execution

2.3.1 Preparation of concrete surfaces2.3.1.1Concrete surfaces to which epoxies are to be

applied shall be exposed parent concrete free of looseand unsound materials. Prepare surfaces by mechanicalabrasion.

2.3.1.2 Mechanical abrasion-Use sandblasting,scarifying, waterblasting, or other approved means.

2.3.2Inspection of concrete surfaces prior to adhesiveapplication

2.3.2.1Inspect all concrete surfaces prior to ap-

plication of adhesive to insure that requirements of thisArticle 2.3.2 are met.

2.3.2.2 Surfaces shall be sound concrete which ex-hibits a minimum 100 psi pullout strength when tested inaccordance with Appendix A of Use of Epoxy Com-pounds with Concrete, reported by ACI Committee 503.

2.3.2.3 Surfaces shall be free of any deleteriousmaterials such as laitance, curing compounds, dust, dirt,and oil. Materials resulting from surface preparation spe-cified in Article 2.3.1 shall be removed.

2.3.2.4 All concrete surfaces shall have a moisture

content not exceeding saturated surface dry condition.Surface temperature shall be at least 40 F to permit wet-ting of concrete surface by epoxy adhesive.

2.3.2.5 Evaluate moisture content for concrete bydetermining if moisture will collect at bond lines betweenold concrete and epoxy adhesive before epoxy has cured.This may be accomplished by taping a 4 x 4 ft poly-ethylene sheet to concrete surface. If moisture collects onunderside of polyethylene sheet before epoxy would cure,then allow concrete to dry sufficiently to prevent the pos-sibility of a moisture barrier between old concrete andnew epoxy.

2.3.3Adhesive mixes2.3.3.1Mix 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), unlessotherwise recommended by manufacturer.

2.3.3.3 Thoroughly blend epoxy components with amechanical mixer to a uniform and homogeneous mix-ture. Mix small batches (up to 1 qt) by use of spatulas,palette knives, or similar devices.

2.3.4Adhesive application and concrete placement2.3.4.1 Ambient temperature is critical during

application of epoxy adhesives and concrete placement.Work shall be performed in accordance with Chapters 7and 3 ofACI 301.

2.3.4.2 Apply epoxy adhesive to concrete surface bybrush, roller, broom, squeegee, or sprayequipment, Ap-ply epoxy compound at a thickness not less than that re-commended by manufacturer.

2.3.4.3 Place fresh plastic concrete while adhesive isstill tacky. If epoxy adhesive cures to extent of losing itstack before plastic concrete is placed, remove or slightlyabrade first coal before placing second coat.

2.3.4.4 Consolidate freshly placed plastic concretein accordance with ACI 301 to insure full bonding of newconcrete.

2.3.4.5 Upon completion of finishing operations,cure concrete in accordance with procedures defined inChapter 12 of ACI 301 and as indicated in the projectspecification.

2.3.5Cleanup2.3.5.1 Protect concrete surfaces, beyond limits of

surface receiving adhesive, against spillage.2.3.5.2 Immediately remove any epoxy compound

applied or spilled beyond desired areas. Perform cleanupwith material designated by epoxy adhesive manufacturer.Avoid contamination of work area.

2.3.6 Safety-Epoxy materials are skin irritants orsensitizers to many people. Accordingly, advise appli-cators to avoid contact with eyes and skin, inhalation ofvapors, and ingestion. Make protective and safety equip-ment available on site. Heed all label warnings by manu-facturer.

2.3.7Field quality performance requirements2.3.7.1The Architect/Engineer shall evaluate bond-

ing of fresh concrete to existing concrete after the freshconcrete has cured for not less than 28 days.

2.3.7.2 The evaluation shall be performed by sound-ing, using one of the following, or similar, methods:

a) Tapping fresh concrete with a blunt metalinstrument

b) Dragging a heavy steel chain across the surface(for horizontal surfaces only)

2.3.7.3 Detection of a hollow sound in any areashall be reason to suspect inadequate bonding, and con-tractor shall then core each such area, as requested bythe Architect/Engineer, to determine bonding adequacy.

2.3.7.4 Coring shall be through the new concreteand into the existing concrete. Core diameter shall be asrequired by the Architect/Engineer. Length of cores shallbe twice the core diameter, or twice the thickness of newconcrete, or as requested by the Architect/Engineer.

2.3.7.5 Cores will be visually inspected, and furthertesting required, if any, will then be determined by theArchitect/Engineer.



--

,,,,,,,

,

,,,,

,,

,,

,,,,,-

-

,,

,,

,

,,

---


11/21

Standard Specification for Producing aSkid-Resistant Surface on Concrete by the Use of a

Multi-Component Epoxy System (ACI503.3-92,reapproved 1997, 200


R.W. GaulChairman

Russell H. BrinkGeorge HoreczkoHarold C. KlassenJoseph A. McElroy


Raymond J. Schutz

Chairman

Milton D. AndersonRoger W. BlackJohn P. CookFloyd E. DimmickWolfgang E. EisenhutJack J. FontanaRobert W. GaulPaul R. Hollenbach

Leonard J. MitchellMyles A. MurrayLeonard Pepper

David P. HuT. Michael JacksonTroy D. MadeleyAlbert MayerJoseph A. McElroyPaul F.McHalePeter Mendis

This specification describes rhe work of producing a skid-resistant surface

on hardened concrete by the application of a multi-componentepoxy

adhesive such as defined for this purpose in ASTM C 881. It includes

controls for adhesive labeling, storage, handling, mixing nndapplication,

surface evaluation and preparation as well as inspectron nnd quality

control.

In addition, it describes an aggregate to be used with the coating.

Keywords: aggregates; coatings; concrete pavements; epoxyresins;

hardened concrete; quality control; skid resistance; specifications;standards.

FOREWORD

This foreword is included for explanatory purposes only; itdoes notform a part of Standard Specification ACI 503.3.

ACI Committee Reports, Guides, Standard Practices, andCommentaries are intended for guidance in designing, plan-


specifications. References to these documents shall not bemade in the Project Documents. If items found in these

documents are desired to be a part of the Project Docu-

ments, they should be phrased in mandatory language and


George SeldenSecretary

G.M. Scales

Raymond J. SchutzGeorge W. Whitesides

Myles A. Murray

Secretary

Richard MontaniJoseph M. PlecnikHamid SaadatmaneshW. Glenn SmoakJoe SolomonMichael M. SprinkelDouglas G. Walters


which theArchitect/Engineermay cite in the project spe-cification(s) for any building project, together with sup-

plementa ry 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 systemmodified to ACI requirements. The

language is generally imperative and terse.

A specification guide andchecklistare included as a

preface to, but not forming a partof, Standard Specification

ACI503.3. The purpose of this guide is to assist the Archi-

tect/Engineers designer(s) and specifier(s) to properly

choose andspecify the necessary supplementary require-

ments for the project specification(s).

* 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 elec-

Ironic 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


--

,,,,,,,

,

,,

,,

,,

,,

,,,,,-

-

,,

,,

,

,,

---


12/21


Specification guide, pg.503.3-2



l.l-Scope1.2-Notation1.3-Specification wording



Part 2.1-Genera1, pg. 503.3-4

2.1.1-Description2.1.2-Submittals

2.1.3-Quality assurance2.1.4-Delivery, storage, and handling2.1.5-Project conditions


2.2. l-Epoxy coating2.2.2-Skid-resistant aggregate


2.3.1-Preparation of surfaces2.3.2-Inspection of surface prior to coating

application2.3.3-Coating mixes2.3.4-Coating application2.3.5-Field quality control2.3.6-Cleanup2.3.7-Safety

SPECIFICATION GUIDE

SGl-Standard Specification ACI 503.3 is intended tobe used essentially in its entirety, by citation in theproject specification, to cover all usual requirements for

producing a skid-resistant surface on concrete by the ap-plication of a multi-component epoxy system. Individual

sections, parts, and articles should not be copied intoproject specifications since taking them out of contextmay change their meanings.

SG2-However, adjustments to the needs of a parti-cular project shall be made by the Architect/Engineersdesigners and specifiers by reviewing each of the itemsindicated in this specification guide and checklist andthen including their decisions on each as mandatory re-quirements in the project specification.

SG3-These mandatory requirements shall designatespecific qualities, procedures, materials, and performancecriteria for which alternatives are permitted or for which

provision is not made in Standard Specification ACI503.3. Or exceptions shall be taken to Standard Spe-cification ACI 503.3 if required.

SG4-A statement such as the following will serve tomake Standard Specification ACI 503.3 an official part ofthe contract requirements:

The producing of an epoxy system skid-resistant sur-face on concrete shall conform to all requirements ofStandard Specification for Producing a Skid-ResistantSurface on Concrete by the Use of a Multi-Com-ponent Epoxy System (ACI503.3), published by theAmerican Concrete Institute, Detroit, Mich., except asmodified by the requirements of this project speci-fication.

SG5-The specification checklist that follows is ad-dressed to each item of ACI 503.3 that requires thedesigner/specifier to make a choice where alternates areindicated, or to add provisions where they are not in-dicated in ACI 503.3, or to take exceptions to ACI 503.3.The checklist consists of section, part, and article headsofACI 503.3, with accompanying notes to the designer/specifier to indicate the action required of them.


Section/Part/Article of ACI 503.3 I Notes to theDesigner/Specifier


1.1 Scope




Review applicability of cited references and take excep-tions if required.

yright American Concrete Institutevided by IHS under license with ACI Licensee=AramcoHQ/9980755100


13/21



Section/Part/Article of ACI 503.3 Notes to the Designer/Specifier

2.1.2Submittals


2.1.4.2 Storage of materials


2.2.2 Skid-resistant aggregate

2.2.2.2 Weight loss of aggregate2.2.2.3 Aggregate moisture content

2.3.2.2 Pullout strength test

2.3.2.4 Concrete surface

To whom sent?

Mixing and application procedures submitted must bein accordance with product manufacturers instructions.

Storing epoxy compounds at other than specified tem-perature range may result in degradation of theproduct. If such storage takes place, manufacturershould be contacted before product is used.

Performance of epoxy systems may be affected by tem-perature, humidity, and surface water. Strict adherenceto the manufacturers recommendations should bemaintained. Where other unusual conditions are en-countered, the material manufacturer should be con-sulted before application.

The aggregate described in this section will provide a

suitable nonskid surface for vehicular traffic. For sur-faces limited to pedestrian traffic only, the designermay desire to choose a less coarse aggregate grada-tion. The preparation and inspection of a small sampleusing the proposed aggregate and coating at their pro-posed rate of application prior to publication of a spe-cification will enable the designer to anticipate the ap-pearance and texture of the surface.

Suitable aggregates meeting these specifications aregenerally a heterogeneous combination of mineralswith a coarse grained microstructure of hard particlescemented by a slightly softer matrix. Examples are cor-undum-rich materials employed by the grinding wheelindustry such as calcined bauxite and emery; well-cemented sandstones and certain metamorphised sand-stone such as metagreywacke.

The test method specifies the bonding of a steel pipecap to the concrete surface with an epoxy adhesive. Ifthe test results not in failure of the concrete but incohesion of the epoxy resin adhesive or any failure inadhesion, the test shall be repeated. Repeated failuresin adhesion, or cohesion in the adhesive, indicate im-proper cleaning of the concrete, incorrect adhesive, orfaulty adhesive application techniques.

When concrete surface is not dry, materials manu-facturer should be consulted regarding suitability ofsystem and adequacy of application techniques. Someepoxy adhesives may be capable of wetting the con-crete surface at temperatures below 40 F. The speci-fication should allow such use only if test data isavailable which conclusively demonstrates adequatebond at the actual concrete temperature expected.


ded by IHS under license with ACI Licensee=Aramco HQ/9980755100


--

,,,,,,,

,

,,,,

,,

,,

,,,,,-

-

,,

,,

,

,,

---


14/21



Section/Part/Article of ACI 503.3 Notes to the Designer/Specifier

2.3.4.1 Coating application

2.3.4.2 Aggregate application

2.3.5 Field quality control


l. l-Scope

1.1.1 This standard specification covers the producingof 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 docu-ments. In case of conflicting requirements, the contractdocuments shall govern.

1.2-Notation1.2.1 ACI: American Concrete Institute

P.O. Box 19150Detroit, MI 48219

1.2.2 ASTM: American Society for Testing and

Materials1916 Race StreetPhiladelphia, PA 19103


13.1 The language of this standard specification isgenerally imperative and terse, and may include incom-plete sentences. Omissions of phrases and of words suchas 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 in-ference.


This rate of coating application is suitable for theaggregate gradation specified in Article 2.2.2.1 and ag-gregate rate of application specified in Article 2.3.4.2.

If either of these is changed the coating applicationrate may have to be adjusted. A sample should be pre-pared to evaluate the resulting surface,

This rate of aggregate application is suitable for theaggregate gradation specified in Article 2.2.2.1 andcoating rate of application specified in Article 2.3.4.1.If either of these is changed the aggregate applicationrate may have to be adjusted and a sample should beprepared to evaluate the resulting surface.

Satisfactory performance using this test assures that theskid-resistant aggregate is adequately bonded to the

epoxy adhesive coating and that the coating isadequately bonded to the concrete.

Care must be taken when bonding the pipe cap tothe skid resistant surface with epoxy adhesive that allvoids are filled with adhesive.

1.4.1 The standards referred to in this Standard Speci-fication ACI 503.3 are listed in Article 1.4.2 of this sec-tion, with their complete designation and title includingthe year of adoption or revision and are declared to bea part of this Standard Specification ACI 503.3 the same

as if fully set forth herein, unless otherwise indicated inthe contract documents.

1.4.2ASTM standards

C 131-81 Standard Test Method for Resistance to De-(Reap- gradation of Small-Size Coarse Aggregate byproved Abrasion and Impact in the Los Angeles1987) MachineC 136-84a Standard Method for Sieve Analysis of Fine

and Coarse AggregatesC 566-84 Standard Test Method for Total Moisture

Content of Aggregate by DryingC 881-87 StandardSpecificationforEpoxy-Resin-Base



Part 2.1-General

2.1.1 Description-This section covers the require-ments for materials and application of the multi-component epoxy coating system.

2.1.2Submittals

2.1.2.1 Contractor shall submit manufacturerscertification verifying performance to material spe-


--`,,,,,,,

`,

`,,,,

`,,

``,,

``,,,,,-`-`,,

`,,

`,

`,,

`---


15/21

EPOXY RESINS 503.3-

cifications specified in Part 2.2.2.1.3 Quality assurance

2.1.3.1Labeling-Clearly mark all containers withthe following information:

a) Name of manufacturerb) Manufacturers product identificationC) Manufacturers instructions for mixingd) Warning for handling and toxicity

2.1.3.2Application control-Submit mixing and ap-plication procedures for approval prior to use.

2.1.4 Product delivery, storage, and handling2.1.4.1Delivery 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 otherwiserecommended by manufacturer.

2.1.4.3Handling of materials-Handle all materialsin a safe manner and in a way to avoid breaking con-

tainer seals.2.1.5 Project conditions

2.1.5.1Environmental requirements-Contractorshall comply with manufacturers recommendations as toenvironmental conditions under which the epoxy com-pound may be applied.

Part 2.2-Products2.2.1Epoxy coating-ASTM C 881. Curing temper-

ature requirements (Class) and viscosity (Grade) shall bedetermined by supplier and contractor and approved byarchitect/engineer after project conditions have beenestablished.

2.2.2 Skid-resistant aggregate2.2.2.1 Aggregate shall meet the following

gradation when tested in accordance with ASTM C 136:

Sieve size

100

6 97-100

8 55-75

16 0-3

Percent passing

2.2.2.2 When tested in accordance with ASTM C131, aggregate shall have a maximum weight loss of 20percent at 500 revolutions.

2.2.2.3 Moisture content of the aggregate shall notexceed 0.15 percent when tested in accordance withASTM C 566, Standard Test Method for Total MoistureContent of Aggregate by Drying.

Part 2.3-Execution2.3.1Preparation of surfaces2.3.1.1Concrete surfaces to which epoxies are to

be applied shall be newly exposed parent concrete free oloose and unsound materials. Prepare surfaces by mechanical abrasion.

2.3.1.2Mechanical abrasion-Use sandblastingscarifying, waterblasting, or other approved means.

2.3.2Inspection of surface prior to coating application2.3.2.1 Inspect all concrete surfaces prior to ap

plication of coating to insure that requirements of thi

Article 2.3.2 are met.2.3.2.2 Surfaces shall be sound concrete whic

exhibits a minimum 100 psi pullout strength when testein 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 deleteriomaterials such as laitance, curing compounds, dust, dirtand oil, and materials resulting from surface preparationas specified in Article 2.3.1, shall be removed.

2.3.2.4 All concrete surfaces shall be dry as definein Article 2.3.2.5 below unless a water-insensitive coatinis 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 betweenold concrete and epoxy coating before epoxy has curedThis may be accomplished by taping a 4 x 4 ft poly-ethylene sheet to concrete surface. If moisture collects onunderside of polyethylene sheet before epoxy would curethen allow concrete to dry sufficiently to prevent thpossibility of moisture between old concrete and new

epoxy.2.3.3Coating mixes

2.3.3.1Mix epoxy components in a clear containfree of harmful residue or foreign particles.

2.3.3.2 Condition epoxy compound components tbe at a temperature between 60-100 F (16-38 C), unlessotherwise recommended by manufacturer.

2.3.3.3 Thoroughly blend epoxy components wita mechanical mixer to a uniform and homogeneous mixture. Mix small batches (up to 1 qt) by use of spatulaspalette knives, or similar devices.

2.3.4 Coating application

2.3.4.1 Apply epbxy coating to concrete surface bbrush, roller, broom, squeegee, or spray equipment. Apply epoxy compound at a uniform thickness of 60 1mils.

2.3.4.2 Apply skid-resistant aggregate while coatinis still fluid at the rate of 12 1

2.3.5Field quality control-The inspector shall deter-mine that coating and skid-resistant aggregate are appliedat a rate at least equal to that specified and that aggregate and coating are securely bonded. The pulloustrength 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 Compoundswith Concrete, reported by ACI Committee 503. Th

failure shall be cohesive within the concrete. There shalbe no failures in adhesion.2.3.6Cleanup

--`,,,,,,,`,`,,,,`,,``,,``,,,,,-`-`,,`,,`,`,,`---


16/21


2.3.6.1 Protect concrete surfaces, beyond limits of 2.3.7 Safety-Epoxy materials are skin irritants orsurface receiving coating, against spillage. sensitizers to many people. Accordingly, advise appli-

2.3.6.2 Immediately remove any epoxy compound caors to avoid contact with eyes and skin, inhalation ofapplied or spilled beyond desired areas. Perform cleanup vapors and ingestion. Make protective and safety equip-with material designated by epoxy coating manufacturer. ment available on site. Heed all label warnings by manu-Avoid contamination of work area. facturer.




17/21

Standard Specification for Repairing Concretewith Epoxy Mortars (ACI 503.4-92, Reapproved 1997, 2003



Russell H. Brink

George HoreczkoHarold C.KlassenJoseph A. McElroy


Raymond J. Schutz

Chairman

Milton D. Anderson

Roger W. BlackJohn P. CookFloyd E. Dimmick

Wolfgang D. EisenhutJack J. Fontana

Robert W. GaulPaul R. Hollenbach

Leonard J. Mitchell

Myles A. MurrayLeonard Pepper

David P. HuT. Michael JacksonTroy D. MadeleyAlbert Mayer

Joseph A. McElroyPaul F. McHale

Peter Mendis

This specification de scri besthe 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 adhesivelabeling 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.

FOREWORD

This forewordis included for explanatory purposes only; it

does not form a part of Standard Specification ACI 503.4.


which the Architect/Engineer may cite in the project speci-

A C I Committee Reports, Guides, Standard Practices, and





documents are desired to be a part of the Project Docu-

ments, they should be phrased in mandatory language and


G.M. Scales

Raymond J. SchulzGeorge W. Whitesides


Richard MontaniJoseph M. Plecnik

Hamid SaadatmaneshW. Glenn Smoak

Joe Solomon

Michael M. SprinkelDouglas G. Walters

fication(s) for any building project, together with sup-

plementary 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 Specifi-

cation ACI503.4. 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

supplementary requirements for the project specification(s).

* Adopted as a standard of the American Concrete Institute effective June 1979.

in accordance with the Institutes standardization procedure. It was revisedaccording to the expedited procedure effective October 1986 and March 1992,.

Copyright 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 elec-tronic or mechanical device. printed or written or oral, or recording for sound orvisual 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


--

,,,,,,,

,

,,,,

,,

,,

,,,,,-

-

,,

,,

,

,,

---


18/21

503.4-2

CONTENTS SPECIFICATION GUIDE




SGl-Standard Specification ACI 503.4 is intended tobe used essentially in its entirety, by citation in theproject specification, to cover all usual requirements forrepairing concrete with epoxy mortars. Individual sec-tions, parts, and articles should not be copied into project

specifications since taking them out of context maychange their meanings.

1.1-Scope1.2-Notation1.3--Specification wording1.4-Reference standards



2.1.1-Description

2.1.2-Submittals2.1.3-Quality assurance2.1.4-Product delivery, storage, and handling2.1.5-Project conditions

SG2-However, adjustments to the needs of a parti-cular project shall be made by the Architect/Engineersdesigners and specifiers by reviewing each of the itemsindicated in this specification guide and checklist andthen including their decisions on each as mandatoryrequirements in the project specification.

SG3-These mandatory requirements shall designatespecific qualities, procedures, materials, and performancecriteria for which alternatives are permitted or for whichprovision is not made in Standard Specification AC I

503.4. Or exceptions shall be taken in Standard Speci-fication AC I 503.4 if required.

SG4-A statement such as the following will serve tomake Standard Specification ACI 503.4 an official part ofthe contract requirements:


2.2.1-Epoxy mortar

Repairing concrete with epoxy mortars shall conformto all requirements of Standard Specification forRepairing Concrete with Epoxy Mortars (ACI503.4),published by the American Concrete Institute, De-troit, Mich., except as modified by the requirementsof this project specification.


2.3.1-Preparation of concrete surfaces2.3.2-Inspection of concrete surfaces prior to mortar

application2.3.3-Mortar mixes2.3.4-Mortar application2.3.5-Cleanup2.3.6-Safety

SG5-The specification checklist that follows is ad-dressed to each item of ACI 503.4 that requires thedesigner/specifier to make a choice where alternates areindicated, or to add provisions where they are not in-dicated in AC I 503.4, or to take exceptions to ACI 503.4.The checklist consists of one column identifying sections,parts, and articles ofAC I 503.4, and a second column ofnotes to the designer/specifier to indicate the action

required of them.


Section/Part/Article ofACI 503.4 Notes to the Designer/Specifier

Section l-Generalrequirements

1.1 Scope



2.1.2 Submittals



To whom sent?



19/21



Section/Part/Article of ACI 503.4


2.1.4.2 Storage of materials


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

Notes to the Designer/Specifier

Mixing and application procedures submitted must bein accordance with product manufacturers instructions.

Storing epoxy compounds at other than specified tem-

perature range may result in degradation of the pro-duct. If such storage takes place, manufacturer shouldbe contacted before product is used.

Performance of epoxy systems may be affected by tem-perature, humidity, and surface water. Strict adherenceto the manufacturers recommendations should bemaintained. Where other unusual conditions are en-countered, the material manufacturer should be con-sulted before application.

Epoxy mortars consist of a two component epoxy sys-tem plus aggregate which may or may not be incorpor-ated in one or both components. Since the amount andtype of aggregate is important to the performance ofthe mortar, the supplier and contractor must be in fullagreement on selection and use. If the aggregate isfurnished with proper instructions by the supplier theproblem is minimized.

The amount and type of aggregate selected can re-sult in a mortar mix that will not adequately wet theconcrete substrate and thus can result in a poor bond.The manufacturers recommendations should be close-ly followed regarding the need for and application of a

primer for the mortar mix selected.Specify limitations, if any, on use of mechanicalabrasion, and on disposal of waste products.

Specify if architect/engineer will also inspect, and ifhold points are required.

The test method specifies the bonding of a steel pipecap to the concrete surface with an epoxy adhesive. Ifthe test results not in failure of the concrete but incohesion of the epoxy resin adhesive or any failure inadhesion, the test shall be repeated. Repeated failures

in adhesion, or cohesion in the adhesive, indicate im-proper cleaning of the concrete, incorrect adhesive, orfaulty adhesive application techniques.

Surface condition of the concrete must be in accor-dance with the suppliers recommendation. Somemortars require a dry surface and a test method shouldbe available to the applicator.

Some epoxy adhesives may be capable of wettingthe concrete surface at temperatures below 40F. Thespecification should allow such use only if test data isavailable which conclusively demonstrates adequate

bond at the actual concrete temperature expected.yright American Concrete Institute


--`,,,,,,,`,`,,,,`,,``,,``,,,,,-`-`,,`,,`,`,,`---


20/21



Section/Part/Article of ACI 503.4 I Notes to the Designer/Specifier

2.3.4.1Mortar application


l . l -Scope

1.1.1 Thisstandard specification covers repairing ofdefects in hardened portland cement concrete with sand-fiied epoxy mortar.

1.1.2The provisions of this standard specification shall

govern unless otherwise specified in the contract docu-ments. In case of conflicting requirements, the contractdocuments shall govern.

1.2-Notation

1.2.1ACI: American ConcreteP.O. Box 19150Detroit, MI 48219

Institute

1.2.2 ASTM: American Society for Testing andMaterials

1916 Race Street

Philadelphia, PA 19103


1.3.1 The language of this standard specification isgenerally imperative and terse, and may include incom-plete sentences. Omissions of phrases and of words suchas 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 in-ference.


1.4.1 The standards referred to in this Standard Speci-fication AC I 503.4 are listed in Article 1.5.2 of thissection, with their complete designation and title in-cluding the year of adoption or revision and are declaredto be a part of this Standard Specification ACI 503.4 thesame as if fully set forth herein, unless otherwise in-dicated in the contract documents.

1.4.2ASTM standardC 881-87 Standard Specification for Epoxy-Resin-Base



Part 2.1-General

Too thin an application of epoxy mortar can result in asurface without adequate integrity for intended use.Too thick an application can result in delamination

caused by temperature changes. See Use of EpoxyCompounds with Concrete reported by Committee 503for a more complete explanation.

2.1.1Description - This section covers the require-ments for surface preparation of hardened concrete andfor materials and application of the epoxy mortar.

2.1.2Submittals2.1.2.1 Contractor shall submit manufacturers

certification verifying conformance to material specifi-cations specified in Part 2.2.

2.1.3Quality assurance2.1.3.1Labeling-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 Applicat ion control-Submit mixing andapplication procedures for approval prior to use.

2.1.4 Product delivery, storage, and handling

2.1.4.1Delivery ofmaterials-Deliver all materialin sealed containers with labels legible and intact.

2.1.4.2 Storage of materials-Store allmaterialstemperatures between 40-100 F (5-38 C) unless otherwiserecommended by manufacturer.

2.1.4.3Handling of materials--Handle all materialsin a safe manner and in a way to avoid breaking con-tainer seals.

2.1.5Project conditions2.1.5.1 Environmental requirements-Contracto

shall comply with manufacturers recommendations as toenvironmental conditions under which the epoxy com-

pound may be applied.

Part 2.2-Products2.2.1 Epoxy mortar-ASTM C 881 Type III. Curin

temperature requirements (Class) and viscosity (Grade),as well as special requirements regarding filling of eitherthe components or the final system, shall be determinedby supplier and contractor after project conditions havebeen established.

Part 2.3-Execution2.3.1Preparation of concrete surfaces

2.3.1.1Concrete surfaces to which epoxies are to beapplied shall be newly exposed parent concrete free ofloose and unsound materials. Prepare surfaces by mech-

i h A i C I i

--`,,,,,,,`,`,,,,`,,``,,``,,,,,-`-`,,`,,`,`,,`---


21/21


anical abrasion.2.3.1.3Mechanical abrasion-Use sandblasting,

scarifying, waterblasting, or other approved means.2.3.2Inspection of concrete surfaces prior to mortar ap-

plication

2.3.2.1 Inspect all concrete surfaces prior toapplication of mortar to insure that requirements of thisArticle 2.3.2 are met.

2.3.2.2 Surfaces shall be sound concrete whichexhibits a minimum 100 psi pullout strength when testedin accordance with Appendix A of Use of Epoxy Com-pounds with Concrete, reported by AC I Committee 503.

2.3.2.3 Surfaces shall be free of any deleteriousmaterials such as laitance, curing compounds, dust, dirt,and oil. Materials resulting from surface preparation spe-cified in Article 2.3.1 shall be removed.

2.3.2.4 All concrete surfaces shall be dry as definedin Article 2.3.2.5 below unless a water-insensitive coatingis used. Surface temperature shall be at least 40 F to per-mit 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 betweenold concrete and epoxy coating before epoxy has cured.This may be accomplished by taping a 4 x 4 ft poly-ethylene sheet to concrete surface. If moisture collects onunderside of polyethylene sheet before epoxy would cure,then allow concrete to dry sufficiently to prevent thepossibility of moisture between old concrete and new

epoxy.2.3.3Mortar mixes

2.3.3.1 Mix epoxy components in a clean containerfree 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), unlesotherwise recommended by manufacturer.

2.3.3.3 Thoroughly blend epoxy components withmechanical mixer to a uniform and homogeneous mixture. Mix small batches (up to 1 qt) by use of spatulaspalette knives, or similar devices.

2.3.4Mortar application

2.3.4.1 Apply epoxy mortar to concrete surface b

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 mortaand entrained air is reduced to the level recommendedby manufacturer.

2.3.4.3 Finish surface of mortar to texture, coloand smoothness required for the specific application.

2.3.4.4 Upon completion of finishing operationallow mortar to cure in accordance with manufacturerrecommendations.

2.3.5Cleanup2.3.5.1 Protect concrete surfaces, beyond limits o

surface receiving mortar, against spillage.2.3.5.2 Immediately remove any epoxy compoun

applied or spilled beyond desired areas. Perform cleanupwith material designated by epoxy mortar manufacturerAvoid contamination of work area.

2.3.6Safely-Epoxy materials may be skin irritants osensitizers to many people. Accordingly, advise applicators to avoid contact with eyes and skin, inhalation ovapors, and ingestion. Make protective and safety equipment available on site. Heed all label warnings by manufacturer. Make application in accordance with applicablsafety laws.