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Presented By: Mike Mudrick
2012 ICRI Carolinas Chapter Fall Convention
Coating Failures, Causes, Preventative Measures & Repairs
Executive Development Center1241 Military Cutoff Rd #A, Wilmington, NC
RESIDENCE INN FRIDAY OCTOBER 12th 2012
Vapor Moisture Transmission In the
Construction Industry
Moisture Activity In Concrete CAN BE ENCOUNTERED EITHER
IN:
• In Liquid Form• Capillary Action• Hydrostatic
Pressure • Measured in psi.
OR
Moisture Vapor TransmissionA COMMON OCCURANCE IN THE FLOORING
INDUSTRY
• In Gas Form• Diffusion Action• Vapor Static
Pressure• Measured in
lb/1000 ft2/24 hr.• (MVER)
DIFFERENCES BETWEENGAS FORM & LIQUID FORM
Vapor Emission (GAS) Pressures:• Humid gas passing through the capillaries of the concrete
with minimal pressure, very little water, and will dry out when surface is not covered.
Hydrostatic (WATER) Pressures:• Generally moderate to high pressure, measured in PSI,
saturates the concrete, moves laterally, and remains constantly wet.
FLOORING FAILURES DUE TO
MOISTURE VAPOR EMISSION
Photo courtesy of Construction Technology Laboratories, Inc."
Acrylic Based VCT Tile Adhesive Failure
Failure of a Polyurethane Adhesive Due to
Moisture Vapor Emission
Example running track
Failure of an Epoxy Mortar Overlay Due To
Moisture Vapor Emission
Failure of Trowel Down Epoxy Coating Due to
Moisture Vapor Emission
Failure of Thin Film Epoxy Coating Due to
Moisture Vapor Emission
All Result In Lost $$$ Increased Liability
The Common Denominators?Probably Could Have Been
Avoided!!
GENERALLY SPEAKINGVAPOR EMMISSION PROBLEMS
CAN BE CATAGORIZED IN ONE OF TWO WAYS
1. Concrete Drying Issues “Closed Slab or Above Grade
Situations”
2. Chronic Diffusion Issues “Open Slab Situations”
A Closed Slab System is where an PERMANENT VAPOR BARRIER or non-perforated metal decking is
in place directly beneath the concrete. In a Closed Slab System the only source of moisture is free-water originating from within the concrete itself.
CLOSED SLAB SYSTEM
OPEN SLAB SYSTEMAn Open Slab System is the most challenging condition for a topical moisture& pH suppression system as moisture within the concrete will typically rise above theoriginally tested levels over time.
WHEREVAPOR EMISSION PROBLEMS
APPEAR
• SLABS ON GRADE
• SLABS ABOVE GRADE
• SLABS BELOW GRADE
SOME COMMON CAUSES OFVAPOR EMMISSION PROBLEMS
• OLDER BUILDING Without Any Under Slab Vapor Barrier
• OLDER BUILDING With a Damaged or Deteriorated Under
Slab Vapor Barrier
COMMONLY OVERLOOKED SITUATIONS LEADING TO
POTENTIAL VAPOR MOISTURE TRANSMISSION PROBLEMS
• Renovation Or Reconfiguration Of Existing Space
• NEW CONSTRUCTION With A Compromised (Direct Contact) V.B.
or Fill Saturated Before Slab Pour
(Indirect Contact)
GENERALLY IGNORED SITUATIONS LEADING TO
POTENTIAL VAPOR MOISTURE TRANSMISSION PROBLEMS
Renovation Or Reconfiguration Of Existing Space
• NEW CONSTRUCTION With Compromised (Direct Contact) V.B.
• Fill Saturated Before Slab Pour (Indirect Contact) V.B.
• FAST TRACK/NEW PROJECT: No Time to Wait for Concrete to Fully Dry
Reasons Achieving Proper RH& or MVER in New Construction Can Be
Difficult
2. WATER Of Convenience In The Fresh Concrete Mix
1. Concrete Or Fill Moisture Events
Amount Of WATER In Fresh Concrete
Example: A simple 6-sack concrete mix consists of
• 564 lb cement/yd3 (Type I, II, …..)
• ~3,200 lb aggregates/yd3
• Water for mixing, placing & hydration of cement
• Additives (superplasticizer, air entrainment, etc.)
W/C (water/cement ratio): 0.5 assumed
• Typical Amount of WATER: 0.5 x 564 lb = 282 lb
= 34 gal/yd3
a. Total WATER in concrete
mix = 34 gal/yd3
b. REQUIRED:
WATER for hydration of cement ~35% = 12 gal/yd3
c. RESULT:
~65% surplus WATER needs
to evaporate = 22 gal/yd3
Rule Of Thumb For Concrete Drying Time:
AT LEAST ONE MONTH PER 1” OF THICKNESS
(Will More Than Double In Winter)
Lightweight Concrete Mix Designs Dry At Rate 2 Times Longer Than Normal
Concrete
ALWAYS TEST TO BE SURE!!!
Isn’t Concrete Is DRY In 28 Days?NO!! Concrete Is Only CURED In 28
Days!Not Acceptable RH%
Not Under 3 to 5 lbs of MVER
WHAT IS DRY CONCRETE ANYWAY?!?!
Concrete Drying Times
How Is Moisture Vapor Emission Measured?
Calcium Chloride Test Kit
ASTM F 18693 Test Kits For The First 1000 S/F of Floor & 1 Additional Test
Kit For Each Additional 1000
S/F
Example: 7000 S/F =
9 Total Test Kits
CALCIUM CHLORIDE TEST ASTM F-1869
Measured in Pounds, of the Amount of Water Emitted from 1000 sq.ft. of Concrete Over 24 hours. (8 lbs = 1 gallon) NOT PSI…..
Proper Testing Requires 1 test per 1000 sq.ft. With a Minimum of Three Tests.
Space MUST Be “Climate Controlled” 48 Hours Prior to Kit Placement and Conditions Be Stable Throughout the Test.
The Surface Should be Ground, Clean and Remain “Open” 24 Hours Prior to Placement. Tests Require 62 to 70 hours.
Improperly Performed Calcium Chloride Tests
X
How Is Moisture Vapor Emission Measured?
Another New Test Method Is Currently Being Used:
ASTM F 2170 Test Method For Determining Relative Humidity In Concrete Floor Slabs Using In-Situ ProbesPros
Precise, accurate
Can be quickly re-measured
Not AS influenced by ambient conditions
Cost effective
Easy to track drying
Proven accuracy
Relative Humidity Probes
ASTM 2170
R. H. Probe Hole Depth 40% Of Slab Thickness
5” Thick Slab x .40” = 2 Inches Deep
Drill & Clean Hole, Insert R. H. Probe
Allow R.H. Probe to Acclimate as Required by Manufacturer Before Obtaining Readings
WHERECAN VAPOR EMISSION PROBLEMS APPEAR?
• SLABS ON GRADE
SLABS ON GRADE
Indoors
Outdoors
WHERECAN VAPOR EMISSION PROBLEMS APPEAR?
• SLABS ON GRADE
• SLABS ABOVE GRADE
SLABS ABOVE GRADE
Concrete on Non-Vented Metal Deck
Structural Concrete Components
Rehabilitation Or Remedial Projects
HOWDOES VAPOR
EMISSION CAUSE FLOORING
SYSTEMS TO FAIL?
Moisture Movement Through Interior Slabs On
Grade
VAPOR EMISSION Varies Throughout The Slab Itself
May Also Fluctuate During Different Times Of Year
Moisture Vapor Emission TRANSPORTS MINERALS & CONDENSATES AT
SURFACE
SOLUBLE METAL IONS
• Calcium Hydroxide: “Free Lime”• Potassium Hydroxide: “Caustic”• Sodium Hydroxide: “Unstable”
• Result: Dissolved metal ions raise the pH levels in the “solution” allowing a chemical attack on the organic compounds.
WHY NOW…. I Never Had Problems Before?!?!
Volatile Organic Content
REQUIREMENTS CHANGED IN THE LATE1990’s
The Real Issue Is High Ph
NEW GENERATION OF PRODUCTS DO NOT PERFORM WELL IN HIGH pH ENVIRONMENTS
pH Scale is Logarithmic
• pH 7 is Neutral• pH 7 and Lower is Acid• pH 7 and Higher is Alkaline
• A pH of 13 compared to a pH 7:
1 MILLION Times More Alkaline!!
• Adhesive Warranty Limits: pH 8.2 to 9
How Should One Proceed When MVER Is Not Within The Required
3 or 5 lbs/24 hr*1000 ft2 or Below 75% RH
•Risk Installing the Floor System?
•Pretend It Is Not A Problem?
•Run Away & Hide?
NO!
APPLYA QUALITY SURFACE APPLIED VAPOR
SUPPRESANT WHEN:
MVER Is Greater Than 3 or 5 lbsOR
Relative Humidity % Is Too High
IF HIGH MVER or RH% IS IGNORED YOU RISK SUFFERING COSTLY
FAILURES & REPAIRS
Various Vapor Suppression Systems
Currently there are 6 major system categories or material methods being marketed to
mitigate a high moisture or pH condition in concrete sub-floors. Treatments range
from single coat applications to multi-stage systems that combine two or more
categories of materials.
1. Reactive PenetrantsReactive penetrants are fluid applied treatments designed to penetrate
the concretesurface and react chemically with the concrete. The goal of such
treatments is toreduce the moisture vapor emission rate (MVER) and to bind up soluble
alkali suchthat high pH levels are not experienced at the concrete/adhesive
interface.The most common reactive formulations used for moisture & pH
suppression arebased on sodium silicate, potassium silicate or lithium silicate.
Before giving consideration to a silicate-based, reactive penetrant one must have
thorough knowledge of the concrete composition and degree of surface carbonation.
Concrete mixtures that contain pozzolanic materials such as Fly Ash or Slag can
reduce available reactive material within the concrete and thus lead to incomplete
reaction of the silicate-based treatment. Concrete that is more than superficially
carbonated may produce a similar result. Not only will un-reacted silicates not
achieve the desired reduction in the moisture vapor emission rate (MVER) but they
can inhibit the bond of subsequent flooring or coating applications.Reactive penetrants, as a stand alone treatment, are considered a very
high riskapproach to topical moisture and pH suppression.
2. Cementitious DensificationModified cementitious overlays are intended to isolate the concrete
surface fromadhesives or coatings applied above. Such systems are intended to lower
moisturetransfer and restrict soluble alkalis within the concrete sub-floor from
reaching theadhesive/overlay interface but can be inconsistent in efficacy.
Various Vapor Suppression Systems
3. SealersFluid applied sealers are available to help reduce moisture transfer and
isolate theconcrete from the adhesive applied above. Most sealers have warranty limits between 8 & 12 lbs or less and low ph stability. Therefore sealers
should be limited for closed slab systems where the demands and required performance is limited.
4. Specialty CoatingsHybrid epoxy-based or epoxy-modified coatings, specifically designed for
highmoisture/pH conditions, reduce the Moisture Vapor Emission Rate (MVER)
and actas an isolation barrier to keep solutions of highly alkaline salts within the
concretefrom reaching the subsequently applied adhesive or coating.
One, two and three coat systems are available. Some systems may require multiple coats to achieve sufficient mil thickness on very aggressively shot
blasted concrete.Additional leveling or cementitious substrate material may be required
over thecoating. When that becomes necessary the materials and processes to
follow should be approved by the manufacturer of the suppressant system.
5. Dispersement MembranesDispersement membranes were historically one of the first approaches to
topicalmoisture suppression that experienced a reasonable measure of success.
Suchsystems utilize a special fabric adhered to the surface of the concrete
whichprovides a lateral avenue for water vapor to diffuse. These membranes are
only for floating systems.
6. Combination SystemsSeveral companies utilize a combination or “Cocktail” approach where two
or moreof the systems discussed above are combined, but this approach is usually
cost prohibitive
DEFICIENCIES OF INFERIOR SURFACE APPLIED VAPOR SUPPRESSANTS
1. MANY VAPOR SUPPRESSANTS CAN ONLY PROTECT UP TO 8, 10 or 12 LBS MVER (NOT FOR OPEN SYSTEMS)
2. FEW VAPOR SUPPRESSANTS CAN WITHSTAND 25 LBS OF MVER
3. STILL LESS ARE 1-COAT SYSTEMS! 2-COAT & 3-COAT SYSTEMS ARE AVAILABLE….BUT WHY?!?
4. BEWARE!!! MANY DO NOT PERFORM IN HIGH ph ENVIRONMENTS OF 13 TO 14
5. HAVE MOISTURE SENSITIVE CHARACTERISTICS
Desired Capabilities Of Quality Surface Applied Vapor Suppressants:
• Must Have Ability To Be Applied To “Fresh” or Old Concrete
• Must Withstand Constant pH 13 – 14 (Normal pH of fresh concrete is 12 – 13) (Aged concrete has a pH 8 – 10)
• Must Provide Proper pH On Surface For Flooring Applications (Neutral = 7)
• Must Tolerate High or Unknown MVER
• Moisture Insensitive Formulation (Damp Surfaces OK!)
HOW MOISTURE RETARDING EPOXY COATINGS WORK
V. B.
Epoxy Vapor Suppressant Penetration
Microscopy Showing Penetration Of The Vapor Suppressant
Vapor Suppressant Thickness
Vapor Suppressant Penetration
STEPS TO SUCCESSFULVAPOR SUPPRESSANT
INSTALLATIONS
ALWAYSEvaluate & Diagnose Existing
Floor
TEST FOR SUCCESS• Extract Core Samples From Both..
Affected & Unaffected Areas
• Analyze Cores In Lab Under Scanning Electron Microscope (SEM)
• Analyze Cores Using Ion Chromatography
• Analyze Cores Using Infra Red Spectro Photometer
Example of Test Cores
Sample Identification Core #1 Core #2
Sample Depth (mm - BTC*) 0-3 mm 3-5 mm 0-3 mm 3-5 mm
IONIC CONSTITUENT CONCENTRATION (ppm)
Sodium (Na) 1410 1090 1160 1140
Potassium (K) 3500 2610 1080 1050
Sulfate (SO4) 2940 4690 3770 2690
Chloride (Cl) 180 110 40 40
Example of Ion Chromatography Test Results
Example of Infrared Spectroscopy Test Results
• Core #1 (MI#28014-01C); 0-3 mm BTC The amount of organic extractable residue comprises approximately 11,100 ppm (1.110%) of the concrete mass. The IR spectrum of the residue indicates the presence of alkyd and polyester resin material.
• Core #1 (MI#28014-01A); 3-5 mm BTC The amount of organic extractable residue comprises approximately 8940 ppm (0.894%) of the concrete mass. The IR spectrum of the residue indicates the presence of alkyd and polyester resin material.
• Core #2 (MI#28014-02A); 0-3 mm BTC The amount of organic extractable residue comprises approximately 16800 ppm (1.680%) of the concrete mass. The IR spectrum of the residue indicates the presence of alkyd and polyester resin material.
• Core #2 (MI#28014-02C); 3-5 mm BTC The amount of organic extractable residue comprises approximately 9,390 ppm (0.939%) of the concrete mass. The IR spectrum of the residue indicates the presence of alkyd and polyester resin material
• .* Note: ''BTC' = Below the Top surface of the Core
Surface Preparation!
ACID ETCHING?
ABSOLUTELY NOT!!!
Proper Surface Preparation
Steel Shotblasting
Proper Surface Preparation
Grinding
Proper Surface Preparation
Scarifying
CSP- 2 CSP- 3 CSP- 4
CSP- 5 CSP- 6 CSP- 7 CSP- 8
Concrete Surface Profiles
X
Degrease If Needed!
Remove All Contaminants
Proper Surface Preparation
Remove Excess Water & Puddles
Mix Thoroughly & Spread Suppressant at Prescribed Rate
Back Roll To Assure A Uniform System Mil Thickness
SUCCESSFUL APPLICATION
RECIPE FOR SUCCESS
• Professional Mitigation Team• RH or Calcium Chloride Testing• Select A Quality Mitigation System• Substrate Core Testing• Proper Substrate Preparation
AND
Call On Your Local
ICRI Carolinas Chapter Professionals
THANK YOU!
QUESTIONS?