Polishing Specs

SECTION 03360 - SPECIAL CONCRETE FLOOR FINISHES


PART 1 GENERAL


1.1 RELATED DOCUMENTS

A. Drawings and general provisions of Contract, including General and Supplementary Conditions and Division ____________ Specification Section, apply to this Section.


1.2 SUMMARY

A. This Section includes polished concrete finish in accordance with Hardscapes™ concept for interior concrete flatwork. Polished concrete finishes for precast concrete, vertical cast-in-place concrete, and exterior concrete are specified in the sections for those types of concrete.

B. Furnish all labor, material, equipment and services necessary for the dry diamond grinding and polishing of concrete floors in accordance with the Hardscapes™ concept.

C. Applying densifying impregnator/sealer and polishing to specified sheen level and aggregate exposure.

D. Concrete must be cured a minimum of 28 days prior to polishing.

1.3 REFERENCES

A. American Concrete Institute (ACI):

1. ACI302.1R-89, Guide for Concrete Floor and Slab Construction.

B. American Society for Testing and Materials:

1. ASTM C779, Standard Test Method for Abrasion of Horizontal Concrete Surfaces.

2. ASTM C805, Impact Strength.

3. ASTM G23-81, Ultraviolet Light & Water Spray.

4. ASTM 1028, Co-efficient of Friction.

5. ASTM C 150, Type I, II Portland cement conformity, depending on soil conditions.

6. ASTM C 33, Aggregate conformity.

C. Other Tests:

1. Reflectivity. Measured in candle power.

2. Gloss reading.



1.4 SUBMITTALS

A. Submit the following in accordance with Division ______ Section “Submittal Procedures”.

B. Product data for each grinding machine, including all types of grinding heads, dust extraction system, joint filler, concrete densifying impregnator, penetrating sealer, and any other chemicals used in the process.

C. Applicators qualification data.

D. Polished concrete samples: size _______, for each Polished Concrete finish required.

1.4 QUALITY ASSURANCE

A. Basis of design: Hardscapes™, manufactured by Global Polishing for Sherwin Williams.

B. Approved Applicators:
1.__________________________________________________
2.__________________________________________________
3.__________________________________________________

C. Pre Installation Conference: Conduct conference at project site to comply with requirements in Division ______, Section “Project Management and Coordination”.

D. Provide project names, addresses, contact names, phone numbers of at least (3) three projects of similar scope completed by the installer.

E. Installer/applicator shall be certified by concrete finish equipment and chemical manufacturer and shall provide adequate number of skilled workmen who are thoroughly trained and experienced in the necessary craft.

F. Manufacturer’s Certification: Provide a letter of certification from both the equipment and chemical manufacturer stating that the installer is a certified applicator and is familiar with proper procedures and installation requirements recommended by the manufacturer.

G. Mock-ups:

1. General Contractor to notify applicator 7 days prior to pour to schedule finish of mock- up.

2. Reserve 100 square feet for each color and finish at location adjacent to floor that will receive polish, but will be covered with another flooring material. Mock-up floor shall be placed on the same day, preferably the same pour as the floors to receive polish.

3. Install mock-ups to verify selections made under sample submittal and to demonstrate methods and workmanship proposed for the project. If mock-up not possible, submitted samples will be accepted as demonstrated methods & workmanship.

4. Aggregate selected must be tested to ensure it will accept polish.

5. If stand alone mockup required, form should be clean and free from extraneous substance and be at least a 12’ x 12’ with a level plywood bottom on level ground with unobstructed access around all four sides.

6. Control joints should be included in mock-up. Sawing performed by General
Contractor can begin as soon as the surface is firm enough not to displace any of the aggregate.

7. Edges should be included in mock-up.

8. Approved mock-ups may become part of the completed work if undisturbed at time of substantial completion.

H. Protection: General Contractor shall protect areas to receive polished concrete finish at all times during construction to prevent oils, dirt, metal, excessive water and other potentially damaging materials from affecting the finished concrete surface. Protection measures listed below shall begin immediately after the concrete slab is poured:

1. All hydraulic powered equipment shall be diapered to avoid staining of the concrete.

2. All vehicle parking shall be prohibited on the finish slab area. If necessary to complete their scope of work, drop cloths shall be placed under vehicles at all times.

3. No pipe cutting machine shall be used on the finish floor slab.

4. Steel shall not be placed on the finish slab to avoid rusting.

5. Acids and acidic detergents will not come in contact with slab.

6. All painters will use drop cloths on the concrete. If paint gets on the concrete, it must be immediately removed.

7. All trades will be informed that the slab must be protected at all times.

I. Environmental Limitations

1. Comply with manufacturers written instructions for substrate temperature and moisture content, ambient temperature and humidity, ventilation and other conditions affecting chemical performance.

2. Flatness and levelness

a. Finish Concrete shall have a minimum Floor Flatness rating of at least 40.

b. Finish Concrete shall have a minimum Floor Levelness rating of at least 30.

c. Finish Concrete shall be cured a minimum of 28 days or at which point equipment can be put on the slab and does not displace aggregate.

3. Application of finish system shall take place a minimum of 21 days prior to fixture & trim installation and/or substantial completion.

4. Finish Concrete area shall be closed to traffic during finish floor application and after application, for the time as recommended by manufacturer.

J. Concrete Mix Design:

1. Concrete Mixture shall be 3500 PSI or higher, non air entrained.

a. Any admixtures, plasticizers, slag, fly ash or anything taking the place of Portland-based cement shall be kept to a minimum.

b. The cement shall be Portland Cement Type I, conforming to ASTM C 150.

c. Maintain concrete temperature below 85 degrees. Keep concrete as cool and moist for as long as possible. In essence, decrease rate of hydration and drying to minimize cracking.

d. Wet cures are most suitable, but if this cannot be achieved, use a penetrating, dissipating or wax based cure and seal. Do not use a densifier/Hardener material due to the grinding of the floor after 6 days. All Cure and Seal must be ground off. Chemical stripping is not an acceptable method of removal.

e. All mix designs must be approved by Architect. Send all approved mix designs to Applicator.

f. The Engineer/Architect shall determine the saw cut patterns, color and layout.

g. Color loads for integral color should never be smaller than 3 cubic yards.

h. Use on source for cement, aggregates and pozzolans throughout the job. Monitor and control incoming material consistency. Do not use calcium chloride-based admixtures. Non-chloride admixtures may be used.

i. Wash out all drums before loading. Keep slumps consistent with a maximum of 4. Minimize driver added water maintaining a .45 water content ratio.

j. Place concrete to achieve as true and smooth a top surface as possible. Mounds, or dips are not acceptable. GC shall control overall flatness and levelness, including on sloping areas to within tolerances permitted by specification – ASTM E1155.

k. Slab shall be protected from indention and footprints during pour and curing.

PART 2 PRODUCTS

2.1 POLISHING MATERIALS

A. Three-phase 480 Volt generator and step down transformer.

B. 2, 3 or 4 head counter rotating variable speed Hardscapes™ Approved Floor Grinder with at least 600 pounds down pressure. For example: HTC 2500IX, HTC 950RX or HTC 800 HD, STI Prepmaster 3030, King PG820, Powerstar Mongrel.

C. Hardscapes™ approved dust extraction system, pre-separator, and squeegee attachments with minimum flow rating of 322 cubic feet per minute.

D. Grinding Heads:
1. Hardscapes™ Metal bonded 16, 25, 40, 80, 150 and/or 300 grits.
2. Hardscapes™ Resin bonded diamonds, 100, 200, 400, 800, 1500 and
3000 grits.

E. Grinding Pads for Edges
1. 40, 60, and 120 grits.
2. 100, 200,400, 800, 1500 and 3000 grits.

F. Hand Grinder with dust extraction attachment and pads.

G. Sher-Crete™ Concrete Hardener: No Substitutions

H. Control Joint and Saw Cut Filler, two part filler or polyurea as specified by construction manager.

I. Pastecoat™, or Tileclad™ floor striping material and layout to specification by owner/architect.

J. Ameripolish™, penetrating, dye or H&C™ reactive acid stain that chemically combines with cured concrete to produce permanent, variegated or translucent color effects or a hydrolyzed, lithium quartz or silicate compound, that works by penetrating and reacting with mineral compounds and/or siliceous materials to create a translucent or marbled color effects.

PART 3 EXECUTION

3.1 PREPARATION

A. Installer shall examine and approve concrete substrate for conditions affecting performance of finish. General Contractor shall correct conditions that are found to be out of compliance with the requirements of this section. Repairs are not acceptable unless specifically approved on a case-by-case basis by the Architect.

B. Verify that base slab meet finish and surface profile requirements listed in Division 3, Section “Cast in Place Concrete”.

C. Provide floor clean of materials and debris.

D. Protect adjacent surfaces as required to prevent damage by the concrete polishing procedure.

E. Setup grinding machine, dust extraction system, tooling, and generator.

F. Ensure floor cured to accept polishing application.

3.2 POLISHED CONCRETE APPLICATION

A. Applicator shall examine the areas and conditions under which work of this section will be provided and the General Contractor shall correct conditions detrimental to the timely and proper completion of the work and the Applicator shall not proceed until unsatisfactory conditions are resolved.

B. Grind the concrete floor to within 2 -3 inches of walls with 16, 25, 40 and 80 grit removing construction debris, floor slab imperfections and until there is a uniform scratch pattern and desired concrete aggregate exposure is achieved. Vacuum the floor thoroughly using a squeegee vacuum attachment.

C. Apply material approved by architect for color effects in accordance with the architectural drawings and the manufacturers recommended guidelines.

D. Fill construction joints and cracks with filler products as specified in accordance with manufacturers instructions colored to match (or contrast) with concrete color as specified by architect.

E. (If specified) Bull float cementations grout coat onto surface to fill all voids, cement grout to match (or contrast) color of concrete, allow to cure overnight. (If specified) Apply epoxy grout coat onto surface; allow curing overnight, as specified by architect or construction manager.

F. Grind the floor to within 2 - 3 inches of walls with metal bonded diamond grits of 150 and/or 300, grinding 90 degrees from each previous grind and removing all the scratches from the previous grit. Vacuum the floor thoroughly after each grind, using a squeegee vacuum attachment.

G. (If specified) Grind the edges with 40, 60 and 120 grit grinding pads, removing all of the scratches from the previous grit. Vacuum the floor thoroughly after each grind, using a squeegee vacuum attachment.

H. Polish the floor, to desired sheen level, with Hardscapes ™ resin bonded diamond grits of 100, Apply Sher-Crete Concrete Hardener™ undiluted at approximately 400-600 square feet per gallon using a soft, long bristled broom. Cover the entire work area liberally and allow to sit for 10 minutes. Apply again to areas where the densifying impregnator has soaked in and allow to sit for an additional 20 minutes. Allow material to dry. Do not remove any of the Sher-Crete Concrete Hardener™ from the floor 200, 400, 800, 1500 and 3000, first polishing the edges (If specified) with pads of the same grit and then the field of the floor, removing all scratches from the previous grit. After each polish, clean the floor thoroughly using clean water and an auto scrubber or a mop and a wet vacuum.

I. (If specified) Apply Sherwin Williams Sher-Crete™ Concrete Hardener™ Sher-Crete Sealer™ for stained or polished concrete, buff with Black Thickline Strip Pad.

J. Upon completion, the work shall be ready for final inspection and acceptance by the customer.


3.3 PROTECTION

A. Protect the floors from damage until substantial completion.


PART 4 SCHEDULES


4.1 SHEEN

A. Polished Concrete Level 1:
1. At a distance of 100 feet, the floor will reflect images from side lighting.

B. Polished Concrete Level 2:
1. At a distance of 30 to 50 feet, the floor will clearly reflect from side and overhead lighting.

C. Polished Concrete Level 3:
1. Looking straight down, the floor will clearly reflect overhead and side light, with the appearance of the floor looking wet.


4.2 EXPOSED AGGREGATE

A. Exposure rate per Architect/Owner selection.


4.3 EDGES

A. Painted

B. Honed

C. Polished

D. Graphic

E. Other


4.4 TRANSITIONS

A. Inside

B. Outside

C. Center

D. Other

Non-Polishing Specs

SECTION 03362 – POLISHED CONCRETE FLOOR FINISHES

PART 1  - GENERAL

1.1                      SUMMARY

A.             Section Includes: Application of penetrating hardener/densifier and polishing of concrete floor slabs.

1.2                      SUBMITTALS

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

B.              Product Data:

1.               Brushes and Pads:  Submit product data for all brushes and pads prior to beginning polishing to verify pad or brush texture.

2.               Penetrating Hardener/densifier: Brand name, chemical composition, installation directions and certificates of compliance with required standards.  Submit 30 days prior to first concrete placement.

C.              Penetrating Hardener/ Densifier Applicator Qualifications:

1.               Provide documentation showing applicator is certified by the hardener/densifier manufacture.

2.               Letter shall be from the product manufacturer stating that the installer is qualified and certified by the manufacturer to install the material to be used, citing the specific project and location.

3.               Provide list of a minimum of 10 projects performed within the last 3 years of similar type, size and complexity as this contract.

4.               Submit 30 days prior to first concrete placement.

D.              Provide name of technically qualified hardener/densifier manufacturer’s field representative.

1.3                      QUALITY ASSURANCE

A.             A technically qualified manufacturer’s field representative of the hardener/densifier product shall be onsite during the initial application of the hardener/densifier and occasional observations during remainder of the applications.

B.              The hardener/densifier representative shall ensure that the correct amount of densifier is onsite and in numbered containers prior to commencement of work.

1.4                      PRODUCT DELIVERY, STORAGE AND HANDLING

A.             Dispense penetrating hardener/densifier finish material from factory numbered and sealed drums. Maintain record of drum numbers.

1.5                      ENVIRONMENTAL REQUIREMENTS

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

B.              Limit and control damage from moisture. Remove standing moisture from floor after hardener/densifier application.

1.6                      WARRANTY

A.             Document 00800 - Supplementary Conditions: Requirements for warranties.

B.              Penetrating Hardener/Densifier Finish:

1.               Provide 20 year manufacturer's material warranty commencing at date of building Substantial Completion.

2.               Manufacturer shall warrant to the Owner that treated surface will remain sealed, dustproof, hardened and abrasion resistant for the duration of the warranty period.

PART 2  - PRODUCTS

2.1                      MANUFACTURERS

A.             Subject to compliance with project requirements, provide products as manufactured by the following to the extent as specified hereinafter for the specific product:

1.               Sherwin Williams, Cleveland Ohio

2.2                      HARDENER/DENSIFIER PRODUCTS

A.             Pre-Hardener/Densifier Floor Cleaner:  WM Pre-Densifier Floor Cleaner, by one of the manufacturers specified above.

B.              Penetrating Hardener / Densifier:

1.               SherCrete Concrete Hardener by Sherwin Williams.

2.3                      POLISHING PRODUCTS

A.             Manufacturers: Provide products for polishing as manufactured by the following or equivalent to the extent as required to produce specified results.:

1.               Sherwin Williams, Inc.

B.              Polishing Pads:  Pads may include the following or similar as required to produce specified results.

1.               7200 Black Stripper Pad by 3M.

C.              Scrubber Machines:  Equipment used for cleaning and polishing operations shall be Clark Encore Max38 or L38  with a head pressure of 150 lbs. or similar equipment as required to produce the specified results.

PART 3  - EXECUTION

3.1                      GENERAL CLEANING AND POLISHING REQUIREMENTS

A.             General Contractor shall perform, or contract to perform, cleaning and polishing operations and shall coordinate  with other associated work and trades.

B.              Coordinate with joint filling operations. Do not perform wet cleaning within 72 hrs prior to joint filling.

C.              Do not use stain or scuff removing agents such as “crete-strip”.

D.              Begin cleaning and polishing operations after application of hardener/densifier.

E.               Utilize riding machines to the maximum extent practical to achieve optimum efficiency.

F.               Final finish sheen shall be equivalent to that as accepted on the Floor Test Slab as specified in Section 03312 and as specified hereinafter.

3.2                      CLEANING

A.             Power sweep floor area and blow out corners and column footings. Use sweeping compound to control airborne dust. Scrape floor to remove remaining saw cut residue and paint droppings. Remove paint droppings with soft, damp cloth and solvent stripper. Do not use stripper with an acidic pH.

B.              Treat oil spots with oil emulsifier and oil absorber materials.

C.              Double scrub floor with automatic scrubber with appropriate brushes or pads and pH compatible detergent.

3.3                      PENETRATING HARDENER / DENSIFIER TREATMENT

A.             Area to be Treated: Apply penetrating hardener/densifier finish to all interior concrete floors except floors with color textured concrete finishes.

B.              Examination and Preparation:

1.               Examine surfaces receiving penetrating hardener/densifier concrete finish. Verify that surfaces conform to product manufacturer's requirements for substrate conditions.

2.               Prior to application, scrub floor with  Sherwin Williams Pre-Densifier Floor Cleaner to remove latent salts. Verify floor is free of curing membrane, bond-breaker, and construction laitance. Do not proceed until unsatisfactory conditions have been corrected.

3.               Beginning of application indicates acceptance of existing conditions.

C.              Application:

1.               Application shall be performed by certified applicator in accordance with manufacturers published instructions.

2.               Schedule to begin 2 days after 7 day curing period.

3.               Employ methods to ensure concrete surface is not damaged during application, including discoloration.

4.               Vacuum and clean saw cut joints and surrounding area so that no dust remains to react with concrete finish material.

5.               If dissipating curing compound has been applied, remove compound prior to application of penetrating hardener/densifier. Remove compound by cleaning and scrubbing in accordance with manufacturer’s instructions.

6.               Black Pad scrub the floor with clean water.  Wet vac waste water from the slab.  Scrub the surface until a smooth uniform appearance is achieved.

7.               Apply penetrating hardener/densifier finish in accordance with manufacturers published instructions.

8.               Apply finish material with low pressure sprayer with enough coverage to keep concrete surface wet for 30 minutes (approximately 400-600 square feet per gallon).

9.               When treated surface gels and becomes dry, move with broom to redistribute special concrete finish material evenly across surface or apply more SherCrete Concrete Hardener.  Do not use water to rewet the surface.  Shercrete Concrete Hardener is not water soluble and will not go back into solution.

10.            Allow product to dry. 

D.              Disposal:

1.               There is no disposal of this product

3.4                      FLOOR POLISHING

A.             Polishing Procedure:  Polish floor surface by such means as necessary to achieve the specified gloss. 

1.               Verify that floor surface is dry prior to polishing procedure.

2.               Methods such as extra scrubbing,, high speed buffing, aggressive polishing pads, or a combination of these and other gloss enhancing procedures shall be considered to produce the specified gloss.

3.               Suitable methods may also include multiple and perpendicular passes of polishing with high speed scrubbing machines using graduated polishing and scrubbing pads including hogs hair pads.

4.               Gloss enhancement may also be improved by attainment of greater degrees of flatness.

5.               Conduct polishing operations until the specified gloss is attained.  Achieve specified gloss not later than 2 weeks prior to Owner Possession.

6.               Sweep, scrub, and polish floors using suitable processes to maintain specified gloss levels until Owner Possession.

B.              Polish Results:

1.               Perform polishing to the degree to attain an average gloss reading of not less than 45 as measured using a Horiba IG-320 Gloss Checker.

2.               Sweep, scrub and polish concrete surface to produce Specified Overall Gloss Value (SOGV) ≥45 and Minimum Local Gloss Value (MLGV) ≥ 30.

3.               Gloss shall be considered as a quantitative value that expresses the degree of reflection when light hits the concrete floor surface. Gloss measurements will be taken independent of ambient lighting and will be taken within a sealed measurement window located beneath the test unit.

3.5                      QUALITY ASSURANCE TESTING (BY OWNER)

A.             Testing will be performed by Owners Construction Testing Laboratory (CTL) at no expense to the Contractor.  A test report of all measurements and a plan and table of the measurements taken will be prepared by the CTL for submission.

B.              Gloss measurements will be taken at 2 weeks prior to Owner Possession and at time of Possession. Contractor shall notify CTL when floors are ready for testing.  

C.              Measurement and reporting of SOGV and MLGV by CTL shall be as follows:

1.               Collect a minimum of three samples per each bay in random, evenly distributed locations.

2.               Record measurement locations on copy of sheet S1.1.

3.               The average of all samples collected in each bay shall meet or exceed SOGV ≥ 45.

a.               If the average of samples collected do not meet the SOGV, collect an addition 3 samples in each bay for each deficient result unless the individual samples fail to meet the MLGV or the average of all collected samples in each bay fail to meet the SOGV.

b.              If samples fail to meet the SOGV, Contractor shall continue sweeping, scrubbing and polishing until the SOGV is achieved.

4.               No single measured value shall be less than MLGV ≥ 30.

a.               If one or more samples fall below the MLGV, Contractor shall continue sweeping, scrubbing and polishing until all samples comply with Specified MLGV and SOGV.

5.               Collect and certify final gloss measurements.

END OF SECTION