01/31/2018 DESIGN No.

016626

SECTION 03733
CONCRETE REPAIR WORK

PART 1 - GENERAL

1.01 DESCRIPTION OF WORK

A. Provide labor, materials, equipment, and services to

provide for the structural repair of concrete members
with manufactured structural repair concrete/mortar as
shown on Drawings and as specified herein. Work
includes removing spalled concrete and cleaning and
coating of exposed steel reinforcement.

1.02 RELATED SECTIONS

A. Concrete Formwork.........................Section 03100

B. Concrete Reinforcement....................Section 03200

C. Epoxy Injection Repair Work...............Section 03736

D. Penetrating Corrosion Inhibitor...........Section 03740

1.03 REFERENCE STANDARDS

References and industry standards listed in this Section are

applicable to the Work. Unless more restrictive criteria or
differing requirements are explicitly stated in the
Specifications, or mandated by governing codes or
regulations, the recommendations, suggestions, and
requirements described in the referenced standards shall be
deemed mandatory and applicable to the Work.

A. American Society of Testing and Materials (ASTM)

B. Steel Structures Painting Council (SSPC)

1. "Hand Tool Cleaning - SP2"

2. "Power Tool Cleaning - SP3"

C. International Concrete Restoration Institute (ICRI)

1.04 SUBMITTALS

A. Product Data

Provide manufacturer's information on the anti-

corrosion coating and structural repair

NYCSCA/ PS 92M CONCRETE REPAIR WORK 03733 - 1

01/31/2018 DESIGN No. 016626

concrete/mortar, including application instructions and

specifications.

B. Quality Control Submittals

1. Certificates:

a. Furnish manufacturer's certification that

materials meet or exceed Specification
requirements.

b. Manufacturer’s training certificate: Furnish

letter from manufacturer stating personnel
performing work have been instructed on the
proper usage of the material.

2. Repair Procedure: Furnish written description of

repair procedures and operations sequencing based
on manufacturer's requirements prior to commencing
the Work.

3. Manufacturer's Field Reports: Submit field report

from manufacturer of repair mortar indicating areas
of surface preparation and mortar placement
inspected.

4. Qualifications

Provide proof of Installer and Manufacturer

qualifications specified under “Quality Assurance”.

5. Mock-up: Provide mock-ups as indicated under

Quality Assurance.

1.05 QUALITY ASSURANCE

A. Qualifications

1. Installer: Company specializing in the Work of

this Section shall have a minimum of three years
experience and at least two projects with similar
quantity of materials. Contractor shall be
trained by the repair mortar manufacturer and
shall have a certificate of training on file from
the manufacturer.

2. Manufacturer: Company specializing in the

manufacture of concrete repair mortars to be used
in this Contract shall have a minimum of ten years
experience.

NYCSCA/ PS 92M CONCRETE REPAIR WORK 03733 - 2

01/31/2018 DESIGN No. 016626

B. Manufacturer's Representative

All work of this Section shall be performed under the

overall supervision of the repair material
manufacturer's representative. The representative
shall attend pre-construction meetings to instruct the
contractor on the proper usage of the material and to
make regular visits during the course of construction
to ensure that surface preparation and method of
installation is acceptable.

C. Job Mockups

Prior to performing the work of this Section, prepare a

sample panel of not less than 12 sq. ft. of concrete
repair work, including a separate mock-up of the
surface preparation. For formed repairs, provide
mockup of pour to ensure that material will be properly
vibrated and finish will be without voids. Do not
proceed further with the work until the Authority’s
representative has approved the sample panel. Sample
shall be a portion of the area to be restored and may
be kept if approved.

1.06 DELIVERY, STORAGE, AND HANDLING

A. Materials specified shall be delivered to the site in

sealed, properly labeled containers. Containers shall
indicate manufacturer's name, trade name of product,
lot number, shelf life of product, and mix ratio (if
applicable).

B. Keep containers tightly closed when not in use. Comply

with manufacturer's printed instructions for storing
and protecting materials.

C. Do not store liquid material in hot sun. Keep material

from freezing.

1.07 ENVIRONMENTAL REQUIREMENTS

A. Do not apply if the temperature is below 50oF or above

85oF unless the material manufacturer is consulted for
recommendations.

B. Do not use frozen materials or materials coated with

ice or frost.

C. Do not apply when there is expectation of rain within

24 hours.

NYCSCA/ PS 92M CONCRETE REPAIR WORK 03733 - 3

01/31/2018 DESIGN No. 016626

PART 2 - PRODUCTS

2.01 MANUFACTURERS

A. Sika Corp, Lyndhurst, NJ 07071

B. Strongwall Industries, Ridgewood, NJ 07451

C. Mapei Corp, Deerfiled Beach, FL 33442

2.02 MATERIALS

A. Structural Repair Concrete - Non-formed/overhead

Application

1. Shall have non-shrink characteristics and be of

high compressive and bond strength. Material
shall be non-sag, capable of being troweled in
place for vertical and overhead applications
without the need of formwork and conform to the
following properties:

a. Compressive strength of 5000 psi in 28 days

when tested in accordance with ASTM C109.

b. Bond strength of 1700 psi in 28 days when

tested in accordance with ASTM C882
(modified). Results of tests showing failure
of base material is acceptable alternative.

c. Flexural strength of 1100 psi in 28 days when

tested in accordance with ASTM C78 or ASTM
C293 or 1400 psi when tested in accordance
with ASTM C348.

d. Maximum linear length change shall be 0.080%

when tested in accordance with ASTM C157 (dry
cure).

e. Modulus of elasticity shall be between 3.0

and 3.5 x 106 when tested in accordance with
ASTM C469.

2. Repair concrete/mortar shall be:

a. Sikatop 123 Plus as manufactured by Sika.

b. SWI-88 as manufactured by Strongwall

Industries.

NYCSCA/ PS 92M CONCRETE REPAIR WORK 03733 - 4

01/31/2018 DESIGN No. 016626

c. Planitop 23 by Mapei.

B. Structural Repair Concrete/Mortar - Horizontal

Application

1. Shall have non-shrink characteristics and be of

high compressive and bond strength. Material
shall be capable of being poured or troweled in
place for horizontal applications and for formed
applications of sufficient dimensions to allow for
proper placement of material and conform to the
following properties:

a. Compressive strength of 5000 psi in 28 days

when tested in accordance with ASTM C109.

b. Slant/shear bond strength of 1700 psi in 28

days when tested in accordance with ASTM C882
modified). Results of tests showing failure
of base material is acceptable alternative.

c. Flexural strength of 1100 psi in 28 days when

tested in accordance with ASTM C78 or
ASTM C293 or 1400 psi when tested in
accordance with ASTM C348.

d. Maximum linear length change shall be maximum

of 0.08% at 28 days when tested in accordance
with ASTM C157.

e. Modulus of elasticity shall be between 3.0

and 3.5 x 106 when tested in accordance with
ASTM C469.

2. Repair concrete/mortar shall be:

a. Sikatop 122 Plus as manufactured by Sika.

b. SWI-81 as manufactured by Strongwall

Industries.

c. Mapecem 202 by Mapei – only 1450 for C882.

C. Structural Repair Concrete/Mortar - Formed Application

1. Shall have non-shrink characteristics and be of

high compressive and bond strength. Material
shall be flowable, capable of being poured in
formed repairs of small dimensions without forming
voids and conform to the following properties:

NYCSCA/ PS 92M CONCRETE REPAIR WORK 03733 - 5

01/31/2018 DESIGN No. 016626

a. Compressive strength of 5000 psi in 28 days

when tested in accordance with ASTM C109.

b. Bond strength of 1700 psi in 28 days when

tested in accordance with ASTM C882
modified). Results of tests showing failure
of base material is acceptable alternative.

c. Flexural strength of 1100 psi in 28 days when

tested in accordance with ASTM C78 or
ASTM C293 or 1400 psi when tested in
accordance with ASTM C348.

d. Maximum linear length change shall be maximum

of 0.08% at 28 days when tested in accordance
with ASTM C157.

e. Modulus of elasticity shall be between 3.0

and 3.5 x 106 when tested in accordance with
ASTM C469.

2. Repair concrete/mortar shall be:

a. Sikatop 111 Plus as manufactured by Sika.

b. SWI-81 as manufactured by Strongwall

Industries.

c. Planitop 15 SCC by Mapei.

D. Anti-corrosion Coating

1. Corrosion-inhibiting, epoxy/acrylic resin,

protective coating for steel reinforcing bars that
will not form a vapor barrier or bond break with
the repair mortar with the following properties:

a. Bond strength of 1500 psi in 2 hours when

tested in accordance with ASTM C882.

b. Flexural strength of 2000 psi in 28 days when

tested in accordance with ASTM C78.

c. Tensile strength of 800 psi in 28 days when

tested in accordance with ASTM C190.

2. Anti-corrosion coating shall be:

a. Armatec 110 as manufactured by Sika.

b. Planibond 3C by Mapei.

NYCSCA/ PS 92M CONCRETE REPAIR WORK 03733 - 6

01/31/2018 DESIGN No. 016626

E. Miscellaneous Materials

1. Water: Potable water, ASTM C94

2. J hooks: 1/4" diameter threaded rod, Type 316

stainless steel

2. Epoxy paste adhesive: ASTM C882

4. Coarse aggregate: Clean, washed crushed stone,

3/8" maximum size, conforming to ASTM C33.

2.03 PRE-INSTALLATION MEETING

A. At least 15 days prior to the start of the concrete

repair work construction schedule, the Contractor shall
conduct a meeting to review the proposed repair and to
discuss the required methods and procedures to achieve
the required quality. The meeting shall include, at a
minimum, the repair mortar installer, repair mortar
manufacturer, Arichitect/Engineer of Record, and the
Authority’s Construction Manager and CID Inspector.
The Contractor shall send a conference agenda to all
attendees prior to the scheduled date of the
conference. The Contractor shall schedule a test
placement to verify proper bond and hardened
properties.

PART 3 - EXECUTION

3.01 EXAMINATION

A. Examine all adjoining work on which this Work is in

anyway dependent for proper installation and
workmanship. Report to the Authority any conditions
that prevent the performance of this Work.

B. The Contractor shall determine the most suitable

material indicated in Part 2 of this Specification to
be used for each application to achieve the most
structural sound repair with appropriate finish, unless
specifically indicated on the Drawings. As an example,
the Contractor may decide to form an application on a
vertical surface in lieu of using the overhead repair
mortar. The contractor shall include in the repair
work procedure what materials will be used where and
how the repair will be achieved for both the structural
integrity of the patch and the correct finish.

NYCSCA/ PS 92M CONCRETE REPAIR WORK 03733 - 7

01/31/2018 DESIGN No. 016626

3.02 PREPARATION AND PROTECTION

A. Protection

Protect adjacent surfaces not to be restored. Protect

sills, ledges, and projections from material droppings.

B. Surface Preparation

1. Remove spalled and weak concrete and remove all

loose and foreign material. Chip substrate by
bush hammering or other mechanical means
acceptable to the repair concrete/mortar
manufacturer to obtain a minimum aggregate-
fractured surface profile of 1/8+” conforming to
an ICRI CSP 7 or greater surface preparation.
Minimum depth of repair shall be 1/2", with the
perimeter of the repair having a minimum of 1/8"
in depth. Feather edging is not permitted.

2. If steel reinforcing is exposed, chip out behind

the reinforcing steel. Chip a minimum of 1/2"
behind the bar and 3" past the point where the bar
is exposed. Concrete behind bars shall be removed
enough to allow for the entire circumference of
the bar to be cleaned. Remove concrete to the
point past where sound material begins.

3. Exposed steel reinforcement and steel beams shall

be free of all rust, scale, oil, paint, grease,
loose mill scale, and all other foreign matter
that will prevent bonding with the repair
concrete. Use power chipping or power driven
brushes and clean to an SSPC-SP2 or SP3 surface
preparation.

4. Where additional reinforcement is not shown to be

anchored in and for patches greater than 11/2" in
depth and overhead patches, install stainless
steel threaded J hooks set in epoxy paste
adhesive. Anchor is to be 3/4" clear minimum from
finished face of repair. Hooks are to be embedded
a minimum of 3" into concrete, installed
diagonally to plane of concrete surface. Holes
are to drilled 1/8" larger than rod diameter and
shall be cleaned thoroughly. Space hooks at 16"
o.c.

NYCSCA/ PS 92M CONCRETE REPAIR WORK 03733 - 8

01/31/2018 DESIGN No. 016626

3.03 ANTI-CORROSION COATING APPLICATION

A. Mix anti-corrosion coating in accordance with

manufacturer's instructions. Apply to dry reinforcing
steel using a stiff bristle brush. Brush in well to
ensure continuous coverage. Apply in two coats of
approximately 10 mils each or as per manufacturer's
latest recommendations.

B. Protect coated steel from weather and allow to dry a

minimum of 30-45 minutes between coats or repair
concrete/mortar application. However, apply repair
material within 20 hours after last coating. If 20
hour period elapses, reapply bonding agent and allow to
dry as above.

3.04 REPAIR CONCRETE/MORTAR APPLICATION

A. Mix structural repair concrete in accordance with

manufacturer's instruction. Follow time limits set by
manufacturer to prevent hardening of material prior to
placement. For material requiring extension with
aggregate due to depth of repair, provide 3/8"
aggregate of proportions specified by the repair mortar
manufacturer.

B. Prior to application of material, thoroughly saturate

surface with water. Remove any standing water prior to
patching.

C. Apply a scrub coat of the repair material of

proportions determined by manufacturer (indicate in
written repair procedure). While still damp, apply
repair concrete/mortar.

D. Apply material behind and around rebars first to

completely fill void.

E. Overhead/Vertical Repairs - Apply repair

concrete/mortar, non-formed/overhead application, on
vertical and overhead members with a trowel or other
such device, all in accordance with the manufacturer's
recommendations. Apply in lifts of up to 2" or as
determined by material manufacturer at a consistency
that the material will not slump. Follow
manufacturer's instructions for scoring, curing,
priming, and approximate time between layers. Do not
leave voids. Trowel exposed surface smooth and to same
shape and finish as the adjacent existing surface.

NYCSCA/ PS 92M CONCRETE REPAIR WORK 03733 - 9

01/31/2018 DESIGN No. 016626

F. Horizontal Repairs - Pour or trowel repair

concrete/mortar, horizontal application, into hole
until it is to the same level and at the same pitch as
the surrounding slab. For deep repairs, extend mortar
with clean aggregate by the amount recommended by the
manufacturer. Provide finish as follows:

1. Surfaces to receive bonded applied cementitious

applications such as full-set terrazzo and
vitreous ceramic tile: Darby and float surface
and follow with a rough broom finish.

2. Surfaces to receive floor coverings such as

resilient flooring, thin-set terrazzo and vitreous
ceramic tile, carpeting, wood floors, or surfaces
which are intended as walking surfaces such as
exposed or painted (cement finish), unless
specified otherwise: Steel trowel surface to a
smooth plane finish, free of score marks, grooves,
depressions and ripples with a tolerance no
greater than +1/8" in ten feet.

3. Surfaces intended to receive roofing,

waterproofing membranes: Darby and float surface.
Leave surface free from depressions, bulges, rough
spots, and other defects.

4. Ramps, Exterior Concrete Steps: Level surface

with wood float and follow with a broom finish
perpendicular to direction of traffic.

G. Formed Repairs

1. Apply repair concrete, horizontal application, on

vertical members where formwork can be utilized to
confine the concrete and the width of repair
permits its proper installation.

2. Apply flowable repair mortar for repairs to be

formed, especially for thin repairs.

3. Place so as not to leave voids. Vibrate forms with

pencil vibrator to removed air bubbles. Remove
formwork as soon as possible and trowel exposed
surface smooth and to same shape and finish as the
adjacent existing surface.

3.05 CURING

A. As soon as surface of patch has hardened, cure patch a

minimum of 48 hours by applying water-based acrylic

NYCSCA/ PS 92M CONCRETE REPAIR WORK 03733 - 10

01/31/2018 DESIGN No. 016626

curing compounds conforming to ASTM C309 or C1315,

misting, wet burlap, etc. For patches to be covered
with other material, only use curing compounds
acceptable to the finish material manufacturer, unless
the compound is removed prior to placing the finish
material in a manner acceptable to the finish
manufacturer.

B. Follow manufacturer's latest recommendations for any

other recommendations. The curing provision of A above
shall not be waved unless manufacturer does not permit
it.

3.06 PROTECTION AND CLEANING

A. Clean all adjacent areas of excess material and clean

all floors and walls of powder and droppings. Remove
misplaced materials from surfaces immediately.

B. Protect material from freezing and from rainfall prior

to final set.

3.07 FIELD QUALITY CONTROL

A. The Authority will inspect surfaces and reject any that

contain cracks or other defects. The repair will be
tested for soundness and structural integrity. Any
defective areas shall be fixed at Contractor's expense.
Notify the Authority’s representative in advance of the
concrete repairs. The Authority’s representative will
review the mixing, surface preparation and proper
application of all materials.

B. Engage the services of the material manufacturer's

representative to inspect the surface preparation,
instruct in the proper usage of the material and to
inspect the work throughout the project. Pay for all
required fees.

C. The Authority’s testing laboratory will perform bond

tests in accordance with ASTM C158,”Standard Test
Method for Tensile Strength of Concrete Surfaces and
the Bond Strength or Tensile Strength of Concrete
Repair and Overlay Materials by Direct Tension (Pull-
off Method)” at a rate of 2 per session. The
Contractor is to repair all test areas. Areas not
meeting the requirements will have further tests
performed. Remove all non-conforming areas.

END OF SECTION

NYCSCA/ PS 92M CONCRETE REPAIR WORK 03733 - 11

01/31/2018 DESIGN No. 016626

NYCSCA/ PS 92M CONCRETE REPAIR WORK 03733 - 12

01/31/2018 DESIGN No. 016626

LIST OF SUBMITTALS

SUBMITTAL DATE SUBMITTED DATE APPROVED

Product Data: _____________

1. Anti-corrosion coating
2. Repair concrete/mortar

Certificates: _____________

1. Material certification
2. Training certificate

Procedure: _____________

1. Detailed written repair

procedure

Reports: _____________

1. Manufacturer’s written
field reports.

Qualifications _____________

1. Installer
2. Manufacturer

Mock Up: _____________

1. Surface Preparation
2. Repair

* * *

NYCSCA/ PS 92M CONCRETE REPAIR WORK 03733 - 13