AIA PermaSpec Resurfacing System

Sweet's Section 03900: Concrete Resurfacing System

1. Literature: Submit name of Resurfacing System company that is being used, and the literature on the exact products that are to be used. Submit with the literature of the product's information on emissions of VOC's, etc. (MSDS).


2. Samples: Prepare a 3' x 3' area or suitable sample for review by the Architect. Do not proceed with resurfacing until Architect approves the sample area.

1. Matrix Mix (PERMA·CRETE®):
   
   1. Concrete compound with a blend of special cements and additives.
   2. Bonds securely to unpainted concrete surfaces.
   3. Used to repair cracked, chipped, spalled and broken concrete bridges, sidewalks, driveways, pool decks, curbs, loading docks, ramps and cement tile roofs.
   4. Non-shrinking.
   5. Used in thickness of 1/8" to 3/4". (Maximum up to 2" when mixed with washed peagravel).
   6. Open to foot traffic in 12-24 hours at 72°F. Open to vehicular traffic in 72 hours at 72°F.
   7. Design strength exceeds ASTM C-387 for High Early Strength Concrete.


2. Matrix Bonding Additive (PERMA·CRETE®):
   
   1. High-solids, water soluble acrylic polymer compound used specifically for modifying a Portland Cement composition such as Matrix Mix.
   2. Used for bonding old concrete to new, patching and resurfacing, spray and fill coats, repairing precast building panels and beams, or repairing industrial floors, highway bridge-decks, and airport runways & ramps.


3. Matrix Colorant (PERMA·CRETE®):
   
   1. Liquid, water based pigment formulated for lasting durability.
   2. Mixed into the Matrix Mix and Bonding Additive mixture.
   3. Also used in hand-coloring of the finished product (patterns) before sealing.
   4. Colors should be highly-resistant to fading or discoloration indefinitely.
   5. Not affected by temperature fluctuations.
   6. Custom or standard colors shall be available.


4. Perma·Seal Sealer (PERMA·CRETE®):
   
   1. Penetrating acrylic, sealer stain applied over Matrix mixture and dries hard.
   2. Resistant to chemicals, acids, salts and detergents.
   3. Provides a strong protective finish that resists cracking, chipping, peeling and mildew.
   4. Resistant to freeze-thaw cycles.
   5. Non-flammable and non-toxic.


5. Color: To match selected sample from PERMA·CRETE® Color Fan Decks (170 colors or 1,000 colors).


6. Texture: Slip and skid resistant (similar to a sandblasted finish).

1. All materials used on the job shall be stored in a single place designated by the Owner or the Architect. Such storage place shall be kept neat, clean, dry and between 40°F -90°F and all damage thereto or to its surroundings shall be made good by the Resurfacing Contractor.
2. All used waste or trash must be removed from the building or site location each night, and every precaution taken to avoid the danger of fire.
3. The Resurfacing Contractor shall protect surfaces and objects outside the building, as well as the grounds, lawns, shrubbery, and adjacent properties against damage. The Resurfacing Contractor shall hold himself responsible for damage to adjacent surroundings.
4. At completion of work, the Resurfacing Contractor shall remove from the premises all surplus materials and all debris created by him; he shall remove all splatters and leave his part of the work in a clean and finished condition.

1. If previous coatings of paint, glue or varnish, are present, they must be removed by shot blasting, electric disk grinder or an appropriate removal product such as Perma·Strip Remover (PERMA·CRETE®). If grease or oil are present, they must be removed with an appropriate removal product such as Orange Power Degreaser (PERMA·CRETE®).


2. Ensure that no utility lines are present within the surface area.


3. Surface Cracks:
   
   1. Determine cause of cracks (shifting surface, lack of expansion joints, surface material failure, substrate deterioration, etc).
   2. For cracks wider than 1/4", wear protective goggles and saw-cut length of crack at least 1/2" deep to open and penetrate bottom of crack into slab to ensure crack repair material has proper bonding capability.
   3. For cracks up to 1/4" wide, wear protective goggles and saw-cut length of crack at least 3/4" deep to open and penetrate bottom of crack into slab to ensure crack repair material has proper bonding capability.
   4. If crack is wider than 3/8" and through slab, fill crack from bottom of slab to within 1" of surface with Matrix mixture prior to crack repair; if crack is 1/8" to 3/8", fill entire crack from top to bottom of slab with crack repair material such as Perma·Bond Crack Repair (PERMA·CRETE®) and coarse sand. Allow mixture to harden.
   5. For aggregate surfaces, saw out cracks as described and completely fill with crack repair material along with coarse sand, and then level aggregate surface with skim coat of Matrix mixture before proceeding.


4. Surface Cleaning:
   
   1. Apply appropriate undiluted cleaning agent containing ethylene glycol monobutyl ether such as Blue Nitro Cleaner (PERMA·CRETE®) with hand sprayer over entire surface. Allow to penetrate and dissolve any film contaminants for approximately 5-10 minutes (Do not allow to dry on surface.)
   2. After scrubbing the surface with synthetic brush or broom to remove deep dirt and contaminants, pressure wash the surface (3000 PSI minimum) before cleaning agent dries on the surface.
   3. If mildew is present, chlorine bleach shall be applied to those applicable areas after cleaning agent is applied.
   4. For very smooth concrete or other nonporous surface, a 15-second surface wash with muriatic acid to etch the surface is recommended using a 6 to 1 mix or stronger before thoroughly rinsing the surface. (Note: Concrete must be at least 7 days old prior to muriatic acid washing).
   5. Low spots in the surface which collect water should be marked or outlined so they can then be parged and leveled with a Matrix Mix skim coat.
   6. Use electric blower to remove leaves, debris or dust prior to parging or leveling (Note: Dust left on the surface prior to the Matrix Mix skim coat or texture coat applications can cause these applications to later delaminate).
   7. Ensure that parged areas and remaining surfaces are thoroughly dry before proceeding.

1. Skim Coat Application: For concrete, aggregate or other surfaces that are spalled (deteriorated & "peeled"), delaminated (a layer of the surface has come up), or have had crack repair applied, a skim coat of Matrix Mix over the entire surface is needed to provide a smooth surface later for the Matrix Mix texture coat application (Note: Do not apply on new concrete which has less than 7 days cure time).
   
   1. Do not apply on asphalt or wood without specific technical advice from manufacturer.
   2. For vertical surface applications, see (4) below. For pool interior surfaces, see (5) below.
   3. Stir Matrix Mix and Bonding Additive together as recommended by manufacturer.
   4. Low spots or fill areas to be leveled with a thick coat (1/4") of Matrix Mix should first receive a liquid coating of Bonding Additive and allowed to dry prior to the Matrix skim coat application. Do not apply over 3/4" thickness of Matrix Mix without allowing it to fully set before applying further fill. Wet-sponge applications over 1/4" thickness to avoid shrink cracking.
   5. If a two-color pattern is desired, add correct quantities of Matrix Mix Colorant to the Matrix skim mixture to achieve desired color for grout lines in the (tile, brick or other) two-color pattern.
   6. Pour Matrix Mixture onto surface and spread over entire surface area with a squeegee or trowel to minimum thickness necessary to level and smooth over spalling or surface deterioration. When skimming the entire surface, it is more important to level the low areas and properly cover the deteriorated areas rather than measurably adding to the high or smooth areas.
   7. Before skim coat dries, use hand-trowel to remove excess skim build-up along surface edges.
   8. When skim coat is dry, scrape or rub surface to remove any ridges or burrs left by squeegee or trowel procedure.
   9. Remove dust with an electric blower.


2. Texture Coat Application: This will create the visible surface to the end user and should be applied with extreme care. Do not apply on new concrete which has less than 7 days cure time.
   
   1. Do not apply on asphalt or wood without specific technical advice from manufacturer.
   2. For vertical surface applications see (4) below. For pool interior surfaces see (5) below. If applying two-color patterns, see (3) below.
   3. Stir Matrix Mix and Bonding Additive together as recommended by manufacturer.
   4. If a two-color pattern is desired, add correct quantities of Matrix Colorant to Matrix Mixture to achieve proper color for tiles, bricks or other in the two-color pattern.
   5. For surfaces that require a smooth finish, steps (f) through (k) below can be eliminated. (Note: A smooth-finish surface can be hand-troweled, sprayed, or applied with a short napped roller, or squeegee with one or two light applications and left as is).
   6. Use an air compressor with hopper gun attachment to apply Matrix mixture. Set the compressor at 5-10 PSI, and the hopper gun nozzle on the largest spray orifice.
   7. Pour mixture into hopper and spray a consistent pattern of small cones or peaks 1-2 inches apart.
   8. Within minutes, as sprayed mixture begins to harden, hand-trowel finish with steel hand-trowel in same or alternate directions, thereby creating the desired textured appearance.
   9. Allow finish to completely harden and thoroughly dry.
   10. Scrape or rub surface to remove any peaks or burrs.
   11. Remove previously applied adhesive tape from expansion joints.
   12. Use an electric blower to remove dust.
   13. Apply self-leveling, colored caulk such as Perma·Caulk Sealant (PERMA·CRETE®) to all existing or newly installed control or expansion joints.
   14. Ensure that finish is smooth and dry before applying Perma·Seal Sealer.


3. Two-Color Pattern Application: This procedure requires two applications of Matrix Mix (skim coat and texture coat).
   
   1. Stir Matrix Mix and Bonding Additive together as recommended by manufacturer.
   2. Add correct quantities of Matrix Colorant to Matrix mixture to achieve proper color for grout lines in the tile, brick or other two-color pattern.
   3. Pour mixture onto surface area and spread a Matrix mixture, skim coat over entire surface area with a squeegee or hand-trowel to a minimum thickness necessary to provide a consistent grout line color (normally 1/16" on smooth surface; greater if leveling is required).
      
   4. When skim coat is dry, scrape or rub surface to remove any ridges or burrs left by squeegee or hand-trowel application.
   5. Use electric blower to remove dust.
   6. Using an airless paint sprayer, apply one to two very light mist coats of Perma·Seal Sealer necessary to achieve desired grout line color which is compatible with the Colorant used in the skim coat mixture; allow to thoroughly dry (1-2 hours at 72°F).
      
   7. Using a mechanical measuring tape or premeasured Adhesive Pattern Tape(PERMA·CRETE®), mark off grout lines to create desired size of tiles or bricks; or measure surface for installation of a Pattern Template(PERMA·CRETE®).
   8. Use reinforced adhesive tape and carefully apply to marked off grout lines; or apply pattern template to the surface.
   9. Be sure that tape or template is applied evenly and completely adheres to surface.
   10. Follow step (a) above and mix more Matrix mixture for the texture coat application; add correct quantities of Colorant to Matrix mixture for proper coloration of bricks, tiles or other in the two-color application.
   11. Apply mixture by hand-trowel, sprayer, or short napped roller depending upon type finish desired.
   12. Within minutes, as the applied mixture begins to harden, hand-trowel a finish on the sprayed application with steel hand-trowel in same, or alternate directions creating the desired texture or lace appearance.
   13. For brick applications, use a small whisk broom and broom finish the brick surface pattern for a brick-textured look.
   14. Use airless paint sprayer to apply 2-3 coats of Perma·Seal Sealer to finished pattern that is compatible with the Colorant used in the texture coat mixture; allow final sealer coat to dry (30-40 minutes at 72°F) and then remove tape while surface is still damp to ensure even breakage along the tile, brick or other pattern edges.
   15. If a pattern template was used, do not remove template after broom whisking the brick or tile surface pattern; allow surface to thoroughly dry; apply two coats of Perma·Seal Sealer with airless sprayer; allow Sealer to thoroughly dry and then remove template; if necessary, touch up any bleed through into grout lines with the PermaSeal color used for grout lines.
   16. After textured finish and Perma·Seal Sealer are completely dry, sweep, rub and blow surface and pattern edges free of dust and loose particles remaining from tape or template removal.
   17. Apply a final, light coat of Perma·Seal Clear Sealer to entire surface after preceding step. This will provide additional protection as well as darken and blend the non-sealed edges of the tiles or bricks that were partially covered by the use of the template or tape.
   18. Inspect surface carefully to ensure that finish is smooth and dry. Leave ample ventilation for 5-6 hours.


4. Vertical Surface Application: This section refers to applications on concrete, concrete block, brick or ICF foam block vertical surfaces, but does not include pool interior surfaces.
   
   1. Vertical surface applications may require 2-3 light applications of Matrix Mix before applying Perma·Seal Sealer.
   2. On previously existing and older, vertical surfaces such as brick or concrete block, apply surface cleaner [as described in III (C) (4) (a)] undiluted with hand-sprayer over entire surface (Note: New construction surface dust and contaminants can usually be removed with 2000 psi pressure washing only).
   3. Allow surface cleaner to penetrate and dissolve any deep film contaminants for 5-10 minutes before pressure washing surface (brick or concrete block) with 3000 psi minimum (However, do not allow cleaner to dry on surface before pressure washing).
   4. Repair all surface cracks in concrete or masonry with appropriate epoxy gel crack repair product such as Perma·Gel Epoxy (PERMA·CRETE®).
   5. Stir Matrix Mix and Bonding Additive together as recommended by manufacturer.
   6. Use Matrix mixture to fill any cracks or seams in foam blocks or masonry and then spray entire surface area with light coat of Matrix mixture before applying a colored fiber cloth mesh, such as the maroon Perma·Mesh Fiber Cloth (PERMA·CRETE®), to the surface area. Lightly trowel mesh down into Matrix mixture.
   7. Continue with further applications of Matrix application(s) to completely fill and cover fiber cloth mesh on surface area until mesh color can no longer be seen.
   8. By using spray hopper assembly or continuous PowerFlo unit (PERMA·CRETE®), or hand troweling, apply initial application of Matrix mixture, colored with desired Colorant, to entire surface and parge uneven areas to achieve smooth, level surface.
   9. Note: Before application of final texture coat,expansion joints may be added. Expansion joints should be installed at each floor level; at changes or breakpoints in the wall substrate such as window or door openings; and at the building structure's existing control or expansion joints. Note: After the final texture coat application, all joints must be caulked with Perma·Caulk Sealant, or equivalent, and, if required by architectural specs, capped with an expansion joint insert.
   10. Apply additional applications of mixture as needed to achieve proper coverage (minimum 3/16" completed thickness) and hand-trowel surface to desired texture or allow sprayed application to remain as the (stucco-type) surface finish.
   11. To achieve a "worm-like" or scraped surface finish, use heavy grit Matrix (containing coarse sand) such as Perma·Grit, Tropic·Grit or Polar·Grit Matrix Mixes (PERMA·CRETE®) and hand-trowel surface.
   12. Apply Perma·Caulk Sealant, or equivalent, and approved weather stripping around all doors and windows.
   13. After all Matrix applications have fully hardened, use airless paint sprayer or roller, along with cut-in brush, to apply 2-3 applications of Perma·Seal Sealer (water base) as needed to surface in the color that complements the Colorant previously used in Matrix Mix applications.
   14. Never use solvent base sealers on the Matrix applications of any foam surface as the solvents may deteriorate the foam through any pinholes left in the Matrix application.
   15. Ensure minimum 4 hours dry time at 72ºF before surface contact with rain, dew, or freezing temperatures.


5. Pool Interior Application:
   
   1. Use plastic or paper to tape off any existing ceramic tile and the surrounding areas.
   2. Apply chlorine bleach over entire surface. Scrub surface and pressure wash off.
   3. Apply muriatic acid using a 6 to 1 mix or stronger over entire surface. Pressure wash off.
   4. Apply surface cleaner [as described previously in 3C (4) (a)] undiluted with hand sprayer over entire surface. Scrub surface thoroughly and pressure wash off with 3000 psi minimum.
   5. If uneven or low spots need to be parged, mix fine silica Matrix Mix such as Pool Interior Matrix Mix (PERMA·CRETE®) and Bonding Additive as recommended by manufacturer.
   6. Use this mixture and hand-parge or level any low or rough pool interior surfaces; allow to dry and then smooth out with rub rock.
   7. Mix more fine silica Matrix Mix and Bonding Additive along with desired Colorant.
   8. Use an air compressor with hopper gun attachment or continuous Power Flo unit (PERMA·CRETE®). Set the compressor at 30 psi and the hopper gun nozzle at the next to smallest spray orifice. Use manufacturer's recomendations for Power Flo unit.
   9. Spray 2-3 separate, light applications of this mixture onto pool interior surface, similar in procedure to spray painting a surface.
   10. Lightly hand-trowel surface with slick rubber, hand-trowel such as Custom Rubber Hand Float (PERMA·CRETE®) after each application to achieve smooth, glass-like finish. Allow all applications to thoroughly dry. Ensure that surface is smooth and no burrs or peaks remain.
   11. Apply one coat of two - component epoxy primer such as Perma·Prime E- coat (PERMA·CRETE®)and 1-2 coats of a two- component acrylic urethane containing a styrene- acrylic copolymer and aliphatic polyisocyanate such as Perma·Thane CRU-750 (PERMA·CRETE®).
   12. Inspect surface carefully to ensure that finish is smooth and dry.
   13. Wait 72 hours at 72ºF before filling pool with water.
   14. Fully cured after 7 days at 72ºF.


6. Perma·Seal Sealer Application (Water Base): Ensure proper ventilation during application.
   
   1. Use waterbase stain sealer such as Perma·Seal Sealer that complements the Colorant previously used in Matrix Mix applications.
   2. Cut in edges of surface area with two-inch brush.
   3. Use airless paint sprayer or roller to apply stain sealer to remaining surface, including previously caulked expansion joints.
   4. Apply 2-3 coats of stain sealer by roller or three coats by airless paint sprayer; second or third coat must be completely dry before applying additional coat of sealer.
   5. For additional non-skid features, add shot blasting sand or SkidTex onto first color coat of stain sealer.
   6. Apply light, additional coat of clear sealer on driveways and high traffic areas.
   7. Allow minimum 4 hours dry time at 72ºF before surface contact with rain, dew, or freezing temperatures.
   8. Allow light foot traffic the first day after 6-12 hours at 72°F. Wait 1-2 days at 72°F for heavy foot traffic. Wait three days at 72°F before setting potted plants and furniture or allowing vehicular traffic.
   9. Ensure that ample ventilation remains during initial 4 hours dry and cure time.