Part 3 - Execution
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3.01 EXAMINATION A. Site Visit: Prior to waterproofing installation, arrange visit to project site with waterproofing manufacturer’s representative. Representative shall inspect and certify that concrete surfaces are in acceptable condition to receive waterproofing treatment.
B. Verification of Substrates: Verify that concrete surfaces are sound and clean, and that form release agents and materials used to cure the concrete are fully removed.
C. Examination for Defects: Examine surfaces to be waterproofed for defects such as honeycombing, rock pockets, faulty construction joints and cracks. Such defects to be repaired in accordance to manufacturer’s product data and 3.02 below.
3.02 PREPARATION A. Surface Preparation: Smooth surfaces (e.g. where steel forms are used) or surfaces
covered with form oil or other contaminants shall be cleaned, water-blasted, lightly sand-blasted, or acid etched as necessary to provide a clean absorbent surface. The surface must also have an open capillary system to provide “tooth and suction” for the Xypex treatment. A minimum of CSP-3 per the International Concrete Repair Institute Concrete Surface Profile Chips or other equivalent standard is required. Surfaces to be acid-etched shall be saturated with water before application of the acid. After acid etching flush concrete thoroughly with clean water. Horizontal surfaces shall have a rough wood float or broom finish. Where a smooth trowel finish is required on horizontal surface, crystalline waterproofing material shall be applied by dry shake method at time of concrete finishing in accordance with manufacturer’s product data.
B. Repair of Defects: Concrete defects shall be repaired in accordance with manufacturer’s technical literature including relevant Method Statements. Procedures are generally as follows:
1. Cracks and Faulty Construction Joints:
a. Chip out cracks, faulty construction joints and other defects to a depth of 1.5 inches (37 mm) and a width of one inch (25 mm). A “V” shaped slot is not acceptable. The slot may be saw cut instead of chipped but ensure that the slot is dovetailed or otherwise shaped such that there will be mechanical interlock of materials placed into the slot at a later stage.
b. Clean slot of debris and dust. Soak area with water and remove excess surface water. Apply a slurry coat of Xypex Concentrate at the rate of 1.5 lb./sq. yd. (0.8 kg/m2) to the slot.
c. While slurry coat is still tacky, fill cavity with Dry-Pac. Compress tightly into cavity using pneumatic packer or block and hammer.
d. This step may be omitted if the area filled with Dry-Pac will be subsequently covered with Xypex coating. Wet Dry-Pac surface lightly with water, then apply a slurry coat of Xypex Concentrate at a coverage rate of 1.5 - 2 lb./sq.yd. (0.8 - 1 kg/m2) over the repaired area to a 6” (150 mm) on either side of slot.
2. Rock Pockets, Honeycombing or other defective concrete: All areas of poor concrete consolidation (honeycomb or rock pockets) shall be repaired.
Note: Where there is active water-flow see Method Statements or contact Xypex Technical Services Representative for assistance.
C. Wetting Concrete: Xypex requires a saturated surface dry (SSD) substrate. Concrete surfaces must be thoroughly saturated with clean water prior to the application so as to aid the proper diffusion of the Xypex chemistry and to ensure the growth of the crystalline formation deep within the pores of the concrete. Remove excess water before the application such that there is no glistening water on the surface. If concrete dries out before application, it must be re-wetted.
3.03 APPLICATION A. Construction Joints: In addition to specified waterstops, apply one coat of Xypex Concentrate slurry at a rate of 2 lb./sq. yd. (1 kg/m2) to joint surfaces between concrete pours. Moisten surfaces prior to slurry application. Apply slurry and keep moist for 12 hours then allow slurry to set or dry. Where joint surfaces are not accessible prior to pouring new concrete, contact Xypex Technical Services Representative for assistance.
Note: Inclusion, type and position of waterstops are at the discretion of the designer. Expanding waterstops may be placed on Xypex after it has dried or before Xypex slurry application. Xypex slurry may only be applied over waterstop if approved by waterstop manufacturer.
B. Sealing Strips: Where hydrostatic conditions exist, sealing strips shall also be applied at construction joints by filling grooves that are created along the joints. Dimensions of the grooves shall be 1 inch (25 mm) wide and 1.5 inches (37 mm) deep. If grooves are not pre-formed then chip grooves to those dimensions. Fill the groves as follows:
1. Apply slurry coat of Xypex Concentrate slurry to slot in accordance with manufacturer’s instructions or recommendations.
2. While slurry coat is still tacky, fill slot with Xypex Concentrate Dry-Pac.
3. Compact tightly using pneumatic packer or hammer and block.
4. This step may be omitted if the area filled with Dry-Pac will be subsequently covered with Xypex coating. Wet Dry-Pac surface lightly with water, then apply a slurry coat of Xypex Concentrate at a coverage rate of 1.5 - 2 lb./sq.yd. (0.8 - 1 kg/m2) over sealing strip and extending to 6" (150 mm) on either side.
Note: For further information, see Xypex Schematic Drawings for standard construction joint details.
C. Form Tie Holes: Form tie holes shall be waterproofed in accordance with manufacturer’s technical literature including relevant Method Statements. Procedures are generally as follows:
1. Prepare the tie hole to create a straight sided void with a profile of at least ICRI CSP-3. For through element ties holes such as those created by taper ties the prepared void is to be at least 5” (125 mm) deep. For cone ties the void is to be to the bottom of the cone.
2. Clean and profile the area to a 12 inch (300 mm) diameter around the tie hole to an ICRI CSP-3 profile.
3. For through-element tie holes create a solid plug of material at the bottom of the profiled hole using Xypex Patch’n Plug leaving at least 4” (100 mm) of empty tie hole from the top of the plug to the surface of the concrete element.
4. Apply a coat of Xypex Concentrate slurry at a rate of 1.5 lb./sq. yd. (0.8 kg/m2) to the inside of the tie hole and to a 12” (300 mm) diameter area around the hole.
5. Fill and compact the tie hole with Xypex Concentrate Dry-Pac.
6. This step may be omitted if the area filled with Dry-Pac will be subsequently covered with Xypex coating. Wet Dry-Pac surface lightly with water, then apply a slurry coat of Xypex Concentrate at a coverage rate of 1.5 - 2 lb./sq. yd. (0.8 - 1 kg/m2) over the repaired area to a 12” (300 mm) diameter area around the filled void.
D. Surface Application: After repairs, surface preparation, treatment of construction joints and sealing strip placement have been completed in accordance with manufacturer’s product data and as specified herein, apply Xypex treatment to concrete surfaces with semi-stiff bristle brush, push broom (for large horizontal surfaces), or suitable spray equipment. The Xypex coating must be uniformly applied and should be just under 1/16” (1.25 mm) thick.
Application rates and locations shall be as indicated in the drawings and in accordance with manufacturer’s product data. When brushing, work slurry well into surface of the concrete, filling surface pores and hairline cracks. When spraying, hold nozzle close enough to ensure that slurry is forced into pores and hairline cracks.
1. First Coat (of one or two coat application): Apply Xypex Concentrate slurry coat to locations indicated on drawings in accordance with manufacturer’s product data.
2. Second Coat (of two coat application): Where indicated on drawings or as required by manufacturer’s product data, apply Xypex Modified or Xypex Concentrate slurry coat after the first coat of Xypex Concentrate has reached an initial set but while it is still “green” (less than 48 hours). Curing by misting the coating with water should be done between coats. Ensure first coat is in SSD condition before application of the second coat.
Note: Prior to the installation, it is recommended that a test section be completed under anticipated ambient and project conditions to demonstrate acceptable bond
E. Sandwich (Topping) Application: When treated structural slabs are to receive a concrete or other topping, place the topping while waterproofing material is still “green” (less than 48 hours) but after it has reached an initial set. The preferred time frame is 12 to 24 hours after the installation of Xypex coating. Curing by misting the coating with water should be done between application of coating and installation of concrete overlay. Ensure coating is in SSD condition prior to placement of concrete.
3.04 CURING A. General: Begin curing as soon as Xypex coating has hardened sufficiently so as not to be damaged by a fine spray. Cure Xypex treatment with a mist fog spray of clean water three times a day for 2 to 3 days. Wet burlap and some specialty curing blankets are also effective for curing during the prescribed period. In warm climates, more than three sprayings per day may be necessary to prevent excessive drying of coating.
B. Air Circulation: Do not lay plastic sheeting directly on the waterproofing coating as air contact is required for proper curing. If poor air circulation exists in treated areas, it may be necessary to provide fans or blown air to aid in curing of waterproofing treatment.
C. Holding Structures: For water holding structures such as swimming pools, reservoirs, water treatment tanks and wet wells, cure Xypex treatment for three days and then allow treatment to set for 12 days before filling. For structures holding hot or corrosive liquids, cure waterproofing treatment for three days and allow to set for 18 days before filling.
D. Protection: During the curing period, protect treated surfaces from damage by wind, sun, rain, puddling of water and temperatures below 36°F (2°C). If plastic sheeting is used for protection, it must be raised off of the waterproofing coating to allow sufficient air circulation.
3.05 INTERFACE WITH OTHER MATERIALS A. Backfilling: Do not backfill for 36 hours after application. If backfill takes place within seven days after application, then backfill material shall be moist so as not to draw moisture from waterproof coating.
B. Paint, Epoxy or Similar Coatings: Do not apply paint or other coatings until waterproofing treatment has cured and set for a minimum of 21 days. Light abrasive blasting or washing the Xypex surface with a 3 - 5% acid solution followed by a rigorous rinse with clean water is recommended before applying the coating. Be sure to flush all acid off the surface. Alternately, removal of the Xypex coating by high pressure washing or abrasive blasting following full curing is acceptable. Consult epoxy and paint manufacturer for additional coating instructions and restrictions.
C. Grout, Cement Parge Coat, Plaster or Stucco: It is recommended that any other cementitious system be applied over the Xypex coating after the Xypex has completely set but while it is still “green” (12 to 48 hours). The 12 to 24 hour window is considered ideal. Contact your Xypex Technical Services Representative regarding surface preparation and other procedures for installations of other materials onto Xypex coatings older than 48 hours. Alternately, removal of the Xypex coating by high pressure washing or abrasive blasting following full curing is acceptable. Use of a polymer additive to help improve bond in the over coating mortar mix should be considered.
D. Responsibility to Ensure Compatibility: Xypex Chemical Corporation makes no representations or warranties regarding compatibility of Xypex treatment with coatings, plasters, stuccos, tiles or other surface-applied materials. It shall be the responsibility of the installer of the surface-applied material that is to be applied over the Xypex waterproofing treatment, to take whatever measures are necessary, including testing, to ensure acceptance by or adhesion to the waterproofing treatment.
Note: Prior to the installation, it is recommended that a test section be completed under anticipated ambient and project conditions to demonstrate acceptable bond.
3.06 FIELD QUALITY CONTROL A. Observation: Do not conceal installed waterproofing system before it has been observed by Architect/Engineer, waterproofing manufacturer's representative and other designated entities.
B. Testing for Tanks and Foundation Works
1. Testing: Fill tanks or, for foundation works, shut off dewatering system as soon as practical so that the structure shall be exposed to it’s normal service conditions. Examine for leaks.
a. Actively leaking cracks and joints shall be left to self-heal for as long as practical. Depending on job site and ambient conditions crack healing can be expected to take several days to weeks.
b. Any crack or joints that do not heal in the allowable time frame shall be repaired by the general contractor.
c. Moving cracks shall be repaired using polyurethane injection or other appropriate method.
3. Repair: Use Xypex repair procedures to seal any static crack or joint that does not self-heal. See Method Statements or contact Xypex Technical Services Representative for appropriate repair procedures.
Note: Lower temperatures will extend the times for crystalline development.
3.07 CLEANING AND PROTECTION A. Cleaning: Clean spillage and soiling from adjacent surfaces using appropriate cleaning agents and procedures.
B. Protection: Take measures to protect completed Xypex coating until the coating is hard enough to not be damaged. In normal conditions protect from pedestrian traffic for 3 days and vehicular traffic for 7 days. If coatings will be exposed to ongoing vehicular traffic or other abrasive environments consult Xypex Technical Services.
END OF SECTION 071616