PPS Concrete Anticorrosive & Waterproofing Work Specification ⊙ PPS Concrete Anticorrosive & Waterproofing Work 1. General Description 1.1 The regulation specifies a general standard for those specially required items with regard to concrete anticorrosive and waterproofing works of concrete structures (concrete structures at sea & along the seashore, sewage·waste water treatment facilities, structures subject to the risk of corrosion with the use of sea sand, bridges subject to sea salt aerosol damage & etc.) requiring the concrete's own water resistivity with the use of Powdered Corrosion-inhibitor

& Waterproof Admixture, prevention of

concrete deterioration due to neutralization & corrosion resistivity against salinity. 1.2 The items related with construction work but not described in this Specification shall comply with the Standard Concrete Specification.

2. Material Property and Performance

& Waterproof Admixture (Standard Name: Hipermix JSCI-99, hereinafter referred as ‘Powdered Corrosion-inhibitor & Waterproof Admixture’ increases the The Powdered PPS Concrete Corrosion-inhibitor

water permeation resistivity by filling the capillary air gap through forming of calcium silicate hydrate crystal through chemical reaction & calcium hydro-oxidation during hydration reaction, whereas the sealing effect of polymer film & fatty acidic metal salt enhances the water absorption resistance by forming the high repellent membrane, and the quality of concrete is enhanced. Plus, the performance and quality standard of Powdered Corrosion-inhibitor

& Waterproof Admixture preventing the corrosion of

steel by forming passivity film on steel surface through oxidation of bi-polar inorganic alkali nitrite ion are as follows.

Test Item

Setting Time Difference (min.)

Quality Standard

Initial Setting

60 ∼ +60

Final Setting

60 ∼ +60

Compression Strength Ratio

1.0 or Above of Existing Concrete

Water Absorption Coefficient Ratio

0.55 or Below of Existing Mortar

Water Permeation Ratio

0.55 or Below of Existing Mortar

Chlorine Ion Penetration Depth Steel Reinforced Bar Corrosion Acceleration Test in Concrete

Test Method

Per KS F 4926

3.0mm or Below Corrosion Resistivity 95% or Higher

Per KS F 2561

3. Construction Scheme JANGSAN CM CO.,LTD

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3.1 Preparation of Construction Plan The Supplier shall submit the Construction Plan containing following items to the Supervisor. ① Construction Status Check List : Inspection Report checking the construction status before & after the concrete casting based on the Check List which enables to confirm the construction status by respective construction phase. ② Quality Control Plan : Quality control plan document specifying the installation procedure & method, material transportation & storage scheme, location & method of pouring, person in charge of construction & etc.

3.2 Submission ① Detail Construction Drawing : The Detail Construction Drawing specifying the work method on construction joint not shown on the design depending on the condition of structure shall be prepared and submitted. ② Product Related Materials : The certificate issued per the national certification system & test report experimented per the Korea National Standard (KS) shall be submitted. ③ Assurance of Product Usage : The commercial invoice or relevant document material regarding the procurement of product shall be submitted in order to assure the designed construction quantity.

4. Storage & Handling of Materials 4.1 The storage & handling of materials shall be secured for safety in accordance with the relevant regulations of Fire Services Act & Industrial Safety & Health Act preparing dust-proof mask, protective eye glass, dust-proof cloth for the safety of laborers when pouring & mixing the Powdered Corrosion-inhibitor

& Waterproof Admixture in the mixer truck, and check the installation

of wind shield or dust proof clean room in advance taking precaution against potential civil appeals on dust or noise.

4.2 Store the packing bags of Powdered Corrosion-inhibitor

& Waterproof Admixture not to be directly

exposed to rainwater, dew drops & etc. stacking the bags by 20 bags or less on 30cm space above the ground not to be affected from the moisture as much as possible.

4.3 The Powdered Corrosion-inhibitor

& Waterproof Admixture, unlike the cement or expansive additive,

is not subject to direct reaction against water, however caution shall be paid not to be contacting with alkaline materials as the properties may be changed due to the characteristic of materials.

5. Raw Materials & Mixing

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5.1 Cement The common 1st class portland cement meeting the KS L 5201(Portland Cement) shall be used for cement material in principle. In the event of using other types of cements, the approval of Supervisor shall be obtained after investigating the basic properties & performance on concrete durability & water resistivity & etc. which the concrete waterproof admixture shall provide.

5.2 Aggregates ① The fine aggregate suitable for the regulation of Standard Concrete Specification shall be used. Particularly, the stone powder as mix-poured into the crushed sand shall be within the range of 3~5% containing the minimum volume of dust. In case to exceeding the value, as the unit quantity of concrete is increased with reduced strength property, careful consideration shall be made prior to the use. ② The aggregate shall be of clean & solid provided with durability not containing dust, mud, organic impure material, chloride & etc. The aggregate of saturated dry surface condition or of equivalent condition similarly managed with above with appropriate mix of large & small in size for granularity of aggregate shall be used. Particularly, if the inner portion of aggregate is of dry condition, the constructability may be deteriorated due to the rapid slump loss.

5.3 PPS Waterproof Mortar ① PPS Waterproof Mortar that is blended to its optimum use with cement, sand, waterproof admixture, and improving agents that enhance specific properties can be used only with the addition of water in accordance with its usage. It enables user to obtain homogenous quality, and it also improves working conditions at the sites because it does not require a large space. ② The waterproofing admixture to be used for PPS Waterproof Mortar should be the PPS Powdered Waterproof Admixture(model name:

a

ltong

JSM-33) that is produced at a dry mortar production

plant.

5.4 Coating of PPS compound. ① After the amount of materials to be used within one (1) hour after mixing is calculated, cement and PPS Powdered Waterproof Admixture are to be measured and put in a mixing container, and drymixed for 30 seconds.

30% water of the amount of the cement should be added and mixed

uniformly with a hand mixer, which is left untouched for about 90 seconds. Appropriate water is added to the mixture, and then it should be mixed homogenously for 60 seconds to be ready for coating. The same procedure will apply to PPS coating compound. ② Depending on moisture, temperature, and surface conditions of the construction site, the first coating application of the optimally blended mixture should be implemented within one hour using a brush, roller, trowel, or spray; the second application should be made at an interval of more than 24 hours after the first coating according to the working conditions of the site.

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5.5 Compounding Materials ① The AE admixture, water reduction agent & high performance AE water reduction agent used to secure the workability shall meet the regulation of KS F 2560(Concrete Compounding Material). The type & property of compounding material to be used shall be notified to the powdered water proofing material supplier not to influence the respective product features each other. ② The fly-ash used as compounding material shall use the 1st Class quality product specified on the KS L 2405(Fly-Ash). Particularly in case of using the massive volume, it is ideal to confirm the performance as per the experiment or reference record. ③ As the bleeding is to slowly be generated or not generated at all due to the use of compounding materials, spraying of sufficient water volume using the high pressure sprayer can suppress the initial cracks developing on the surface of concrete cast due to the loss of moisture in order to prevent the rapid moisture loss from the surface.

5.6 Ratio of Water-Cement Mixture ① The ratio of water-cement mixture shall be less than 55%. The ratio can be 5% higher in case of mass concrete but caution shall be paid not to create the material segregation. Particularly, in case of single body floor slab, thorough consideration shall be made on the symptom of cracking increase as the ratio of water-cement increases. ② The concrete mixture design of singly body floor slab & overlaying floor slab with the volumetric percentage of cement paste not exceeding 27.0% of the total volume can reduce the cracking of floor slab.

5.7 Slump The dry contraction can be reduced by maintaining the slump value as small as possible reducing the material segregation & bleeding as well. Being the slump values not even in line with the mixture design of respective ready mix concrete manufacturers, the highest performance enhancing effect can be obtained by measuring the increased/decreased values of slump when pouring the Powdered Corrosion-inhibitor

& Waterproof Admixture and adjusting with the minimum slump value within the

range of feasible work depending on the type of structure.

5.8 Air Volume of Concrete ① The volume of air within concrete added with the Powdered Corrosion-inhibitor

& Waterproof

Admixture for concrete mixture application shall be of 4.5±1.5% in order to improve the workability & durability against the weather conditions, using the AE admixture of air entraining agent as necessary to satisfy the required air volume. ② Adjusting the specified air volume with maximum value for concretes of single body floor slab & bonded concrete overlay floor slab allows obtaining of the crack reducing effect.

5.9 Quantity of Corrosion-inhibitor & Waterproof Admixture Pouring JANGSAN CM CO.,LTD

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① The input quantity of Powdered Corrosion-inhibitor

& Waterproof Admixture shall be 11kg/m3 in

case compressive strength is less than fck=27MPa; in case it is more than fck=27MPa, a fixed quantity of 12kg/m

3

should be added.

② Mixing should be completely made until all the concrete materials reaches to even state, and adding of water when pouring & mixing into ready mix concrete is absolutely not allowed.

5.10 Mixture of Corrosion-inhibitor & Waterproof Admixture The one of following shall be selected for the place to pour the Powdered Corrosion-inhibitor

&

Waterproof Admixture. ① Mix the cement and aggregate simultaneously inside the batcher plant installed with powder storage silo and execute casting. ② In the event Powdered Corrosion-inhibitor

& Waterproof Admixture is input into a truck agitator on

its way from the ready mixed concrete production plant or it is added after the truck agitator arrives at the construction site, the compound should be mixed at a high-speed rotation (810RPM) for more than 2.5 minutes so as to become homogenous before it is cast.

6. Construction 6.1 Preparation of Work ① Completely remove the laitance & alien materials from the concrete cast earlier in case of continuous concrete cast. ② Execute correction work as necessary upon checking if the water stopping material is solidly installed on the concrete surface.

6.2 Form Work ① The method of tying molds for basement walls of buildings and water tanks where the waterproof admixture mixed with concrete is to be used requires, in principle, embedded form ties; however flat ties are inevitably used, their use should be approved by a construction supervisor in connection with surface finishing and treatment. Regardless of the types of form ties to be used, ring-type, expansible water stops should be inserted before setting the ties. ② Since movements of form ties caused by shocks generating when the molds are disassembled can lead to possible leakage, an adequate period of time stipulated in the specification should be allowed for curing of concrete before careful dismantling of the molds. ③ For the single body floor slab & overlaying floor slab concrete, the material stacking & equipment transportation are possible upon reaching to the sufficient strength in holding the construction weight, and loading of weight earlier shall be done with care as it may fail to acquire the proper water resisting effect caused by fine cracks unable to detect with visual inspection.

6.3 Construction Joint The construction joint areas are decided as per the size of building, daily concrete casting volume,

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concrete form area or number of workers in the event of building the concrete structure. Further, the continuous concrete casting tends to be vulnerable point in terms of strength, water tightness, neutralization & etc. Accordingly, the construction shall be executed in appropriate manner suitable for each respective condition by selecting the least affected points in line with the nature of structure & at the same time minimizing the continuous cast areas.

① Continuous Casting of Not Hardened Concrete The continuous casting of not hardened concrete shall set the interval of continuous concrete pouring within 60 minutes to prevent the cold joints first of all when the exterior temperature is lower than 25℃. (40 minutes except with the event of exterior temperature of higher than 25℃). The concrete is to be cast upon laying PPS mortar of about 3∼13㎜ thickness or coating adhesives or synthetic resin emulsion after making up of full grown strip scale or groove, prior to casting the next concrete as for the indispensable horizontal construction joint.

② Continuous Casting of Hardened Concrete The materials such as non-expansive water inhibiting rubber board, steel plate & etc. prepared for the purpose depending on the applications, in case of casting new concrete next to the already hardened concrete as the water tightness of the area can not be expected. Particularly, the nonexpansive water inhibiting rubber board satisfactorily demonstrates the water proofing effect if the applied method is appropriate but, in practical construction the water leakage could often be generated as the air gap is created on the area due to the concrete casting shock or pressure caused by folding of water inhibiting board, therefore sufficient consideration & accurate construction is requested in advance.

③ Expansion Joint Area The water tightness of expansion joint area is the most important for underground structure. The waterproofing method for the expansion joint area shall use the water inhibiting materials of outstanding elasticity & soft nature considering cases of accompanied uneven sinking & vibration, and caution shall be paid not to damage the water inhibiting board in case the continuous concrete casting of opposite side is not executed.

④ Treating the Perimeter of Penetrating Material When the pipe laying steel pipe, wiring sleeves, H-Beam & etc. are penetrating the concrete, the water inhibiting steel plate welded with approximately 80mm width shall be installed around the penetrating materials inhibiting water by attaching the non-expansive water inhibiting rubber on the penetrating material.

⑤ Removal of Form Tie and Water Inhibiting Treatment Stripping of form ties from molds and disposal of stagnant water: In case of embedded form-ties,

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the corns of the form ties should be treated, after the stripping of the molds, so that it should be easily filled with a filler added by high-quality PPS Waterproof Mortar or Powdered Corrosioninhibitor

&Waterproof Admixture.

In the event flat ties are used, the two exposed sides should be

coated with epoxy to ensure waterproofing.

6.4 Concrete Casting ① The Measurement Report confirming & checking the construction state of concrete waterproofing works by each respective construction step shall be submitted to the Supervisor, and approved upon selecting the qualified contractor of relevant concrete types or water proofing types prior to the starting of construction ② In case of installing concrete water proofing only on given one area among the wall or slab, the concrete mixed with water proofing material shall be cast on area approximately 1~2 meters extended from the location not installing the concrete water proofing. ③ In case of continuous casting wall structure, when the use of water proofing material is not necessary as the certain portion of underground structure does not touch the ground the application range of water proofing material shall be extended by about 1~2 m from the location contacting the ground and cast.

6.5 Finishing and Curing ① The flat surface finishing shall be made according to the slope & accuracy required for the surface with finishing method as described on the Specification, and sufficiently compounded with the vibrator, trowel & stamping rod so that the thick aggregate is to get stuck below the surface. In case of slab, the final surface finishing is better be made within 7 hours after the concrete casting. ② The effect of removing initial cracks and acquiring enhanced concrete strength can be obtained by finishing the surface with the method described in the Specification, if proper water spraying is made on the concrete surface using the high pressure sprayer before the horizontal surface is dried up, for those sinking cracks generated by the confined reinforced steel bar within concrete or underground laying material and plastic shrinkage crack generated during the initial curing phase. ③ The wet curing shall thoroughly be done particularly during Summer season as lots of hydration heat is to be generated when the high strength is manifested, and in the Winter season the warm curing shall be done. To enhance the strength & water tightness, the wet curing (ponding, spray, web-burlap & etc.) method supplying water additionally is more effective than the membrane curing method keeping the moisture of surface after final surface finishing. ④ When work for the final finish layer is carried out on the integrated one-unit floor plate with PPS Waterproof Mortar or unreinforced concrete, an ordinary repair method can be used if deterioration occurs on the surface of concrete or damaged spots form on it; however, they should be coated with the PPS compound before the final layer is finished.

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7. Test and Inspection 7.1 Submission of Test Report of Authorized Institutes In the event of inspecting the product quality according to the tested values, the confirmation of latest test reports performed as per the KS F 4926 Performance Test Procedure (Waterproof Admixture for Concrete Mixture Application) can substitute the inspection. And if the independent confirming inspection is required, extract the test sample and check the performance requesting a test to the authorized test institutions on the specified items to be tested.

7.2 Compression Strength Test The probability of compression strength test value performed on concrete test cylinder less than the standard design strength compression strength shall be 5% or below for the compression strength of concrete using JANGSAN's product. In case the probability falling short of design standard strength based on the concrete aged 28 days exceeds 5%, the concrete is regarded as possessing the required quality, as per the shortage probability of the quality assurance test executed on 42 days aged concrete as the manifestations of strength are sometimes delayed depending on the manufacturers' process.

7.3 Water Proof Performance Test ① The testing of water proofing performance of mortar test specimen excluded with thick aggregate as per the KS F 4926(Concrete Mixture Pouring Waterproof Admixture) using the mortar water penetration tester at the laboratory enables to confirm the performance most accurately since the power of discrimination of thick aggregate is less than that of sand for it's own absorption power, while the water tightness is distinguished whether the cement, water & water proofing material generate the substance of absorption & water permeation resistivity nature by the chemical reaction inside the hydraulic cement paste. ② The water tightness of two test specimens can be confirmed by measuring the penetrating depth of section crushed by the compression strength tester after drying the test specimen for 3 days at 105℃ and completion of curing underwater for 28 days settling for about 10 days within clean water for 28 days, upon building of test specimen using water proofing material with application test method and common concrete specimen at a job site not equipped with the mortar water permeation tester per KS F 2403(Test Specimen Building Method for Concrete Strength Test). In this case, though the differences of penetration depth & moisture density are generated, the result of visual measurement of penetration depth within 20mm is regarded as favorable waterproofing performance. ③ The field water filled test shall be executer for those structures applicable for water leakage test owing to the water filling either interior or exterior section of structures. However, the visual inspection on construction quality condition shall be executed using the appropriate tools & devices checking the aggregate segregation area of concrete surface, defect on construction joint section for the construction area not applicable for the water filled test.

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