427

Item 427
Surface Finishes for Concrete
1. DESCRIPTION

Finish concrete surface as specified.

2. MATERIALS
Furnish materials in accordance with this Article for the type of surface finish specified.

2.1. Coatings.

2.1.1. Adhesive Grout and Concrete Paint. Provide coatings in accordance with DMS-8110, “Coatings for
Concrete.” Match color of coating with Federal Standard 595C color 35630, concrete gray, unless otherwise
shown on the plans.

2.1.2. Opaque Sealer. Provide penetrating-type sealer in accordance with DMS-8110, “Coatings for Concrete.”
Match color of coating with Federal Standard 595C color 35630, concrete gray, unless otherwise shown on
the plans.

2.1.3. Silicone-Based Paint. Provide silicone resin emulsion paint (SREP) meeting the requirements of
DMS-8141, “Paint, Silicon Resin for Concrete.” Match color of coating with Federal Standard 595C color
35630, concrete gray, unless otherwise shown on the plans.

2.2. Exposed Aggregate Finish. Provide approved aggregates meeting the grading requirements shown on the
plans. Provide gravel consisting of predominantly rounded particles unless otherwise shown on the plans.
Use crushed stone when a bush-hammered finish is desired. Provide a concrete surface retardant. Provide
clear Type II permanent anti-graffiti coating in accordance with DMS-8111, “Anti-Graffiti Coatings.”

3. EQUIPMENT
The Engineer may require demonstration of the equipment’s capabilities.

3.1. Low-Pressure Water Blasting. Use equipment capable of supplying a minimum pressure at the nozzle end
of 3,000 psi at a minimum flow rate of 3 gpm. Use a 0° rotary, vibratory, or wobble-type nozzle. Use
equipment capable of including abrasives in the water stream when specified on the plans.

3.2. Abrasive Blasting. Use equipment with filters to produce oil-free air and also water-free air when dry air is
required.

3.3. Slurry Blasting. Use equipment capable of combining air and abrasives with water to form a wet blast media
capable of cleaning and preparing surface without creating dust.

3.4. Spraying. Use equipment with fluid and air pressure regulators and gauges to allow for adjustment to
produce a uniform spray pattern for spray applications.

3.5. Off-the-Form Finish Forms. Use nonstaining, nonporous, high-quality forming materials (e.g., steel or
medium-density and high-density overlaid plywood forms). Use steel or high-density overlaid plywood forms
when the same form will be used more than twice.

1
 427
3.6. Form Liners. Provide form liners capable of producing a patterned finish as shown on the plans. Use form
liners that provide a clean release from the concrete surface without pulling or breaking the textured
concrete.

4. CONSTRUCTION
Provide the finish specified on the plans for the specific surface areas.

4.1. Surface Areas of Finish. “Surface area of finish” designates the areas where the specified surface is to be
applied.

4.1.1. Surface Area I.

 surfaces of railing;
 exterior vertical faces of fascia beams, slabs, slab spans, arches, and box girders;
 the outside bottom surface of fascia beams and girders;
 the underside of overhanging slabs to the point of juncture of the supporting beam;
 the entire underside of slab spans when shown on the plans;
 vertical and underside surfaces of bents and piers;
 all surfaces of tie beams, abutments, bridge wingwalls, culvert headwalls and wingwalls, and retaining
walls exposed to view after all backfill and embankment is placed; and
 all other exposed surfaces shown on the plans to require surface treatment.

4.1.2. Surface Area II. Surfaces of railing, all wingwalls, and the exterior vertical faces of slabs.

4.1.3. Surface Area III. Only the top and roadway faces of all concrete railing and bridge wingwalls.

4.1.4. Surface Area IV. Areas designated on the plans.

4.2. Coatings. Apply the coating specified on the plans.

4.2.1. Preparation. Clean the surface thoroughly before applying a coating by chemical cleaning, if required, and
by blast cleaning.

Submit a containment plan that details the procedures proposed to keep public property, private property,
and the environment from being adversely affected by the cleaning and painting operations. Do not
discharge washwater into body of water or conveyance without TCEQ approval. Collect and properly dispose
of any paint or debris dislodged as a result of cleaning operations.

4.2.1.1. Chemical Cleaning. Clean surfaces contaminated with oil, grease, or other contaminants by scrubbing the
area with an approved detergent or other concrete cleaning material before blast cleaning. Do not use a
solvent that will stain the surface or inhibit coating adhesion. Perform the following test to check for surface
contamination of oil type materials:
 Spray the surface with a fine mist of potable water.
 Examine the area to see if water beads up.
 Clean the surface if beading is found.

4.2.1.2. Blast Cleaning. Blast clean the designated surface to remove weak surface material, curing compound, and
other contaminants before applying a specified coating, leaving a lightly etched uniformly textured surface.
Use an approved abrasive propelled by oil-free air with or without the addition of potable water, or blast with
potable water with or without the addition of an approved abrasive at sufficient pressure to effectively clean
and prepare the surface. Maintain the stand-off-distance of the nozzle to a maximum of 12 in. from the
surface being cleaned when water blasting.

2
 427
Do not damage concrete surface by gouging, spalling, or exposing coarse aggregate by the blasting
operation.

Blow clean oil- and moisture-free air on all surfaces with sufficient pressure to remove loose particles
immediately before application of any coating. Perform the following test to check for surface cleanliness as
directed:
 Press a 10 in. long strip of 2 in. wide clear packing tape on the surface by rubbing with moderate
pressure.
 Grasp the free end of the tape, and remove the tape from the surface with a sharp jerk.
 Examine the surface of the tape for clinging particles.

Continue cleaning the concrete surface until there are no particles clinging to the tape surface for subsequent
tests. An additional test that can be used to check the surface for dust is to wipe the surface with a dark cloth
and then examine the cloth for discoloration.

4.2.2. Application. Mix coating materials thoroughly with a mechanical mixer at a speed that causes the mixture to
rotate entirely in the container. Ensure complete mixing by probing the container with a stirring device
searching for non-dispersed or settled material.

Apply coatings once the new concrete has aged a minimum of 28 days except for the adhesive grout coating.
Do not apply coatings when weather conditions will be detrimental to the final surface finish as determined by
the Engineer. Do not apply coatings when surface temperature of the concrete exceeds 110°F.

Apply coatings to obtain a consistent color and texture.

4.2.2.1. Adhesive Grout. Apply coating on a moistened surface to a uniform minimum thickness of 1/16 in. Apply
when ambient temperature is at least 50°F.

4.2.2.2. Concrete Paint. Apply the coating on a dry surface in 2 coats for a total maximum application rate of
150 sq. ft. per gallon. Match the color of the applied coating with the color standard shown on the plans. Do
not thin material unless approved. Apply when ambient temperature is between 50°F and 100°F.

4.2.2.3. Opaque Sealer. Apply the coating to a dry surface in 2 coats for a total maximum application rate of
200 sq. ft. per gallon. Match the color of the applied coating with the approved color standard shown on the
plans. Do not thin the material unless approved. Apply when ambient temperature is between 40°F and
100°F.

4.2.2.4. Silicone Resin Paint. Apply the coating on a dry surface in 2 coats at a rate not exceeding 300 sq. ft. per
gallon per coat. Do not thin the material unless approved. Wait a minimum of 12 hr. between coats. Apply
when ambient temperature is between 50°F and 100°F.

Repair surface finish where coating has been applied that exhibits peeling, flaking, or discoloration or has
been damaged during construction. Remove defective or damaged coating. Clean and recoat repair area in
accordance with the requirements of this Item.

4.3. Special Surface Finishes. Submit a work plan to the Engineer for any special finish shown on the plans.
Include in the work plan the type of aggregates, materials, variation of panel or pattern arrangement,
dimensions, construction methods, and other features affecting the work as is necessary for the “Special
Surface Finish” specified.

4.3.1. Blast Finish. Provide surface profile as shown on the plans, or meet the minimum requirements of
Section 427.4.2.1., “Preparation.” Construct a 4 × 4 ft. sample panel using the same concrete used in
construction of the member to receive the blast finish. Prepare the surface of the sample panel to meet the
specified finish, and obtain approval of the sample finish. Use the approved sample panel finish as the
standard for surfaces requiring a blast finish.

3
 427
4.3.2. Slurry Coat Finish. Provide cementitious slurry coat finish to concrete surfaces within 14 days of placing
concrete or later as approved. Water blast surface to moisten surface before application when application of
slurry coat occurs more than 14 days after placing concrete. Do not apply slurry coat finish to surfaces
receiving another type coating finish.

Submit for approval proposed slurry recipe including cement, latex concrete additive, with or without sand,
and other additives before application. The Engineer will direct the level of surface texture the slurry coat will
have, whether to include sand, and what fineness of sand is to be used. Tint mixture of slurry as specified on
the plans and as directed. Maintain consistent slurry throughout project only modifying recipe to account for
color variations being noticed as work progresses.

Rub in slurry with carborundum stone, stiff bristle brush, or other approved device. Limit thickness of applied
slurry to a maximum of 1/16 in. thick. Demonstrate application methods for slurry coat and obtain approval of
proposed surface. Apply slurry coat to obtain a tightly adhering cementitious finish to concrete surface.
Remove material and reapply if slurry coat is not tightly adhering or is cracked.

4.3.3. Rub Finish. Provide a finish to the surface by rubbing the surface with a carborundum stone or other
approved material. Begin rubbing the surface immediately after forms have been removed. Provide blast
finish or other finish as directed at no additional cost to the Department if rubbing surface is delayed to the
point where the surface is dry and unable to be rubbed to produce an acceptable finish. Perform the
requirements to obtain the ordinary surface finish specified in Section 420.4.13., “Ordinary Surface Finish,”
concurrently with rubbing the surface. Rub concrete-patching areas after the patch material has thoroughly
set and blend the patch in with the surrounding area to produce a surface with uniform color and texture
where concrete patching is performed.

Keep the surface continuously wet after form removal until the rubbing is complete. Rub the surface
sufficiently to bring the wetted concrete surface to a paste producing a smooth dense surface without pits,
form marks, or other irregularities. Do not use cement grout to form the paste on the surface. Stripe the
surface with a brush to conceal the rubbing pattern and allow the paste to reset. Wash the concrete with
potable water after the paste has sufficiently set to leave it with a neat and uniform appearance and texture.
Apply membrane curing, if required, in accordance with Item 420, “Concrete Substructures,” after rubbing is
complete.

4.3.4. Off-the-Form Finish. Provide a finish with minimal surface defects and uniform color and texture by using
non-staining, non-porous, high-quality forming materials. Use the same type of forming materials for like
elements for the entire structure.

Use mortar-tight forms to prevent leakage and discoloration. Seal joints with compressible gasket material,
caulk, tape, or by other suitable means that are not detrimental to the concrete finish if necessary. Use one
brand and type of form-release agents for all surfaces unless another product produces a similar concrete
surface appearance. Do not use barrier-type (wax, fuel oil, carrier oil, etc.) release agents. Use form-release
agents containing a rust inhibitor on steel forms. Clean rust off steel forms before use. Use plywood that will
not cause discoloration of the concrete surface.

Direct special attention to consolidation and vibration of the concrete around the form surfaces to minimize
bug holes. Modify concrete placement and vibration techniques if surface contains an excessive amount of
bug holes. Remove all forms without interruption once form removal begins to prevent discoloration due to
differing form curing times.

Do not use membrane curing on surfaces with off-the-form finish.

Repair honeycombed and spall areas with least dimension larger than 2 in. in accordance with the concrete
surface repair procedures outlined in Item 420, “Concrete Substructures,” to obtain an ordinary surface finish
as defined in Section 420.4.13., “Ordinary Surface Finish.” Patch honeycombed and spall areas with least
dimension greater than 3/4 in. but smaller than 2 in. by filling defect with repair material omitting the chipping
operation. Do not patch honeycombed and spall areas with least dimension smaller than 3/4 in. Perform
required repairs as soon as forms are removed. Match repair material color and texture with surrounding

4
 427
concrete surfaces. Minimize the area of repair by not smearing the repair material over acceptable concrete
surfaces in an attempt to blend the repair with the surrounding concrete. Cut out form ties at least 1/2 in.
below the surface, and patch accordingly. Perform repair work as soon as possible after removing forms so
that concrete and repair material have similar ages. Replace or refurbish the forms when the Engineer
determines defective formwork is causing an excessive amount of repair work.

4.3.5. Form Liner Finish. Provide patterned finish as shown on the plans. Do not splice form liner panels in a way
that causes a noticeable transition or line between pieces. Wash and clean form liners after each use when
the forms can be reused. Replace form liners that have become damaged or worn.

Construct a sample panel for each form liner finish. Approval is required to verify the sample panel meets the
requirements of the plans and specifications before beginning work. Upon approval, the sample panel
becomes the model panel that all other work will be compared against. Deviation in color, grade, or depth
from the model panel is grounds for rejection of the form liner finish. Removal of defective work may be
necessary as determined by the Engineer and in accordance with the surface finish requirements outlined in
Item 420, “Concrete Substructures,” to obtain an ordinary surface finish as defined in Section 420.4.13.,
“Ordinary Surface Finish.”

Seal all form liner joints in a manner acceptable to the Engineer to prevent leakage at the surface.

4.3.6. Exposed Aggregate Finish. Provide exposed aggregate finish as indicated on the plans. Provide a depth of
finish between 3/8 in. and 1/2 in. unless directed otherwise.

Apply a concrete surface retarder that penetrates approximately 1/4 in. into the forms or concrete surface to
help achieve the desired finish. Apply 2 or 3 coats to wood forms to account for absorption if necessary.
Tape or caulk form joints to prevent escape of the retarder during the placing operations. Protect the form
surfaces from sun and rain while exposed to the atmosphere. Re-treat form surfaces with retarder if
disturbed. Protect adjacent areas of concrete not requiring exposed aggregate finish from the retarder.

Remove forms 12 to 15 hr. after concrete placement but not before concrete has gained sufficient strength to
support the self-weight of the member unless directed otherwise. Expose the aggregate for the finish
immediately after form removal. Remove the grout paste covering the aggregate to be exposed by an
approved method. Do not loosen the aggregate by the grout removal operation. Maintain required curing on
all surfaces except for the time while the aggregate is being exposed. Cure using wet mats or membrane
after the aggregate is exposed.

Repair defective areas as determined by the Engineer.

Re-clean exposed aggregate surfaces by an approved method. Apply a coat of clear Type II permanent anti-
graffiti coating to cleaned exposed aggregate surface. Apply anti-graffiti coatings by spray, roller, or brush at
the application rates recommended by the manufacturer and in accordance with Item 740, “Graffiti Removal
and Anti-Graffiti Coating.”

5. MEASUREMENT
When surface finishes for concrete is shown on the plans to be a pay item, measurement will be by the
square foot of the type of surface finish specified.

This is a plans quantity measurement Item. The quantity to be paid is the quantity shown in the proposal,
unless modified by Article 9.2., “Plans Quantity Measurement.” Additional measurement or calculations will
be made if adjustments of quantities are required.

6. PAYMENT
Unless otherwise specified on the plans, the work performed, materials furnished, equipment, labor, tools,
and incidentals will not be paid for directly but will be considered subsidiary to pertinent Items.

5
 427
When a surface finish for concrete is specified as a pay item, the work performed and materials furnished in
accordance with this Item and measured as provided under “Measurement” will be paid for at the unit price
bid for “Adhesive Grout Finish,” “Concrete Paint Finish,” “Opaque Sealer Finish,” “Silicone Resin Paint
Finish,” or “Blast Finish.” This price is full compensation for materials; cleaning and preparing surfaces;
application of materials; and equipment, labor, tools, and incidentals.

Slurry coat, rub, off-the-form, form liner, or exposed aggregate finishes (including anti-graffiti coating) will not
be paid for under this Item but are subsidiary to other pertinent Items.