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Mockup Planning and Approval
A polished concrete mockup establishes the finish the project team approves before production polishing begins. Build it with the materials and procedures intended for the floor, include joints, edges and a sample repair, and retain the approved mockup for comparison with completed work.
The Concrete Polishing Council (CPC) guide specification and ACI SPEC-310.1-20 set out requirements for mockup construction and approval. The Albuquerque Public Schools (APS) specification adds an approval step after the initial grind. Mockup size and approval responsibilities follow the project specification.
Our polished concrete guide for builders places mockup approval within the wider installation process.
Make the mockup representative of the floor
The mockup needs to demonstrate what the proposed mix, crews and polishing process can produce together.
| Source | Mockup requirements |
|---|---|
| CPC guide specification, §1.4 | A slab 10 feet square, using the project mix design. The same personnel who will place and finish the project concrete also place and finish the mockup. Grinding, honing and polishing use the project personnel and scheduled process. The guide’s dimension is editable by the project specifier. |
| APS specification, Section 03 35 43 | A 100-square-foot panel at the jobsite, at a location as directed, under conditions similar to actual placement. |
| ACI SPEC-310.1-20, §1.8.3 | A field mockup before polishing work, at an acceptable on-site location. Unless otherwise specified, use the procedures, equipment and materials intended for production. |
Include edges, joints and a sample repair
ACI §1.8.3 requires the following preparation and demonstrations:
- Allow the concrete in the mockup area to cure for at least 28 days.
- Verify surface hardness with a Mohs hardness testing kit before mockup installation starts.
- Include slab-edge polishing.
- Complete joint filling and demonstrate polishing over one or more floor joints.
- Include a simulated repair demonstrating acceptable procedures and a color and texture match.
- Provide preconditioned, previously used bonded abrasives, with a complete tooling range for different concrete surface hardnesses.
The 28-day requirement applies to the concrete in the mockup area. See the ACI 310.1-20 specification guide for how the specification is incorporated into project requirements.
Locate a suspended-slab mockup on the suspended slab
American Society of Concrete Contractors (ASCC) authors writing in Concrete Contractor recommend building a suspended-slab mockup on the suspended slab itself. A ground-level sample does not reproduce the elevated slab’s flatness, cracking, variable crack widths and deflection. Those differences can affect grinding depth and aggregate exposure.
The suspended concrete slab guide explains the grinding and coordination issues.
Settle appearance decisions on the mockup
Two appearance decisions can be settled on the mockup. Under the APS specification, the Architect and Owner’s Representative approve aggregate exposure after the initial grind, before the mockup is completed. The simulated repair establishes an acceptable color and texture match, and a color-matching advisory recommends a project authority sign off on the final repair or joint-filler color.
APS requires exposure approval after the initial grind
The APS specification requires the Contractor to notify the Architect and Owner’s Representative after the mockup’s initial grind. They approve the desired aggregate exposure before the remaining grinding and polishing of the mockup are completed.
APS also requires ASTM D523 testing as cited in its Section 2.02 Finishes, with printed results provided to the Architect before work starts. Allow 24 hours for mockup inspection before proceeding. Once accepted, the mockup demonstrates the minimum required quality.
Approve repair and filler colors in the mockup
Use the simulated repair to establish an acceptable color and texture match. Metzger/McGuire’s color-matching advisory recommends that a project authority select and sign off on the final repair or joint-filler color, because more than one color may appear to be a reasonable match.
Our repair color and visibility guide covers color selection, signoff and the conditions for judging filled imperfections.
Obtain approval before production polishing
The approval requirements differ by specification:
| Source | Approval before work starts |
|---|---|
| CPC guide specification | Obtain the Architect’s approval for compliance with approved submittals, aggregate exposure class, appearance level and specified color, where a colored finish is specified. |
| ACI §1.8.3.6 | The Architect/Engineer, Owner’s Representative or both review and approve the mockup as the minimum standard for acceptance. |
| ACI §1.8.3.7 | Do not begin concrete polishing work until the Owner’s Representative has accepted the mockup in writing. |
Under ACI §1.8.3, approving a mockup does not approve departures from the Contract Documents. The Architect/Engineer must specifically approve those departures in writing.
Retain the mockup through acceptance
CPC requires approved mockups to remain protected and undisturbed during construction. ACI requires protection from physical damage and retention until final acceptance.
Under ACI, production grinding and polishing follow the process used for the approved mockup. Specified aggregate exposure and distinctness of image (DOI) must meet both the applicable tables and the approved mockup. Unless otherwise specified, color application follows the manufacturer’s methods to match the mockup; repairs also conform to it.
The Architect/Engineer periodically checks completed areas against the accepted mockup. Establish the frequency and criteria for those observations at the preconstruction conference.
Final visual comparison with the mockup is one acceptance requirement. It does not replace measured DOI, gloss and haze requirements. The finish testing and acceptance guide explains those separate checks.
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Frequently Asked Questions
Use the project specification. The CPC guide gives a 10-foot-square slab as an editable value; the APS specification requires a 100-square-foot jobsite panel. These examples are not universal minimums.
The CPC guide requires the Architect’s approval. ACI SPEC-310.1-20 provides for review and approval by the Architect/Engineer, Owner’s Representative or both, and separately requires the Owner’s Representative’s written acceptance before concrete polishing begins.
Under the APS specification, after the mockup’s initial grind and before its remaining grinding and polishing are completed. The Architect and Owner’s Representative approve the desired exposure at that stage.
No. Under ACI SPEC-310.1-20, mockup approval does not authorize deviations from the Contract Documents unless the Architect/Engineer specifically approves those deviations in writing.
No. Under ACI SPEC-310.1-20, comparison with the approved mockup is one acceptance requirement. The applicable measured requirements for DOI, gloss and haze remain separate.
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