934Rapid Setting Patching Materials for Portland Cement Concrete

934.1 General Description

This section includes the requirements for rapid setting patching materials used in Portland cement concrete.

934.1.01 Related References

A. Standard Specifications Section 886—Epoxy Resin Adhesives B. Referenced Documents AASHTO ASTM T 97 T 260 C 31/C31M C 109/C 109M C 140 C 666 Federal Hazardous Products Labeling Act QPL 27

934.2 Materials

934.2.01 Rapid Setting Patching Materials

A. General Requirements 1. Use rapid setting patching materials that have the following characteristics: • Are nonmetallic. • Have a color similar to Portland cement concrete. • Can be mixed and placed like concrete. • Have accelerated hardening characteristics. • Yield a permanent patch in concrete that can withstand traffic within 2 hours. For a list of sources, see QPL-27. 2. Type I Use Type I to patch reinforced or nonreinforced horizontal Portland cement concrete surfaces. 3. Type II Use Type II to patch only nonreinforced horizontal Portland cement concrete surfaces. 4. Type III Use Type III to patch reinforced vertical or overhead Portland cement concrete surfaces. 5. Classify Type I, Type II, and Type III as follows: a. Class A, Premixed: Use these materials as received by adding water or an activator solution, according to the manufacturer’s instructions. Section 934 — Rapid Setting Patching Materials for Portland Cement Concrete NOTE: Do NOT add extra aggregate to Class A patching material without approval from the Office of Materials and Research. b. Class B, Non-Premixed: These materials contain no aggregate. Add aggregate (fine and/or coarse) according to the manufacturer’s recommendations c. Class B, Non-Premixed: These materials contain no aggregate. Add aggregate (fine and/or coarse) according to the manufacturer’s recommendations. 6. Type IV Use elastomeric patching material to patch nonreinforced horizontal Portland cement concrete surfaces. 7. Type V Use two-component cross linked resins to patch nonreinforced horizontal Portland cement concrete surfaces. 8. Type VI Use cementitious, rapid setting, structural repair mortar to patch nonreinforced horizontal Portland cement concrete surfaces. B. Physical Requirements 1. Use Type I, Type II, and Type III patching materials that have been evaluated by the National Transportation Product Evaluation Program (NTPEP) or other approved test facility, and meet the following requirements. Requirement Measurement Flow of Mortar, Type I and Type II Type III 100% minimum 80% to 100% Flexural Strength, Minimum 500 psi (3.5 MPa ) in 24 hours Compression Strength, Minimum 2 hours 1,200 psi (8.5 MPa) 24 hours 3,000 psi (20 MPa) 7 days (moisture cure) 4,000 psi (27.5 MPa) Absorption, Maximum 10% Shear Bond, Minimum 200 psi (1.5 MPa) in 24 hours Freeze Thaw Durability Factor 75% of the reference concrete after 300 freeze-thaw cycles Total Chlorides Type I and Type III Type II 0.6 lb./yd.³ (0.4 kg./m.³) maximum No limits Section 934 — Rapid Setting Patching Materials for Portland Cement Concrete C. Fabrication 1. Packaging a. Package this material in strong, moisture-proof paper bags or other suitable containers that can withstand shipping, normal handling, and storage without breaking. b. Clearly label each container of the components of a patching system with the following information: • Component designation, if two components. • Manufacturer’s batch number. • Mixing ratio and directions. • Potential hazards and precautions displayed according to the Federal Hazardous Products Labeling Act. D. Acceptance 1. Follow the mixing instructions of the manufacturer to create test specimens. 2. Air-cure all test specimens except for the 7-day moisture cure cubes. 3. Test Types I, II, and III using the following methods: Test Method Flow of mortar ASTM C 230 Flexural strength AASHTO T 97 Compressive strength ASTM C 109/C 109M or C 31/C 31M, whichever is applicable Absorption ASTM C 140 Shear bond strength See Subsection 934.2.01.D, “Acceptance”, Step 4 Rapid freeze thaw ASTM C 666 Total chlorides AASHTO T 260 4. Shear Bond Strength a. Place a Type II epoxy resin adhesive meeting the requirements of Section 886 on the surface of a cured mortar bar 16 x 3 x 3 in. (400 x 75 x 75 mm). b. Cast a 16 x 2 x 0.5 in. (400 x 50 x 13 mm) rapid-setting material patch in the center of the mortar base. c. Air-cure the test sample for 24 hours. d. Saw the mortar bar base and the cured rapid setting material patch into 2 in. (50 mm) segments for testing. e. Use a holding device and plunger to apply a load at a rate of 0.05 in. (1.3 mm) per minute to the patch until the patch fails. f. Read the load in pounds (newtons) on the plunger. g. Calculate the shear bond strength in pounds per square inch by dividing the load in pounds by the interfacial area of the patch in square inches. Calculate the metric equivalent for shear bond strength in MPa by dividing the load in newtons by gravitational acceleration (9.81 m/s²). 5. Use Type IV, Type V and Type VI patching materials that have been evaluated by NTPEP, and received a subjective field rating of > 4 on an ascending scale from 1 to 5. 6. The Department will reject a patching system that meets all the requirements of this specification, but does not work as required in actual use. Section 934 — Rapid Setting Patching Materials for Portland Cement Concrete E. Materials Warranty Ensure that the material has a minimum storage life of at least 1 year under conditions of 40° to 90° F (4° to 32° C) and maximum relative humidity of 90 percent.