1039Polymer Products

1039.10.1 Scope. This specification covers epoxy resin to be used to bond plastic concrete or mortar to

hardened concrete or mortar.

1039.10.2 General Requirements. The epoxy shall be furnished as a system in accordance with the

requirements of ASTM C 881, Type II, Grade 2, Class B or C.

1039.10.3 Manufacturer and Brand Name Approval. Prior to approval and use of this material, the

manufacturer shall submit to Construction and Materials a certified test report showing specific test results from an independent laboratory in accordance with all requirements of these specifications. The certified test report shall contain the manufacturer's name, brand name of material, lot tested, date of manufacture and ratio of components. In addition, the manufacturer shall submit a one-quart sample of each component, A and B, for laboratory testing accompanied by a technical data sheet and an MSDS. With approval from the engineer of the certified test report and satisfactory results of tests performed on the sample submitted, the brand name and manufacturer will be placed on a qualified list of concrete bonding compounds. New certified test results and samples shall be submitted any time the manufacturing process or the material formulation is changed and may be required when random sampling and testing of material offered for use indicates nonconformity with any of the requirements herein specified.

1039.10.4 Acceptance. To obtain final acceptance of this material, the manufacturer shall furnish certification to

the engineer at the destination that the material supplied is in accordance with all requirements specified and stating that the material is the same system and is identically formulated to the material tested for manufacturer and brand name approval. SECTION 1039.20 TYPE III EPOXY.

1039.20.1 Scope. This specification covers epoxy to be used in the grouting of dry cracks, in epoxy mortar for

patching concrete and in epoxy mortar surface leveling.

1039.20.2 General Requirements. The epoxy shall be furnished as a system in accordance with the

requirements of ASTM C 881, Type III, Grade 1, Class B or C.

1039.20.3 Manufacturer and Brand Name Approval. Prior to approval and use of this material, the

manufacturer shall submit to Construction and Materials a certified test report showing specific test results from an independent laboratory in accordance with all requirements of these specifications. The certified test report shall contain the manufacturer's name, brand name of material, lot tested, date of manufacture and ratio of components. In addition, the manufacturer shall submit a one-quart sample of each component, A and B, for laboratory testing accompanied by a technical data sheet and an MSDS. With approval from the engineer of the certified test report and satisfactory results of tests performed on the sample submitted, the brand name and manufacturer will be placed on a qualified list of concrete bonding compounds. New certified test results and samples shall be submitted any time the manufacturing process or the material formulation is changed and may be required when random sampling and testing of material offered for use indicates nonconformity with any of the requirements herein specified.

1039.20.4 Acceptance. To obtain final acceptance of this material, the manufacturer shall furnish a certification

to the engineer at destination certifying that the material supplied is in accordance with all requirements specified and stating that the material is the same system and is identically formulated to the material tested for manufacturer and brand name approval. SECTION 1039.30 EPOXY OR POLYESTER BONDING AGENTS FOR DOWELS.

1039.30.1 Scope. This specification covers a multi-component epoxy or polyester bonding agent to be used in

anchoring epoxy coated dowel bars in concrete for pavement repair.

1039.30.2 General Requirements. Epoxy or polyester bonding agents for anchoring epoxy coated dowel bars

shall be furnished as a multi-component system. The system shall include automatic mixing, whether in cartridge or bulk form. The component ratios shall be shown on the label of each cartridge or bulk container.

1039.30.3 Properties. The epoxy or polyester bonding agent shall exhibit good bonding properties between the

epoxy coated dowel bar and the existing concrete and shall cure in accordance with the manufacturer’s recommendation. Bonding agents, when initially mixed, shall have a viscosity, which prevents flow from a horizontal hole. When tested in accordance with MoDOT Test Method TM 49, the minimum pull-out load shall be 8,100 pounds.

1039.30.4 Manufacturer and Brand Name Approval. Prior to approval and use of this material, the

manufacturer shall submit to Construction and Materials a certified test report from an independent laboratory showing specific test results in accordance with all requirements of this specification. The certified test report shall contain the manufacturer's name, brand name of material, lot tested, date of manufacture, ratio of components by volume and system tested. In addition, the manufacturer shall submit to Construction and Materials a sample representing the system for laboratory testing accompanied by a technical data sheet, an MSDS and any special installation instructions relative to the system being submitted, including recommended curing time. With approval from the engineer of the certified test report and satisfactory results of tests performed on the sample submitted, the brand name and manufacturer will be placed on a qualified list of bonding agents for dowels. New certified test results and samples shall be submitted any time the manufacturing process or the material formulation is changed and may be required when random sampling and testing of material offered for use indicates nonconformity with any of the requirements herein specified.

1039.30.5 Acceptance. To obtain final acceptance of this material, the manufacturer shall furnish certification to

the engineer at the destination that the material supplied is in accordance with all requirements specified and stating that the material supplied is the same system and is identically formulated to the material tested for manufacturer and brand name approval. SECTION 1039.40 EPOXY BONDING AGENTS FOR RESIN ANCHOR SYSTEMS.

1039.40.1 Scope. This specification covers a multi-component epoxy bonding agents to be used in anchoring

steel components in concrete for structures.

1039.40.2 General Requirements. The epoxy shall be furnished as a system in accordance with the

requirements of ASTM C 881, Type IV, and Grade 3 and as described herein. When a cartridge dispensing system is used the epoxy shall have a gel time as stated in ASTM C 881 paragraph 5.2. Epoxy bonding agents are not approved for sustained tension loads.

1039.40.3 Pull Test. The epoxy bonding agent shall exhibit good bonding properties between the anchored

product and the existing concrete and shall cure in less than 24 hours or manufacturer’s recommendation. For acceptance on the qualified list, Resin Anchor Systems shall be tested in accordance with ASTM E 488. The ultimate minimum pull-out load shall be in accordance with the following table when installed per manufacturer’s recommendation. Resin Anchor Systems shall also have a minimum strength of 9,000 lbs when tested in accordance with MoDOT Test Method TM-74. TM-74 testing will not be required if the Resin Anchor System has a current International Code Council Evaluation Service (ICC-ES) evaluation indicating the material complies with the latest edition of the International Building Code. Pull-Out Specification Requirements Diameter of Threaded Rod or Reinforcing Bar Minimum Ultimate Pullout Strength 1/2” 9,800 lbs 5/8” 15,500 lbs 3/4” 20,400 lbs 7/8” 27,500 lbs 1” 33,600 lbs

1039.40.4 Manufacturer and Brand Name Approval. Prior to approval and use of this material, the

manufacturer shall submit to Construction and Materials a certified test report from an independent laboratory showing specific test results in accordance with all requirements of this specification. The certified test report shall contain the manufacturer's name, brand name of material, lot tested, date of manufacture, bar or rod size tested, embedment depth and ratio of components. In addition, the manufacturer shall submit a one- quart sample of each component, A and B, for laboratory testing accompanied by a technical data sheet and a material safety data sheet. A copy of the current ICC-ES evaluation for the material shall be submitted to waive TM-74 testing. With approval from the engineer of the certified test report and satisfactory results of tests performed on the sample submitted, the brand name and manufacturer will be placed on a qualified list of Epoxy Bonding Agents for Resin Anchor Systems. New certified test results and samples shall be submitted any time the manufacturing process or the material formulation is changed and may be required when random sampling and testing of material offered for use indicates nonconformity with any of the requirements herein specified.

1039.40.5 Acceptance. To obtain final acceptance of this material, the manufacturer shall furnish certification to

the engineer at the destination that the material supplied is in accordance with all requirements specified and stating that the material is the same system and is identically formulated to the material tested for manufacturer and brand name approval. SECTION 1039.50 SAND FOR EPOXY MORTAR.

1039.50.1 Scope. This specification covers sand for use in epoxy mortar for the repairing of concrete surfaces.

The epoxy material used in epoxy mortar shall be Type III epoxy in accordance with Sec 1039.20.

1039.50.2 Properties. Sand for mortar shall be a quartzite sand, Ottawa sand or equal. The sand shall be clean

and dust free. The maximum moisture content shall be 2 percent. The gradation shall be in accordance with the following requirements: Gradation Requirements Sieve SizePercent Passing by Weight No. 16 100 No. 30 97-100 No. 50 5-35 No. 100 0-2 No. 200 0-0.4

1039.50.3 Acceptance. The manufacturer shall furnish certification to the engineer at the destination that the

material supplied is in accordance with all requirements of this specification. Acceptance will be based on certification and testing. SECTION 1039.60 EPOXY POLYMER WEARING SURFACE.

1039.60.1 Scope. This specification covers epoxy polymer and aggregate to be used for an epoxy polymer

wearing surface.

1039.60.2 Epoxy Polymer. The infrared spectrum for each component of the epoxy polymer shall essentially

match that of the standard infrared spectrum for the particular component as specified in AASHTO T 237, Sections 4 and 5. The epoxide equivalent for Component A shall not exceed 270. The mixed epoxy polymer shall meet the following requirements: Property Requirement Pot life (at75 F), minutes 10 to 55 Tensile Strength (at 75 F, 7 days), psi, min. 1500 Tensile elongation (at 75 F), percent, min. 20 Water Absorption, percent, max. 0.8 Compressive Strength (at 4 hr), psi, min. 1000 Compressive Strength (at 48 hr, wet), psi, min. 4000 Ash Content, percent, max 0.5 Rotational Viscosity, (at 75 F, spindle 3, 60 rpm), poise 7 to 25 Volatile Content, percent, max. 3.0 Thermal Shear (shearing, shrinkage, expansion or scaling)None

1039.60.2 1 Classes. Epoxy resin shall be formulated for use at specific temperatures as specified in ASTM C

881. The controlling temperature shall be that of the hardened concrete surface to which the polymer is applied. Where unusual curing rates are desired and upon the approval from the engineer, a class of epoxy resin may be used at a temperature other than that for which the epoxy resin is normally intended.

1039.60.2 2 Packaging. Containers shall be identified as "Component A--Contains Epoxy Resin" and

"Component B--Contains Hardener" and shall show the type, class and mixing directions. Each container shall be marked with the name of the manufacturer, class, batch, or lot number, date of packaging, date of shelf life expiration, pigmentation, if any, manufacturer, and the quantity contained in pounds and gallons.

1039.60.3 Aggregate. Aggregate shall be bauxite, crushed porphyry, aluminum oxide, flint chat or other

similarly hard, durable, dry aggregates with less than 0.2 percent moisture. Aggregate shall be in accordance with the following gradation: Sieve Size% Passing By Weight No. 4 100 No. 20 0-5 No. 200 0-1.0

1039.60.3 1 Lead Content. Aggregate produced as a by-product from lead or zinc mining operations shall not

have a total lead content greater than 4,500 ppm, as determined by EPA Method 3050A, “Acid Digestion of Sediments, Sludges and Soils. Suppliers of this aggregate shall provide certification to the engineer for each shipment that the total lead content of the aggregate does not exceed this value, and attach a typical test report from the same source no older than 12 months prior to the shipment.

1039.60.3 2 Aggregate Recommendation. For each contract, the epoxy polymer supplier shall supply a letter to

the engineer specifically recommending the use of a designated aggregate and source, which has been previously approved by Construction and Materials.

1039.60.4 Epoxy Polymer Performance. The epoxy polymer system shall not exhibit shearing, shrinkage,

expansion or scaling.

1039.60.5 Test Methods. Tests will be performed in accordance with the following methods:

Test Methods Rotational Viscosity ASTM C881 Epoxy Equivalent ASTM C881 and AASHTO T237 Volatile Content a ASTM D 1259, Method B, for mixed system Filler Content ASTM C881 Ash Content ASTM D 482 Pot Life AASHTO T 237 Tensile Strength ASTM D 638 Compressive StrengthASTM C 881 Water Absorption ASTM D 570 Thermal Shear ASTM C881 a Sample cured 4 days at room temperature and weighed on a previously weighed metal foil.

1039.60.6 Manufacturer and Brand Name Approval. Prior to approval and use of this material, the

manufacturer shall submit to Construction and Materials a certified test report showing specific test results in accordance with all requirements of this specification. The certified test report shall include the manufacturer's name, brand name of material, lot tested, date of manufacture, ratio of components by volume and system tested. In addition, the manufacturer shall submit to Construction and Materials a sample representing the system for laboratory testing accompanied by a technical data sheet, an MSDS and any special installation instructions relative to the system being submitted. Upon approval of the certified test report and satisfactory results of tests performed on the sample submitted, the brand name and manufacturer will be placed on a qualified list of epoxy resin material for epoxy polymer concrete wearing surface. New certified test results and samples shall be submitted any time the manufacturing process or the material formulation is changed and may be required when random sampling and testing of material offered for use indicates non-conformity with any of the requirements herein specified.

1039.60.7 Product History. The epoxy polymer shall have a proven record of a minimum of two years on

similar bridge decks within the United States. A list including the location, the name of the agency involved with the project, and a name and phone number of a contact person with that agency, shall be provided for each location used as evidence of satisfactory use.

1039.60.8 Acceptance. The manufacturer shall furnish certification to the engineer at the destination that the

material supplied is in accordance with all requirements specified and stating that the material supplied is the same system and is identically formulated to the material tested for manufacturer and brand name approval. Acceptance will be based on certification and testing. SECTION 1039.70 POLYMER CONCRETE.

1039.70.1 Scope. This specification covers polymer concrete consisting of a fast setting epoxy based solid that

may contain aggregate for use at bridge expansion joints.

1039.70.2 General Requirements. The polymer concrete shall be resilient, self-adhering, water tight and shall

withstand and remain bonded to the surrounding material under repeated impact and thermal cycling. The polymer concrete shall not flow or become tacky at temperatures up to 130 F, shall be resistant to ultraviolet radiation, petroleum products and abrasion, and shall be capable of curing at all temperatures above 50 F. Mixing and placement shall be in accordance with the manufacturer's recommendations.

1039.70.2 1 The combined liquid components with no aggregate added shall be in accordance with the

following requirements: Epoxy Requirements Property Specific Value Mixing Ratio, by Volume 1:1 Viscosity (ASTM D 2393), Poises, Spindle 2, 30 rpm, 25 C ± 2 C 9-20 Color Black Gel Time (AASHTO M-200-73), minutes 25-50 Elongation (ASTM D 638a), percent 45-55 Tensile Strength (ASTM D 638a), psi , min. 900 Shore D Hardness (ASTM D 2240), 77 F 45-75 a Test Method Type 1, Molded Specimens, 0.25 inches thickness

1039.70.2 2 The cured polymer concrete including aggregate, which shall be supplied by the manufacturer, shall

be in accordance with the following requirements: Polymer Concrete Requirements Property Specific Value Compression strength (ASTM C 579), psi min. at 24 hours2,500 Bond Shear Strength (ASTM C 882), psi 700 Abrasion Resistance (ASTM C 501), Wear Index (Taber H-22), max. 1.0 Compressive Stress (OK/OHD L-6), psi 350 Resilience (OK/OHD L-6), percent 70

1039.70.3 Manufacturer and Brand Name Approval. Prior to approval and use of this material, the

manufacturer shall submit to Construction and Materials a certified test report from an independent laboratory showing specific test results in accordance with all requirements of this specification. The certified test report shall contain the manufacturer's name, brand name of material, lot tested, date of manufacture and ratio of components. In addition, the manufacturer shall submit a one-quart sample of each component, A and B, for laboratory testing accompanied by a technical data sheet and a material safety data sheet. With approval from the engineer of the certified test report and satisfactory results of tests performed on the sample submitted, the brand name and manufacturer will be placed on a qualified list of polymer concretes. New certified test results and samples shall be submitted any time the manufacturing process or the material formulation is changed and may be required when random sampling and testing of material offered for use indicates nonconformity with any of the requirements herein specified.

1039.70.4 Acceptance. To obtain final acceptance of this material, the manufacturer shall furnish certification to

the engineer at destination certifying that the material supplied is in accordance with all requirements specified and stating that the material is identically formulated to the material tested for manufacturer and brand name approval. SECTION 1039.80 METHYL METHACRYLATE (MMA) POLYMER SLURRY WEARING SURFACE.

1039.80.1 Scope. This specification covers MMA primer, polymer slurry and top coat; and broadcast aggregate

to be used for a MMA polymer slurry wearing surface.

1039.80.2 Preapproved Product. The following material has been preapproved for use under this specification:

Transpo T-18 Thin Overlay and SterlingLloyd Bridgemaster.

1039.80.3 MMA Primer. The MMA primer shall be wax-free low odor and comply with the following

requirements: Property Requirement Test Method Viscosity, cps 50 to 70 ASTM D2393 Density, lb/gal 8 to 9 ASTM D2849 Pot Life (at 70 F), minutes 10 to 30 ASTM C881 Flash Point, F, min 43 ASTM D1310 Solids Content (w/catalyst), %, min. 100 ASTM D1644

1039.80.4 MMA Polymer Slurry. The MMA polymer slurry shall comply with the following requirements:

Property Requirement Test Method Elongation at Break, percent, min. 50 ASTM D 638 (Type 1) Tensile Strength (at 75 F), psi 500 to 900 ASTM D 638 Tensile Adhesion, psi, min. 250 ASTM C 1583 Water Absorption (at 24 hr), %, max. 0.8 ASTM D 570 Volatile Content, percent, max. 3.0 ASTM D 2369

1039.80.5 Broadcast Aggregate. Aggregate shall be in accordance with Sec 1039.60 unless otherwise specified.

Unless otherwise specified, aggregate shall be light-colored (i.e. flint rock or similar).

1039.80.5 1 All aggregates shall be furnished in appropriate packaging that is clearly labeled and protects the

aggregate from any contaminates on the jobsite and from exposure to rain or other moisture.

1039.80.6 MMA Top Coat. The MMA top coat shall comply with the following requirements:

Property Requirement Test Method Viscosity, cps 200 to 400 ASTM D 2393 Flash Point, F, min. 50 ASTM D 1310 SECTION 1039.90 POLYESTER POLYMER WEARING SURFACE.

1039.90.1 Scope. This specification covers MMA primer, polyester resin binder and aggregate to be used for a

polyester polymer wearing surface.

1039.90.2 Primer. The prepared surface shall receive a wax-free low odor, high molecular weight methacrylate

prime coat complying with the following requirements: Property Requirement Test Method Viscosity (Brookfield RVT w/UL adapter, 50 rpm at 77 F), Pa-s, max. 0.025 ASTM D 2196ª Specific Gravity (at 75 F), min. 0.90 ASTM D 1475ª Volatile Content, %, max. 30 ASTM D 2369ª Flash Point, F, min. 180 ASTM D 3278ª Vapor Pressure (at 77 F), mm Hg, max. 1.0 ASTM D 323ª Tack Free Time (at 77 F), minutes, max. 400 ASTMC 679 PCC Saturated Surface-Dry Bond Strength (24 hrs at 70 F +/- 1°), psi, min. 500 California Test 551 ªTested prior to adding initiator

1039.90.2 1 Mixing Requirements. The prime coat initiator shall consist of a metal drier and peroxide. If

supplied separately from the resin, at no time shall the metal drier be mixed directly with the peroxide.

1039.90.2 2 Storage. The containers shall be stored in a manner that will not allow leakage or spillage from one

material to contact the containers or materials of the other.

1039.90.3 Aggregates. The aggregates shall comply with Sec 1005, except as specified herein.

1039.90.3 1 Crushed Particles. Aggregate retained on the No. 8 sieve shall have a maximum of 45 percent

crushed particles as determined by AASHTO T 335.

1039.90.3 2 Absorption. The aggregate absorption shall not exceed one percent as determined by AASHTO T

85.

1039.90.3 3 Moisture Content. At the time of mixing with the resin, the moisture content of the aggregate, as

determined by AASHTO T 255, shall not exceed one half of the aggregate absorption.

1039.90.3 4 Temperature. The aggregate temperature shall be between 45 F and 100 F at the time of mixing.

1039.90.3 5 Combined Gradation. Aggregate for polyester polymer concrete shall comply with the following

requirements: Sieve Size1/2” Maximum % Passing by Weight3/8” Maximum % Passing by Weight ½” 100 100 3/8” 83 – 100 100 No. 4 65 – 82 62 – 85 No. 8 45 – 64 45 – 67 No. 16 27 – 48 29 – 50 No. 30 12 – 30 16 – 36 No. 50 6 – 17 5 – 20 No. 100 0 – 7 0 – 7 No. 200 0 - 3 0 - 3

1039.90.3 6 Fine Aggregate. The fine aggregate shall consist of natural sand.

1039.90.3 7 Finishing Sand. The sand for abrasive finish shall be commercial quality blast sand having at least

95 percent passing the No. 8 sieve and at least 95 percent retained on the No. 20 sieve when tested in accordance with AASHTO T 27. The absorption of the sand shall not exceed 1 percent when tested in accordance with AASHTO T 84.

1039.90.4 Polyester Resin Binder. The resin shall be an unsaturated isophthalic-styrene co-polymer

conforming to the following requirements: Property Requirement Test Method Viscosity (RVT, No. 1 Spindle, 20 rpm at 77 F), Pa-s 0.075 to 0.200 ASTM D 2196ª Specific Gravity (at 77 F) 1.05 to 1.10 ASTM D 1475ª Elongation (Type I at 0.45 inch/minute, thickness = 1/4" +/- 0.04), %, min. (Sampling Condition) 35 ASTM D 638 18h at 77 F & 50% RH + 5h at 158 F ASTM D 618 Tensile Strength (Type I at 0.45 inch/minute, thickness = 1/4" +/- 0.04), psi, min. (Sampling Condition) 2500 ASTM D 638 18h at 77 F & 50% RH + 5h at 158 F ASTM D 618 Styrene Content (by weight), % 40 to 50 ASTM D 2369ª Silane Coupler (by weight of polyester-styrene resin), %, min. 1.0 PCC Saturated Surface-Dry Bond Strength (24 hrs at 70 F +/- 1 F), psi, min. 500 California Test ª Tested prior to adding initiator

1039.90.4 1 Silane Coupler. The silane coupler shall be an organsilane ester,

gammamethacryloxpropyltrimethoxysilane.

1039.90.4 2 Hardener. The promoter/hardeners shall be compatible with suitable methyl ethyl ketone peroxide

(MEKP) and cumene hydroperoxide (CHP) initiators. MEKP initiators shall be used when the surrounding concrete temperatures are above 60 F. A blend of initiators may be used as approved by the engineer when the surrounding concrete temperature is 50 – 60 F.