623Polymer Products

623.10.1 Description. This work shall consist of preparing the surface, furnishing and applying the concrete

bonding compound to be used to bond plastic concrete mortar to hardened concrete as shown on the plans or as directed by the engineer.

623.10.2 Material. All material shall be in accordance with Division 1000, Material Details, and specifically as

follows: Item Section Type II Epoxy 1039

623.10.3 Construction Requirements.

623.10.3 1 Surface Preparation. The surface of the hardened concrete to which the plastic concrete mortar is to

be bonded shall be surface dry and thoroughly cleaned such that all loose and unsound concrete is removed prior to application of the bonding agent.

623.10.3 2 Application. The bonding agent shall be applied when both the air and surface temperature is within

the manufacturer’s written recommendations.

623.10.3 2.1 Components shall be mixed in accordance with manufacturer’s written recommendations. The

components may be warmed with indirect heat to a maximum temperature of 100 F to reduce the viscosity. No solvents shall be added to the compound.

623.10.3 2.2 The mixed bonding agent shall be applied in such a manner as to thoroughly work the bonding

compound into the hardened concrete surface. The thickness of the application shall be 20 to 25 mils. If the concrete absorbs the bonding agent, additional coats shall be applied until the correct thickness is attained.

623.10.3 2.3 The plastic concrete mortar shall be placed while the bonding agent is still tacky. If there is a delay

in placing the plastic concrete mortar and the bonding agent becomes tack free, another coat of bonding agent shall be applied.

623.10.4 Basis of Payment. No direct payment will be made for furnishing material, surface preparation or

application. SECTION 623.20 EPOXY MORTAR.

623.20.1 Description. This work shall consist of preparing the surface, furnishing and applying epoxy mortar as

shown on the plans.

623.20.2 Material. All material shall be in accordance with Division 1000, Material Details, and specifically as

follows: Item Section Type III Epoxy 1039 Sand for Epoxy Mortar 1039

623.20.3 Construction Requirements.

623.20.3 1 Surface Preparation. The surfaces to which the epoxy mortar is to be applied shall be free of dust,

water or any other material that may affect the adhesion.

623.20.3 2 Application. The epoxy mortar shall be prepared and placed when the weather is dry and the air

temperature is in accordance with the manufacturer’s written recommendations.

623.20.3 2.1 The contractor shall mix only the number of containers of material that can be placed in 20 to 40

minutes.

623.20.3 2.2 Epoxy shall be thoroughly mixed in accordance with the manufacturer’s written recommendations.

Mixing shall continue as permitted to ensure uniformity.

623.20.3 2.3 When the epoxy material has been thoroughly mixed, sand shall be added at the manufacturer’s

recommended rate while mixing continues. After the proper quantity of sand has been added, mixing shall continue until the mixture is uniform.

623.20.3 2.4 Areas to be patched or leveled shall be thoroughly primed with an application of neat epoxy. After

the area is primed, the mortar shall be placed and struck off to grade. The surface shall have a rough finish equal to that of a Portland cement concrete deck.

623.20.3 2.5 The patched or leveled area shall be protected during the curing period to prevent damage. Material

shall be cured in accordance with the manufacturer’s written recommendations. Curing acceleration by direct flame application will not be permitted.

623.20.4 Basis of Payment. No direct payment will be made for furnishing material, surface preparation or

application. SECTION 623.30 EPOXY POLYMER WEARING SURFACE.

623.30.1 Description. This work shall consist of constructing an epoxy polymer wearing surface on a prepared

surface in accordance with this specification, as shown on the plans or as directed by the engineer. Epoxy polymer wearing surface shall be composed of the following components - prime coat and two courses of epoxy polymer and aggregate.

623.30.2 Material. All material shall be in accordance with Division 1000, Material Details, and specifically as

follows: Item Section Epoxy Polymer Wearing Surface 1039

623.30.3 Construction Requirements.

623.30.3 1 Manufacturer Representation. The wearing surface manufacturer's representative shall witness the

entire testing phase of each field test. The manufacturer's representative shall verify that all operations are performed by acceptable practices.

623.30.3 2 Handling and Storage of Material. Handling and storage of material shall be in accordance with

the manufacturer’s written recommendations.

623.30.3 3 Field Test. Prior to the start of the wearing surface operation, a test area of the complete wearing

surface system shall be placed on the bridge deck in a contractor proposed location that is approved by the engineer. When multiple bridges are included in a project, a test area will be required on each bridge. The contractor may utilize one-half of the bridge deck or an area equal to one day's placement operation, whichever is smaller, as a field test. The degree of cleaning used on the test area shall be the minimum used on the remainder of the structure. The surface for the test wearing surface shall be prepared in accordance with the test method prescribed in ACI 503R - Appendix A of the ACI Manual of Concrete Practice to establish an approved cleaning practice. The approved cleaning practice shall remove all potentially detrimental material which may interfere with the bonding or curing of the wearing surface. Concrete shall be sound, with mortar soundly bonded to the coarse aggregate, with clean and open pores to be considered adequate for bond. All areas of asphalt and pavement markings shall be removed. Preparation of the surface shall produce a surface relief equal to International Concrete Repair Institute (ICRI) surface preparation level 6 or 7 or ASTM E 965 pavement macrotexture depth of 0.04 to 0.08 inch.

623.30.3 3.1 Visible moisture on the prepared deck at the time of placing the wearing surface will not be

permitted. Moisture in the deck shall be checked by taping a plastic sheet to the deck for a minimum of 2 hours in accordance with ASTM D4263.

623.30.3 3.2 In addition to the above requirements, the cleaning practice shall provide an adhesion strength test

result greater than 250 psi or a failure area into the base concrete that is greater than 50 percent of the test area. After the test area has cured for a minimum of 72 hours, adhesion shall be checked in accordance with ACI 503R. A test result will be the average of three tests on a sample area of the test patch. A minimum of three sample areas per test patch shall be tested. Successful test results will be required from each sample area.

623.30.3 3.3 If the test of a sample area fails to meet the above requirements due to a cohesive failure of the

substrate concrete, the adhesive strength of the sample area will be considered acceptable.

623.30.3 3.4 Successful completion of the adhesion strength tests will be required before the full-scale wearing

surface operation is to begin. All cleaning operations shall equal those used for the adhesion strength test areas, in both profile and cleanliness. If changes are made to the established cleaning practice, new adhesion strength testing shall be performed at the contractor’s expense.

623.30.3 3.5 Test patches shall be installed with the same material, equipment, personnel, timing, sequence of

operations and curing period that will be used for the installation of the wearing surface.

623.30.3 3.6 If the test fails, the contractor shall remove the material represented by the failed test patches and

provide another test patch, at the contractor’s expense, until satisfactory test results are obtained.

623.30.3 4 Surface Preparation. Before placement of the wearing surface, the entire deck surface shall be

prepared by the cleaning practice established in the field adhesion strength tests in accordance with Sec

623.30.3 3 by shot blast method. Sand blasting will not be permitted. Clean-up and disposal of blast material

shall be in accordance with Sec 202.3.1.3.

623.30.3 4.1 If the engineer determines that the weather has changed significantly since the application of the

field test patch, the contractor shall verify through adhesion strength tests that the practice is acceptable, at the contractor’s expense.

623.30.3 4.2 No traffic of any kind shall be permitted on any portion of the deck which has been shot blasted or

on the wearing surface without approval from the engineer. The time between surface preparation and application of the first course shall not exceed 24 hours.

623.30.3 4.3 All patching and cleaning operations shall be inspected and approved prior to placing the wearing

surface.

623.30.3 4.4 If the deck or intermediate course is contaminated by foreign material or water after initial

cleaning, the contamination and any detrimentally affected wearing surface material shall be removed. Both courses shall be applied prior to opening the area to traffic.

623.30.3 5 Equipment. The contractor's equipment shall be as recommended by the epoxy manufacturer.

623.30.3 6 Epoxy Mixing. Mixing of epoxy polymer components shall be in accordance with the

manufacturer's recommendations, except that the use of a volumetric mixer will be required. When mineral fillers are specified, the mineral fillers shall be inert and non-settling or readily dispersible. Material showing a permanent increase in viscosity or the settling of pigments that cannot be readily dispersed with a paddle shall be replaced at the contractor's expense. At least 95 percent of the filler shall pass the No. 200 sieve.

623.30.3 7 Application. Application of epoxy polymer shall be performed by the manufacturer or by a factory

trained or licensed applicator with written approval from the manufacturer of the epoxy system.

623.30.3 7.1 The handling and mixing of epoxy polymer shall be in accordance with the manufacturer's written

recommendations. The epoxy polymer shall not be placed when weather or surface conditions are such that the material cannot be properly handled, placed and cured within the specified requirements of traffic control, or when rain is forecasted within 24 hours of application.

623.30.3 7.2 The wearing surface shall consist of a two-course application of epoxy polymer and aggregate. A

prime coat shall be used if recommended by the manufacturer. Each of the two courses shall consist of a layer of epoxy polymer covered with a layer of aggregate in sufficient quantity to completely cover the epoxy polymer. The thickness of each course shall be approximately equal. The total thickness of the wearing surface shall be no less than 1/4 inch.

623.30.3 7.3 The temperature of the bridge deck surface at the time of application shall be less than 90 F and in

accordance with the manufacturer’s recommendation.

623.30.3 7.4 Dry aggregate shall be applied in such a manner as to cover the epoxy polymer completely within 5

minutes of application. The dry aggregate shall be placed in a manner such that the level of the epoxy polymer is not disturbed.

623.30.3 7.5 The first course shall be swept to remove loose aggregate prior to the second course application.

Sweeping shall be done without removing embedded aggregate. First course applications which do not receive enough aggregate prior to gelling shall be removed and replaced. A second course applied with insufficient aggregate may be left in place, but additional applications shall be placed at the contractor’s expense before opening to traffic.

623.30.3 7.6 The thickness of the wearing surface shall be verified to be at least 1/4-inch, measured from the

deck surface to the top of the epoxy polymer. The contractor shall provide a minimum 1/2-inch diameter hole at a rate of at least one hole per 100 feet of traffic lane. Hole placement shall be at locations designated by the engineer. Thin areas shall be recoated and reverified at the contractor’s expense.

623.30.3 7.7 When additional applications or recoating are required, the engineer may require additional

adhesion strength tests by the contractor, at the contractor’s expense, in accordance with ACI 503R to verify the contractor's procedure.

623.30.3 7.8 All adhesion strength test areas, thickness test holes or any debonded areas shall be repaired by

filling with wearing surface material before final acceptance.

623.30.3 7.9 The first epoxy polymer course shall be cured at least one hour, or until brooming or vacuuming

can be performed without tearing or otherwise damaging the surface. No traffic or equipment shall be permitted on the first course surface during the curing period.

623.30.3 7.10 After the curing period, all loose aggregate shall be removed by brooming or vacuuming and the

next epoxy polymer course applied as specified in the contract documents.

623.30.3 7.11 The epoxy polymer mixture shall not be permitted to run into drains.

623.30.3 7.12 Unless otherwise specified, the epoxy polymer courses shall be applied over the expansion joints

and joint seals of the bridge deck. The expansion joints and joint seals shall be provided with a bond breaker. Prior to opening to traffic, the wearing surface shall be removed over each joint by removal of the bond breaker in accordance with the epoxy polymer manufacturer’s recommendations.

623.30.3 7.13 Prior to opening a section to public or construction traffic, the wearing surface shall be allowed to

cure in accordance with the manufacturer’s recommendations. First course applications shall not be opened to traffic.

623.30.3 7.14 Damaged or debonded areas of an epoxy polymer course shall be removed and repaired prior to

acceptance. Repair shall consist of saw-cutting in rectangular sections to the top of the concrete deck surface and replacing the various courses in accordance with this specification at the contractor’s expense.

623.30.4 Method of Measurement. Final measurement will not be made except for authorized changes during

construction or where appreciable errors are found in the contract quantity. Where required, the area of epoxy polymer wearing surface will be measured to the nearest square yard based on measurement longitudinally from end to end of bridge deck and transversely between roadway face of curbs, excluding the area of any expansion devices. The revision or correction will be computed and added to or deducted from the contract quantity.

623.30.5 Basis of Payment. The accepted quantity of epoxy polymer wearing surface will be paid for at the

contract unit price. Payment will be considered full compensation for all labor, equipment and material necessary to complete the described work SECTION 623.40 POLYMER CONCRETE.

623.40.1 Description. This work shall consist of furnishing and placing polymer concrete as shown on the plans

or as directed by the engineer.

623.40.2 Manufacturer Representation. The manufacturer's representative shall be present at the start of

surface preparations and polymer concrete installation for at least one day. The contractor shall furnish the manufacturer's recommendations to the engineer as to the acceptability of all aspects of the operation. The contractor shall contact the manufacturer’s representative at least two weeks prior to installation.

623.40.3 Material. All material shall be in accordance with Division 1000, Material Details, and specifically as

follows: Item Section Polymer Concrete 1039

623.40.4 Construction Requirements.

623.40.4 1 Equipment. The contractor's equipment shall be in accordance with the manufacturer’s

recommendations.

623.40.4 2 Surface Preparation. Portland cement concrete shall be allowed to cure and dry for a minimum of

seven dry days prior to installing the polymer concrete. Days with cold, wet or inclement weather which may be a detriment to curing of the Portland cement concrete will not count in this seven day minimum curing and drying time. The concrete surface shall be dry when placing the polymer concrete. The substrate shall be structurally sound and sand or shot blasted to be free of all foreign matter, grease, dirt and laitance for all areas that will be in contact with the polymer concrete. Steel surfaces shall be cleaned in accordance with SSPC-SP 10 surface preparation requirements. Clean-up and disposal of blast material shall be in accordance with Sec 202.3.1.3. After sand or shot blasting is completed, the joint shall be cleaned of debris by using oil and water free compressed air at a minimum of 90 psi or by vacuuming. These areas shall then be primed in accordance with the manufacturer’s recommendations.

623.40.4 3 Placement. The polymer concrete shall be mixed, placed and cured in accordance with the

manufacturer's recommendations and as shown on the plans. Before opening to traffic, the material shall be tack free and fully cured as determined by the engineer.

623.40.5 Method of Measurement. Final measurement will not be made except for authorized changes during

construction or where appreciable errors are found in the contract quantity. Where required, the volume of polymer concrete will be measured to the nearest 1.0 cubic feet of accepted, in-place polymer concrete. The revision or correction will be computed and added to or deducted from the contract quantity.

623.40.6 Basis of Payment. The accepted quantity of polymer concrete will be paid for at the contract unit

price. SECTION 623.50 Methyl Methacrylate Polymer Slurry Wearing Surface.

623.50.1 Description. This work shall consist of constructing a methyl methacrylate (MMA) polymer slurry

wearing surface on a prepared surface in accordance with this specification as shown on the plans or as directed by the engineer. MMA polymer slurry wearing surface shall be composed of the following components – MMA primer; MMA polymer slurry; broadcast aggregate; and MMA top coat.

623.50.2 Material. All material shall be in accordance with Division 1000, Material Details, and specifically as

follows: Item Section MMA Polymer Slurry Wearing Surface 1039

623.50.2 1 Mixing and Application. Mixing and application shall be done in accordance with the

manufacturer’s recommendations.

623.50.2 2 Delivery of Material. All material shall be delivered in their original containers bearing the

manufacturer’s label, specifying date of manufacturing, batch number, trade name, and quantity. Each shipment shall be accompanied by a MSDS.

623.50.2 3 Storage of Material. The material shall be stored to prevent damage by the elements and to ensure

the preservation of their quality and fitness for the work. The containers shall be stored in a manner that will not allow leakage or spillage from one material to contact the containers or material of the other. The storage space shall keep the material clean and dry and shall contain a high-low thermometer. The temperatures of the storage space shall not fall below nor rise above that recommended by the manufacturer. Every precaution shall be taken to avoid contact with flame.

623.50.2 3.1 Stored material shall be inspected prior to their use and shall meet the requirements of this

specification at the time of use.

623.50.2 3.2 Sufficient material to perform the entire MMA polymer slurry wearing surface application shall be

in storage at the site prior to any field application, so that there shall be no delay in procuring the material for each day’s application.

623.50.2 4 Training. The contractor shall arrange to have the material supplier furnish technical service related

to application of material and health and safety training for personnel who are to handle the material.

623.50.2 5 Technical Support. The material supplier shall have a representative onsite during the surface

preparation and placement of the wearing surface. The material representative shall provide onsite consultation as Quality Control of the installation of the product, but the engineer will have final decision-making authority in all matters.

623.50.3 Preconstruction Requirements.

623.50.3 1 Experience. The contractor shall have experience placing similar thin polymer wearing surfaces on

at least three structures prior to doing work on this project. Written proof of this experience along with project contacts shall be provided to the engineer in writing for approval prior to the preconstruction meeting. Prior to installation of the wearing surface, the contractor shall also provide certification by the material supplier that the contractor is a trained and qualified installer of the selected wearing surface.

623.50.3 2 Mix and Application Procedure. The contractor shall prepare and submit all applicable mixing and

application procedures to the engineer for approval prior to the preconstruction meeting. The contractor shall not begin ordering materials for application of the wearing surface until the mixing and application procedures are approved. All equipment and materials used in the mixing and application procedure shall be in accordance with the manufacturer’s requirements.

623.50.4 Construction.

623.50.4 1 Trial Area. The contractor shall demonstrate their proficiency by preparing and placing the wearing

surface on a 10-foot by 10-foot area (or approved equivalent area) prior to the placement of the production wearing surface. The engineer shall select the location of the trial area. Final wearing surface production shall not proceed without the approval of the engineer.

623.50.4 2 Deck Preparation.

623.50.4 2.1 Procedure. The contractor shall submit in writing to the engineer for approval the deck preparation

procedure. The contractor’s procedure shall include, but not be limited to; equipment used for surface preparation and deck cleaning, shot size, rate of speed to achieve required profile and method of surface profile testing for Quality Control.

623.50.4 2.2 Existing Wearing Surface. On existing concrete decks with an existing wearing surface, the

wearing surface shall be removed and the exposed concrete surface shall be prepared in accordance with Sec

623.50.4 2.4.

623.50.4 2.3 Unsound Deck. Any areas of unsound deck encountered shall be completely removed to sound,

natural concrete. Polymer concrete or other patching material, approved by the engineer, may be used to repair the deck. Surfaces of concrete patches shall be prepared in the same manner as the rest of the deck. Any new concrete or concrete patches shall cure a minimum of 28 days prior to application of overlay system. All deck repairs shall be in accordance with Sec 704.

623.50.4 2.4 Surface Preparation. The concrete surface shall be prepared in accordance with Sec 623.30.3.4 by

shot blast method, except as specified herein.

623.50.4 2.4.1 The contractor shall remove pavement marking and other surface contaminants. Upon approval

by the engineer, scarifiers or hand grinders may be used to aid in the removal of pavement marking and other surface contaminants but shot blast will still be required for final acceptable surface preparation.

623.50.4 2.4.2 The contractor shall remove residual bituminous based crack sealer and any debris from the

entire deck including: within cracks, pop-outs or other deck irregularities, tining grooves, deck grooves, gutter lines or any other areas that have trapped material. Removal shall be to the satisfaction of the engineer. The contractor shall be responsible to make note of the deck conditions prior to bidding.

623.50.4 2.5 Reflective Cracks. Reflective cracks in the deck shall be prepared if specified on the plans. The

deck shall be blasted to clean out cracks and be dry prior to priming. Before starting priming operations, all cracks shall be blown out with dry high-pressure air.

623.50.4 2.5.1 Reflective cracks or any open cracks greater than 0.06 inch shall be treated to keep the primer

material from leaking through the joints of the deck panels below.

623.50.4 2.5.2 All panel deck joints below open deck cracks greater than 0.06 inch shall be identified, mapped

and sealed from below at the panel joints with a material resistant to effects of the deck primer to prevent leakage of the deck primer through the bridge deck.

623.50.4 2.5.3 After sealing of the required deck panel joints from below, deck cracks above greater than 0.06

inch shall be prefilled with deck primer.

623.50.4 2.5.4 After cracks greater than 0.06 inch are prefilled, a flood primer application shall be done to the

concrete surface to fill all other smaller and fine cracks.

623.50.4 3 Application of Wearing Surface.

623.50.4 3.1 General. The primer, slurry or top coat shall not be permitted to run into drains. Unless otherwise

specified, the wearing surface shall not be applied over the expansion joints and joint seals of the bridge deck. Prior to opening a section to public or construction traffic, the wearing surface shall be allowed to cure in accordance with the manufacturer’s recommendations. Surfaces with primer only shall not be opened to traffic. During primer, slurry and top coat applications; the contractor shall provide neat clean lines for staging, joints, obstacles or any break in production.

623.50.4 3.1.1 The wearing surface shall not be placed when the relative humidity is above 90 percent. If placed

at night, care should be taken that the relative humidity does not rise rapidly with falling temperatures.

623.50.4 3.2 Prime Coat. One coat of the MMA primer coat shall be applied to the prepared concrete surfaces

immediately before placing the MMA polymer slurry in accordance with the manufacturers recommended procedures. The prime coat shall be uniformly applied to completely cover the surface to receive the MMA polymer slurry. The area receiving the prime coat shall be dry and had no exposure to any moisture within the past 24 hours. Prior to applying the prime coat, the surface shall be cleaned with compressed air to remove accumulated dust and any other loose material. Do not allow traffic on the prepared surface prior to wearing surface placemen.

623.50.4 3.2.1 The concrete bridge deck surface shall be between 45 F and 90 F when applying the prime coat.

623.50.4 3.2.2 If the primed surface becomes contaminated, the contaminated area shall be cleaned by abrasive

blasting and re-primed at no additional expense to the Commission.

623.50.4 3.3 MMA Polymer Slurry. The MMA polymer slurry shall be placed on the prime coat according to

the manufacturer’s recommendations, but no later than two hours after placing the prime coat.

623.50.4 3.3.1 The surface temperature of the area to receive the MMA polymer slurry shall be the same as

specified in Sec 623.50.4.3.2.1 or as approved by the manufacturer’s representative.

623.50.4 3.3.2 The contractor shall prevent any cleaning chemicals from reaching the MMA polymer slurry

components during the mixing operation.

623.50.4 3.3.3 The MMA polymer slurry shall be placed at a minimum thickness of 1/4 inch and a maximum of

3/8 inch.

623.50.4 3.4 Broadcast Aggregate. Dry aggregate shall be applied in such a manner as to cover the MMA

polymer slurry completely within 5 minutes of application prior to the gelling of the MMA polymer slurry. The dry aggregate shall be placed in a manner such that the level of the MMA polymer slurry is not disturbed.

623.50.4 3.4.1 After the MMA polymer slurry curing period, all loose aggregate shall be removed by brooming

or vacuuming. Any loose aggregate reclaimed for reuse as broadcast aggregate shall be approved by the engineer. At a minimum the reclaimed aggregate shall be screened and verified to be clean, uncontaminated and dry. All reclaimed aggregate must be in conformance with the requirements in Sec 623.50.2.

623.50.4 3.5 Top Coat. The surface should be dry and the top coat should not be allowed to puddle. Top coat

shall be placed no later than two hours after the slurry has cured. During the course of work, the contractor shall ensure the top coat is applied to all wearing surface areas prior to any forecasted rain events.

623.50.4 4 Testing. Bond testing shall be performed for each bridge placement per stage on each day. Testing

will be conducted at three locations 24 hours after placement. Testing will be performed in accordance to ASTM C 1583. A passing test is the failure of the concrete substrate or bond strength above 250 psi. Do not perform tests if the deck temperature is above 90 F.

623.50.4 4.1 All adhesion strength test areas, thickness test holes or any debonded areas shall be repaired by

filling with wearing surface material before final acceptance.

623.50.4 4.2 Any material which is rejected because of failure to meet the required tests or has been damaged so

as to cause rejection shall be immediately replaced at the contractor’s expense.

623.50.4 4.3 Damaged or debonded areas of the wearing surface shall be removed and repaired prior to

acceptance. Repair shall consist of saw-cutting in rectangular sections to the top of the concrete deck surface and repairing using the same procedure called for in the specification. All repairs shall be at the contractor’s expense.

623.50.5 Method of Measurement. Final measurement will not be made except for authorized changes during

construction or where appreciable errors are found in the contract quantity. Where required, the area of MMA polymer slurry wearing surface will be measured to the nearest square yard based on measurement longitudinally from end to end of bridge deck and transversely between roadway face of curbs, excluding the area of any expansion devices. The revision or correction will be computed and added to or deducted from the contract quantity.

623.50.6 Basis of Payment. The accepted quantity of MMA polymer slurry wearing surface will be paid for at

the contract unit price. Payment will be considered full compensation for all labor, equipment and material necessary to complete the described work.