00556.10 515 Section 00556 - Multi -Layer Polymer Concrete Overlay
Description
00556.00Scope - This Work consists of sealing and resurfacing bridge decks with a multi -layer
polymer concrete overlay (MPCO).
00556.03Submittals - At least 21 Calendar Days before the pre-placement conference, provide the
following information to the Engineer for approval:
A manufacturer's safety data sheet for each MPCO component. Manufacture dates and shelf -life expiration dates for each production lot of primer/sealer and polymer components. Tabulated data indicating the estimated cure time, in minutes, for the allowable ambient temperature range, in increments of 10 °F. A detailed work plan for the MPCO preparation, application, and cleanup. Include estimated dates and timeframes. Equipment information according to 00556.20. Personnel Qualifications according to 00556.30. An inclement weather plan according to 00556.04.
00556.04Inclement Weather Plan - Submit an inclement weather plan when application conditions
of 00556.40(b) are not met. The inclement weather plan includes all Materials, Equipment, and methods to be used to heat the substrate, Aggregate, and resi n. If concrete moisture content or capillary moisture is to be tested, provide Equipment information and calibration certificates.
00556.05Pre -placement Conferences:
Subcontractors, Suppliers, MPCO manufacturer and other personnel who will be involved in the overlay Work . Meet at a mutually agreed time approximately 2 weeks in advance of the Work . Present and discuss all phases of the overlay Work .
overlay Work crew at the Project Site 1/2 hour before overlay Work begins to discuss placement duties and procedures. Do not begin the overlay Work until this meeting is held.
Materials
00556.10Materials - Furnish Materials meeting the following requirements:
Resin shall meet the requirements of ASTM C881, Type III.
00556.20 516 (b) Multi -Layer Polymer Concrete Overlay Aggregate - Furnish MPCO Aggregate from the QPL.
Sample the furnished Aggregate and test according to the following: Property Test Method Requirements Moisture Content * AASHTO T 255 0.20% max. Moisture Content ** AASHTO T 255 1.00% max.
* At time of A ggregate production. ** Field test at time of mixing the polymer resin.
Equipment
00556.20Equipment - Provide approved Equipment to place the MPCO. Remove all Equipment
that leaks oil or other contaminants from the w ork area until they are repaired.
00556.21Miscellaneous Equipment :
the polymer resin.
Furnish a power broadcaster to uniformly apply the MPCO Aggregate.
Furnish pickup type power brooms capable of removing loose Aggregate.
in diameter.
• Meets the requirements of ASTM D4541 Type V Is compatible with the core tested. • Can exert a tensile load to the core sufficient to exceed 300 psi. • Is equipped with a measuring device capable of reading tensile force exerted within 1 percent accuracy.
between 65 °F and 85 °F.
Aggregate to a minimum of 70 °F as measured at the time of placement.
Equipment that:
Can apply indirect heat to ensure that the entire completed membrane will meet the bond test requirements of 00556.43. Can maintain a minimum temperature of 70 °F within the heated area and does not exceed 110 °F. Will not segregate, shove, tear or gouge the MPCO system.
00556.40 517 (g) Concrete Moisture Meter - Furnish a pin-type, instant read, concrete moisture meter meeting ASTM F2659. Provide current calibration documentation.
Measures deck sur face temperature accurate to ± 1 °F Measures ambient temperature and dew point accurate to ± 1 °F
Labor
00556.30Personnel Qualifications - Provide employees meeting the following requirements:
• Workers that are certified, in writing, by the MPCO manuf acturer that they are qualified to place the MPCO. • A MPCO manufacturer technical representative that is experienced in MPCO application and mix designs.
The MPCO manufacturer technical representative duties include:
• Be present at both pre-placement conferences. • Be at the Project Site and verify deck surface preparation quality control activities . • Be at the Project Site during overlay placements and monitor the placement for MPCO quality control activities .
Construction
00556.40Construction :
perform the installation and required repairs, and qualified personnel are at the Project Site. Prepare the entire deck surface, including the deck edge against t he curb, to receive the MPCO. Remove all grease, oil, paint, dirt, laitance, rust, and all other contaminants that would affect adhesion of the MPCO.
conditions are met:
The deck surface has been vi sually dry for at least 72 hours. The ambient temperature and deck surf ace temperature are between 50 °F and 90 °F, or as specified by the resin manufacturer’s product data sheet, whichever is more restrictive. The deck sur face temperature is at least 5 °F above the dew point. No rain is forecasted for the duration of the estimated MPCO cure time, based on ambient and surface temperatures.
prepared surfaces when the following conditions are met:
If the dec k has been dry for less than 72 hours, mechanically heat the deck to a minimum of 300 °F and a maximum temperature of 350 °F. Perform one of the following tests after applying heat: • Test for capillary moisture using the plastic sheet method, according to ASTM D4263, with a minimum test time of 2 hours. Perform one test per 500 square feet. 00556.41 518 • Test for concrete moisture content using a pin-t ype moisture meter according to 00556.21(g). Maximum allowable deck moisture content is 4 percent. Perform number of tests and locations according to ASTM F2659, with a minimum of eight tests per primer placement. Test additional locations as directed by the Engineer. The ambient temperature and deck surface temperature are between 40 °F and 90 °F. If the temperature falls, or is forecasted to fall below 50 °F perform the following: • Pre-heat the Aggregate to a minimum of 70 °F. • Heat the MPCO to a minimum of 70 °F to facilitate curing. Do not exceed 110 °F on the MPCO surface. The deck surface temperature is at least 3 °F and rising above the dew point. No rain is forecasted for the duration of the estimated MPCO cure time, based on ambient and surface tem peratures. Do not place MPCO when temperatures are below 40 °F.
the deck surface or MPCO Material. When the deck surface is mechanically heated, do not proceed with Work until the surface temperature is less than 90 °F.
00556.41Surface Preparation : Prepare all surfaces that are to be in contact with the MPCO
according to Section 00504. Block out interior expansion joints with rigid polyethylene foam or other approved Material and place MPCO over joints.
00556.42Placing Multi -Layer Polymer Concrete Overlay:
as recommended by the manufacturer.
MPCO according to the approved submittals and meeting the requirement of 00556.40(b).
After each Lift , before gelling of the polymer resin occurs, broadcast a layer of Aggregate at a rate of 1-2 pounds of Aggregate per square foot , as required to achieve refusal with no visible wet spots.
For each Lift , sweep the entire deck surface after the polymer has cured and remove all loose material.
Feather the MPCO to the end bridge joints located at approach slabs. Sawcut interior joints to allow for expansion joint installation prior to opening to traffic .
If application of the MPCO surface does not meet the requirements of the approve d submittals in 00556.03, stop the operation until revised methods, changes in Equipment , or correction of procedures are proposed and approved.
curing time and temperature chart before subjecting it to loads or traffic. Only allow traffic on portions of the MPCO with the final L ift complete and fully cured.
00556.80 519 Heating MPCO Materials to facilitate cure and decrease cure times ma y be performed, at no additional cost to the Agency, when application conditions of 00556.40(b) are met and heating is performed according to 00556 .40(d).
00556.43Bond Strength Test - Perform at least two bond tests for each Day of placement in the
presence of and at locations designated by the Engineer. Test the bond strength within 48 hours after placing the MPCO overlay. Cut 2 inch to 3 inch diameter cores from in -place MPCO at least 1/2 inch into concrete substrate and conduct bond tests on the cores. Test according to ASTM D4541, Method “E”, using Type “V” tester. The bond test consists of:
Coring through the MPCO overlay and approximately 1/2 inch into the existing concrete. Attaching a 50 mm (2 -inch) test dollie to the top of the core. Exerting a tensile load to the core sufficient to cause failure or achieve 300 psi, whichever occurs first. Avoid taking cores in the wheel tracks.
Perform bond tests when the deck surface temperature is less than 80 °F.
A successful test i s the failure of the concrete substrate or bond failure at or above 250 psi. After coring and testing, restore the area voided by the cores by blowing with compressed air and filling with MPCO Material.
00556.44Delamination Survey and Repair - Perform a deck delamination survey, in the presence
of the Engineer, using chain drag, coring, or other approved methods. If directed by the Engineer, perform additional bond tests according to 00556.43, at locations directed.
Repair all delaminated areas of 1 s quare foot or greater. Delaminated areas of less than 1 square foot will not require repair. Repair limits to be approved by the Engineer. Repair to the satisfaction of the Engineer at no additional cost to the Agency. Make all repairs before opening to traffic or, if the resurfaced area is opened to traffic at the Contractor's request before completing repairs, all additional traffic control to complete the repairs will be at no additional cost to the Agency.
00556.45Use of New Surface :
is complete according to 00556.42( d).
traffic, re move all loose Aggregate by power brooming and open all drains.
Measurement
00556.80Measurement - The quantities of Work performed under this Section will be measured
according to the following:
• Furnish MPCO Material and Constructing MPCO - Furnishin g and constructing multi -layer polymer concrete overlay will each be measured on the area basis. The area will be determined by measuring the actual surface area of the resurfaced bridge deck.
00556.90 520 Payment
00556.90Payment - The accepted quantities of Work performed under this Section will be paid at
the Contract unit price, per unit of measurement, for the following items:
Pay Item Unit of Measurement
Payment will be payment in full for furnishing and placing all Materials, and for furnishing all Equipment , labor, and Incidentals necessary to complete the Work as specified.
No separate or additional payment will be made for the inclement weather plan or heating deck surface or MPCO Materials .