00557.02 521 Section 00557 - Premixed Polymer Concrete Overlays
Description
.00 Scope - This Work consists of constructing premixed polymer concrete (PPC) pav ement overlays as shown or specified.
00557.01Definitions :
PPC System - The combination of compatible resins and primers, mixed with Aggregates and other specified ingredients and applied as specified, that produces an acceptable PPC pavement overlay . System Provider - The polymer concrete Supplier experienced in PPC mix design and the application of PPCS ystems.
00557.02Submittals - At least 21 Calendar Days before the pre-placement conference, provide the
following information and samples to the Engineer for approval:
The inclement weather plan according to 00557.04. Test results, from an independent testing laboratory, for the first lot of primer manufactured for use on this Project, showing that the primer complies with the requirements of 00557.10. Provide a Certificate of Compliance from the manufacturer for each subsequent lot of primer, indicating that the primer was manufactured to the same formulation as the first lot. Test results, from an independent testing laboratory, for the first lot of polyester resin binder manufactured for use on this Project, showing that the binder complies with the requirements of
00557.12(a). Provide a Certificate of Compliance from the manufacturer for each subsequent
lot of resin binder, indicating that the polyester resin binder was manufactured, to the same formulation as the first lot. A Certificate of Compliance for each lot stating that the primer and resin binder will not expire prior to use on this Project based on the published shelf life and manufacture date. A detailed work plan for the PPC preparation, application, and cleanup. Include estimated dates and timeframes. The finishing Equipment according to 00557.22. Rebound Hammer calibration documentation and correlation number established per ASTM C805 used to determine when to open the overlay to traffic. The type of scarifying Equipment that will be used for deck preparation according to Section 00504. The method and Materials used to contain, collect, and dispose of all concrete debris generated by the scarifying process, including provisions for protecting adjacent traffic from flying debris. The method and M aterials used to contain the high molecular weight methacrylate ( HMWM ) resin and the PPC mixture within the deck area that will receive the overlay. The PPC mix design. Certification from the System Provider stating that the polyester resin and the primer are approved and are fully compatible with one another and that they are compatible with the PCC repair material used for repairing Class 2 and Class 3 areas. Notice when bulk resin will be used on the Project. Bulk resin is resin that is stored in containers exceeding 55 gallons. A Material Safety Data Sheet for the polyes ter resin binder and HMWM resin. The personnel qualifications according to 00557.30. 00557.04 522 Two 50-pound samples of the blended Aggregate. Heating plan according to 00557.44.
Provide all Material delivery receipts upon availability, but no later than one hour af ter the end of the work shift.
00557.04Inclement Weather Plan - Submit an inclement weather plan when application conditions
of 00557.40(b)(1) are not met. The inclement weather plan includes all Materia ls, Equipment, and methods to be used to heat the substrate. If concrete moisture content or capillary moisture is to be tested, provide Equipment information and calibration certificates.
00557.05Pre -placement Conferences:
personnel, S ubcontractors, Suppliers, the System Provider's technical representative (SPTR), the quality control technician (ACI Concrete Field Testing Technician G rade 1), and all other personnel who will be involved in the PPC pavement overlay work. Meet at a mutually agreed time at least 14 Calendar Days before placing the PPC pavement overlay including the trial overlay. Schedule the pre-placement conference after all submittals have been reviewed and approved. Present and discuss all phases of the PPC pavement overlay work.
pavement overlay crew, the quality control technician (ACI Concrete Field Testing Technician Grade 1), and the SPTR at the Project Site 1/2 hour before the first placement begins to discuss placement duties and procedures. Do not begin PPC pavement overlay work until this meeting is held.
Materials
00557.10Resin Primer - Furnish a wax -free, low odor, high molecular weight methacrylate resin
prime coat that has a maximum volatile content of 30 percent before adding an initiator, when tested according to ASTM D2369, and meeting the following requirements:
High Molecular Weight Methacrylate (HMWM) Resin Property Requirement Test Method Viscosity* 25 cps max. (Brookfield RVT with UL adaptor, 50 RPM at 77 °F) ASTM D2196 Specific Gravity* 0.90, min. at 77 °F ASTM D1475 Flash Point* 180 °F, min. ASTM D3278 Vapor Pres sure* 0.039 in. Hg, max. at 77 °F ASTM D323 Tack -free time 400 minutes, max. at 77 °F California Test 551** * Perform test before adding initiator. ** Copies of California Test 551 are available from the Engineer.
Concrete - Furnish premixed polymer concrete consisting of polyester resin binder and dry
Aggregate.
binder meeting the following requi rements:
00557.12 523 Polyester Resin Binder Property Requirement Test Method Viscosity* 75 - 200 cps (RVT, No. 1 Spindle, 20 RPM at 77 °F) ASTM D2196 Specific Gravity* 1.05 to 1.10 at 77 °F ASTM D1475 Elongation 35% min. Type I at 0.45 in./min. Thickness = 0.25 ± 0.03 inch ASTM D638 Sample Conditioning: 18/25/50 + 5/70 ASTM D618 Tensile Strength 2,500 psi min. Type I at 0.45 in./min. Thickness = 0.25 ± 0.03 inch ASTM D638 Sample Conditioning: 18/25/50 + 5/70 ASTM D618 Styrene Content* 40 to 50 % (by weight) ASTM D2369 Silane Coupler** 1.0% min. (by weight of polyester styrene resin) n/a PCC Saturated Surface -Dry Bond Strength 500 psi, min. at 24 hours and 70 ± 2 °F California Test 551*** * Perform test before adding initiator. ** An organosilane ester, gammamethacryloxypropyltrimeth-oxysilane. *** Copies of California Test 551 are available from the Engineer. Perform bond test using mixed PPC and primer.
Provide a promoter that is compatible with suitable methyl ethyl ketone peroxi de.
Initiate and thoroughly blend the polyester resin binder just prior to mixing with Aggregate.
peroxide. If the initiator is supplied separately from the resin, do not directly mix the metal drier with the peroxide. Store containers in a manner that prevents leakage or spillage from one Material to contact the containers or M aterial of the other.
recommended by the System Provider.
00557.14 524 (d) Aggregate - Furnish washed, clean, and dry 3/8" - 0 size Aggregate meeting the following requirements:
Meets the following combined gr adation according to AASHTO T 27 and AASHTO T 11:
Sieve Size Percent Passing (by Weight) 3/8" 100 No. 4 62 - 85 No. 8 45 - 67 No. 16 29 - 50 No. 30 16 - 36 No. 50 5 - 20 No. 100 0 - 7 No. 200 0 - 3 Combined Aggregate absorption does not exceed 1 percent according to AASHTO T 84 and AASHTO T 85. Moisture content does not exceed 0.2 percent at the time of Aggregate production according to AASHTO T 255. Field tested moisture content does not exceed 1.00 percent according to AASHTO T 255. Test field moisture content prior to production Work, during the trial overlay strip. Perform additional field moisture tests, as directed by the Engineer . The largest size Aggregate does not exceed one-half the minimum depth of the overlay. Aggregate retained on the No. 8 to No. 200 sieves only consists of natural Sand. When Aggregate retained on the No. 4 and No. 8 sieves is combined, the Aggregate shall have a maximum of 45 percent crushed particles with at least one fractured face when tested according to AASHTO T 335.
Deliver Aggregate to the mixer in containers that maintain the specified moisture content.
and moisture content requir ements of the Aggregate with 95 percent of the Sand passing the No. 8 sieve, and 95 percent of the S and retained on the No. 20 sieve.
00557.14PPC Mixture Tolerances and Limi ts - Provide a uniform, consistent, workable PPC
mixture with a polyester resin content, by weight, of 12 ± 1 percent of the Aggregate weight.
00557.16Acceptance of Premixed Polymer Concrete :
strength test results.
00557.22 525 (b) Requi red Properties and Tolerances - The properties and requirements of the PPC are:
Property Requirement Test Method Compressive Strength for Traffic 2,000 psi, min. before opening to traffic ASTM C805 Surface Tolerance See 00557.45(c) n/a Bond Strength 250 psi, min. See 00557.44(f) Set Time 30 to 90 minutes Visual Density See ( c) below ASTM C138 Modulus of Elasticity at 7 D ays 1,000 ksi, min. 2,000 ksi, max. ODOT TM 759 Surface Preparation Depth 1/16 inch, min. ASTM E965
Perform acceptance testing according to the referenced tests, and furnish samples to the Engineer as required. Failing test results may be cause for rejection of the mix with removal and replacement of the affected material at no additional cost to the Agency. If the Engineer determines that the PPC is suitable for the intended purpose, the PPC may be allowed to remain in place, subject to a price adjustment according to 00150.25.
(ASTM C138). Submit test results to the Engineer. The correlation factor established through density testing will be used to determine equivalency between weight and volume for purposes of payment. Perform density testing at the rate of one test per batch.
Equipment
00557.20General - Remove all E quipment that leaks oil or other contaminants from the Project Site
until they are repaired.
00557.21Mixing Equipment - Furnish mechanically operated continuous mixers specifically built or
modified for PPC that:
Employ an auger screw or chute device. Is equipped with a positive- displacement pump that is calibrated yearly and is connected to an adjustable catalyst pump. Is equipped with a metering device that is calibrated yearly and automatically measures and records the Aggregate weight and the corresponding resin weight. Repeat calibration at the beginning of the Project and when changes are made to the mix truck that may affec t the accuracy of the truck measurements. Has a readout ga uge, visible to the Engineer at all times, which displays the weights being recorded.
00557.22Finishing Equipment - Furnish slip-form finishing equipment with an automatic grade
control device t o strike off the PPC mixture to the established grade and Cross Section, or other Equipment such as 30 foot floating beams as approved by the Engineer. Fit the finishing equipment with vibrators or other means of consolidating the PPC.
00557.23 526 00557.23 Miscellaneous Equipment :
with approved vibrators attached to consolidate and finish smaller areas where it is impractical to use a finishing machine.
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 250 psi. Is equipped with a measuring device capable of reading tensile force exerted within 1 percent accuracy.
made up of diamond cutting blades to correct non-specification surface variations.
ASTM F2659. Provide current calibration documentation.
Measures deck surface temperature accurate to ± 1 °F. Measures ambient temperature and dew point accurate to ± 1 °F .
Labor
00557.30Personnel Qualifications - Perform the PPC pavement overlay work using a company
and personnel experienced in PPC pavement overlay work. Demonstrate the company's qualifications and experience and the qualifications of personnel scheduled to perform the PPC pavement overlay work by providing the Engineer the following:
The name of the company that will be performing the PPC pavement overlay work. A project reference list of at least three PPC pavement overlay projects, successfully co mpleted within the last five years, that has used the same PPC pavement overlay system and materials that will be used on this Project. The minimum PPC overlay qualification area is 2,000 square feet. Include the following information for each qualifying project: A brief description of each project. Each project's name. The owner’s contact person’s name, title, and current phone number for each project. Alternate owner's contact person's name, title, and current phone number for each project. The amount of PPC overlay material used on each project. Identify a SPTR, the mixer operators, and the finishing machine operators that will perform the PPC pavement overlay work. Include documentation that they have relevant experience with PPC pavement over lay work and that they have completed at least one PPC pavement overlay project within the last three years. 00557.40 527 A brief description of experience using slip-form screeds for either PPC or PCC roadway wearing surfaces.
The Engineer may suspend the PPC pavemen t overlay work if the Contractor substitutes unapproved personnel during construction. Submit requests for substitution of SPTR, mixer operators, and finishing machine operators to the Engineer. The Engineer will respond within seven Calendar Days of each request.
00557.32Quality Control Personnel - Provide the following certified technicians:
Sample and test the blended Aggregate from the conveyor belt during the trial overlay to verify gradation, and moisture content. Provide split of blended A ggregate samples to the Engineer. Provide test results to the Engineer before placing PPC overlay.
Attend pre-placement meetings. Be at the PPC placement site when PPC placement is in progress. Performs applicable field testing. Notify the Contractor and the Engineer immediately when the PPC is not in compliance with Specifications.
Modulus testing.
Guide development of the PPC mix design. Attend pre-placement meetings and be present at the trial overlay placement. Verify that the primer gels, as mixed and applied. Guide the calibration of each mechanically operated mixer used on the Project. Be present throughout all mixing to control adjustments to the mix, if necessary. Be at the PPC placement site during PPC placement and evaluate each batch delivered and control adjustments to the mix, if necessary.
Construction
00557.40Construction :
to perform the installation and required repairs, and qualified personnel are at the Project Site.
are met:
The deck surface has been visually dry for at least 5 Days. The ambient temperature and deck surface temperature are between 50 °F and 90 °F. 00557.41 528 The deck surface temperature is at least 5 °F above the dew point. No rain is forecasted within 12 hours from the start of PPC placement.
prepared surfaces when the following conditions are met:
If the deck has been dry for less than 5 Days, 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 and the surface temperature is less than 110 °F: • Test for capillary moisture using the plastic sheet method, according to ASTM D4263, with a mini mum test time of 2 hours. Perform one test per 500 square feet. • Test for concrete moisture content using a pin-type moisture meter according to 00557.23(f). Maximum allowable deck moisture content is 4 percent, or the primer manufacturer’s recommendation, whichever is lower. 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. The deck surface temperature is at least 3 °F above the dew point and rising. Deck surface temperature may be mechanically heated to raise the temperature to at least 5 °F above the dew point. No rain is forecasted within 12 hours.
When the deck surface is mechanically heated, do not proceed with Work until the surface temperature is less than 110 °F.
00557.41Trial Overlay Strip - Before constructing the trial overlay strip, in the presence of the
Engineer, verify weights of resin and Aggregate being recorded by calibrating each mechanical mixer used on the Project using certified scales. Use the calibrated mixer to conduct one or more trial overlays on a concrete base approved by the Engineer to determine the initial set time and to demonstrate the effectiveness of deck preparation, mixing, placing, and finishing equipment proposed. Roughen the surface of the trial overlay strip leaving an exposed aggregate surface texture depth profile of at least 1/16 inc h, determined according to ASTM E965 (standard volumetric test).
Construct trial overlays meeting the acceptance criteria of 00557.16, except test the modulus of elasticity at 24 ± 1 hours. Perform testing at locations designated by the Engineer. Construct each trial overlay 12 feet wide by at least 20 feet long, and at the same thickness as the final PPC overlay. Construct trial overlays when weather conditions are similar to those ex pected during construction of the PPC overlay. Use the same equipment, including deck preparation equipment, that will be used for the PPC overlay. Sample the blended Aggregate from the conveyor belt and test according to 00557.12(d) while constructing t he trial overlay strip.
Do not proceed with PPC overlay work until the Engineer approves the trial overlay strip.
Remove and dispose of the trial overlay and the concrete base according to 00290.20.
00557.42Surface Preparation - Prepare all surfaces that are to be in contact with the PPC
according to Section 00504.
Block out expansion joint openings with rigid polyethylene foam or other approved Material, compatible with the resin and primer, before constructing the overlay. Place the PPC over the blocked 00557.44 529 out joint openings. Create the expansion joint openings by sawcutting the overlay along each joint edge. Sawcut expansion joint openings each shift prior to allowing traffic.
00557.43Placing Prime Coat - When conditions of 00557.40 ar e met, apply primer according to the
following:
Blow clean with compressed air to remove accumulated dust and all other loose material. Flood the deck surface with the resin primer at a rate of 75 to 100 square feet per gallon. Allow the resin primer to penetrate into the concrete and fill all cracks. Do not allow the primer coat to leak from cracks or other openings in the deck. Redistribute and work the applied resin primer into cracks with squeegees or brooms in a manner that does not cause foaming. Maintain free flowing consistency of the resin primer at all times. Only use enough initiated promoted resin that is needed to apply a prime coat. A noticeable increase in viscosity of the prime coat resin before it is placed will be cause for rejection. Do n ot allow traffic on the primed surface. Allow the prime coat to pond and penetrate into the deck surface a minimum of 15 minutes before placing the PPC. If the primed surface becomes contaminated, or if the prime coat fails, clean the contaminated area by abrasive blasting, and re-prime at no additional cost to the Agency.
00557.44Premixed Polymer Concrete Pavement :
and relative humidity meet the requirements on the manufacturer’s written data sheet.
Use initiators to produce a set time of between 30 and 90 minutes after placement. Use accelerators or inhibitors, if required for the 30 to 90 minute set time, as recommended by the resin Supplier.
Initiate and thoroughly blend the polyester resin binder before introduction of Aggregate to the binder. Use all bags or other containers of A ggregate that are opened at the time of mixing, otherwise discard them.
Before it gels or within 15 minutes after the addition of the initiator, whichever is first. Discard the PPC if it is not placed within this time. During the same work shift the prime coat is applied. Place P PC with a minimum thickness of 3/4 inches or as shown. Place PPC in Panel widths which hold the location of the longitudinal joints to the lane lines.
Accelerators or inhibitors may be required as recommended by the polyester resin binderS upplier and as approved by the Engineer.
4 by 8 inch cylinder specimens from each batc h of PPC placed on the Project. 00557.44 530 Cast one additional set of three 4 by 8 inch cylinder spec imens for every ten batches of PPC placed on the Project, minimum of one set per Day. Submit the additional set to the Engineer for verification testing. Cast the PPC cylinders with a minimum of two lifts, rodding 25 times for each lift. Keep the cylinders level and stationary until PPC overlay rebound test has been completed.
A batch is defined as "per mixer" or "portion of it placed". Test each set according to ODOT TM 759 to determine modulus of elasticity at 7 Days. Use a CSTT to perform modulus t esting.
Do not allow traffic and Equipment on the PPC overlay until the overlay has reached a minimum compressive strength of 2,000 psi as verified by the rebound number determined according to ASTM C805. Test the deck surface at locations as directed.
and at locations designated by the Engineer. Test the bond strength within 48 hours after placing the PPC overlay. Cut 2 inch to 3 inch diameter cores from in -place PPC 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 PPC 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 250 psi, whichever occurs first. Avoid taking cores in the wheel lines.
A successful test is the failure of the concrete substrate or bond failure above 250 psi.
After coring and testing, restore the area voided by the cores by blowing with compressed air and filling with PPC.
the time and date of each recording.
Furnish a batch ticket to the Engineer at the end of each w ork shift or as requested. Batch tickets shall contain the following information:
Name of PPC Supplier. Serial number of the delivery ticket. Date; starting time, and finishing time. Identification number of batching and mixing Equipment. Name of purchaser. Specific designation of the job (Name, Location and Contract Number). Aggregate weight in pounds. Resin weight in pounds. Sampled PPC Unit Weight in pounds per cubic yard. Amount of PPC in cubic yards. 00557.80 531 Signature or initials of the person operating the batching or mixing equipment.
Batch tickets may be computer generated, hand written, or a combination of both.
00557.45Roadway Finish :
surface texture Sand or PPC Fine Aggregate to the ov erlay surfaces at a rate of 1.8 pounds per square yard.
A steel -tined tool with 1/8 inch wide tines that will mark the finished PPC to a depth of 1/8 to 3/16 inch. Randomly space the markings from 3/4 to 1 1/2 inch as approved. Orien t the texturing perpendicular or longitudinal to the R oadway centerline and full width of the Roadway width except leave smooth strips 14 inches wide along each curb faces. Do not overlap texturing.
Correct all non-specification surface texturing, at no additional cost to the Agency, according to the following:
Correct texturing after PPC curing and before opening the R oadway to traffic. Cut grooves 1/8 inch wide and 1/8 to 3/16 inch deep. Unequally space grooves from 3/4 to 1 1/2 inch apart. Remove saw slurry and laitance from the sawing operation while cutting the grooves. Orient the grooves perpendicular or longitudinal to the Roadway centerline and full width of the Roadway width except leave smooth strips 14 inches wide along each curb faces. Do not overlap grooves.
straightedge, shall not vary by more than 1/4 inch. Furnish the straightedge and operate it under the direction of the Engineer.
Correct all non- specification surface tolerance with a diamond grinder at no additional cost to the Agency.
Measurement
00557.80Measurement - The quantities of W ork performed under this Section will be measured
according to the following:
will be measured on the volume basis. The quantities will be determined by converting the weight identified on the mixer's automatic metering device to volume, using the yield factor according to AASHTO T 121 (ASTM C138).
concrete overlays will be measured on the area basis. Field measurement of the area will not be made. The area w ill be determined by calculating the area from the dimensions shown.
00557.90 532 Payment
00557.90Payment - The accepted quantities of Work performed under this Section will be paid for
at the Contract unit price, per unit of measurement, for the following item(s) :
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 constructing and disposing of the trial overlays .