1046EPOXY OVERLAY

1046.1DESCRIPTION—This work is construction of a multiple layer wearing surface of epoxy and

aggregate on in-service bridge decks.

1046.2MATERIAL—

solids which holds the aggregate firmly in position once all components are combined. All components will come from a single manufacturer listed in Bulletin 15 and conform to Table A. Cure specimens at 73F ±2F, relative humidity 50% ± 2% and test specimens at 73F ±2F.

Table A Binder Requirements Property Requirement Test Method Viscosity (poises) 10 – 70 ASTM D2556-14, Model RVT Brookfield, Spindle No. 3 at 20 rpm Gel Time (minutes) 15-45 ASTM C881, para. 11.2 modified, 70 ml sample Ultimate Tensile Strength (psi) 2,000-5,000 at 7 days ASTM D638 Ultimate Tensile Elongation (%) 30-70 at 7 days ASTM D638 Absorption (%) 1 max. at 24-hrs. ASTM D570 Compressive Strength (psi) 1,000 min. at 3 hours 5,000 min. at 24 hours ASTM C109, 50 mm square mortar cube with plastic inserts Permeability to chlorideion

Thermal Compatibility (Mixed with aggregate) No delamination ASTM C884 Infrared spectrum Established for each component by the Manufacturer AASHTO T 237, paragraph 4 and 5

of angular silica sand, basalt, or other highly siliceous metamorphic or igneous rock . Provide aggregate free of dirt, clay, asphalt, and other foreign or organic materials conforming to Table B.

Table B Aggregate Requirements Property Requirement Test Method Moisture Percentage (%) Less than 0.2 AASHTO T 255 Mohs Scale Hardness 6.5 min. average Mohs Hardness Test Aggregate Gradation Requirements - Sieve Analysis Sieve Size Total Percent Passing (No. 4) 100 (No. 8) 30-75 (No. 16) 0-5 (No. 30) 0-1

For aggregate, provide independent testing from an AASHTO certified laboratory to verify the Table B requirements are met . Independent testing must be less than 12 months old at the time aggregate is

furnished to the project . Submit the I ndependent testing results for local approval as specified in Section

106.02(a)2.c

1046.3CONSTRUCTION

information having a cumulative minimum of 1,000 square yards of epoxy overlays placed within the past 3 years. Include contact information for the three projects. An installer not meeting the minimum requirements will be allowed to perform the installation operation if approved in writing by the binder manufacturer.

Plan for acceptance before material placement. I nclude key personnel, equipment, materials, proposed methods of installation and operation, and the following:

1.a Designated QC Plan Administrator. Provide a designated QC Plan Administrator having full authority to institute any action necessary for the successful operation of the QC Plan and is responsible for the following:

• Identify and provide contractor procedures for:

ͦ Documenting areas and quantities used of binder and aggregate of each layer at each epoxy overlay site to verify application rates conforming to Table C. ͦ Documenting the temperature of each component of the binder before use. ͦ Moisture control methods for the aggregate. ͦ Cleaning and maintenance schedule for machinery and equipment. ͦ Corrective actions for unsatisfactory construction practices and deviations from the specifications. Any deviation from the accepted QC Plan will be cause for immediate suspension of operations.

• Contractor performance of required field QC sampling, testing and record keeping in conformance with the approved QC Plan and contract documents.

• Maintain and make available upon request, complete records of sampling, testing, corrective actions, and QC inspection results.

1.b Manufacturer’s Technical Representative. A manufacturer’s technical representative responsible for the following:

• Train and provide recommendations to construction personnel in the safe handling and proper application of materials before placing the epoxy overlay.

• Required to be onsite for the first 2 days of installation if the installer does not meet the minimum requirements as specified in Section 1046.3(a).

• Required to be onsite if corrective work is necessary.

• Required to be onsite if directed

overlay:

• Deck patching location(s)

• Surface preparation – surface profile level or depth, cleanliness, substrate pull off test locations and results

• Moisture test results

• Environmental conditions at the time of placement – include ambient air temperature, deck temperatures and weather conditions

• Product Data Sheets (PDS)

• Safety Data Sheets (SDS)

• Material information:

ͦ Resin – manufacturer, component expiration dates, proportioning method and rate, and yield computations for each layer ͦ Aggregate – type of aggregate and yield computation as well as visual inspection of surface covering

• Final adhesion testing locations and results

• Document all repairs needed because of defective work

pre-epoxy overlay placement meeting to review the specification, method and sequence of placement, QC Plan, and protective measures.

application before field preparation. Store materials in a clean, dry environment according to the manufacturer’s recommendations. Do not expose the aggregate to rain or moisture. At the storage area, post SDS, PDS, and other information from the manufacturer pertaining to health hazards, worker protection, and safe practices for the storage, handling, and disposal of the materials. Provide the manufacturer's name, date of manufacture, batch/lot number, trade name, quantity, and mixing ratio on each binder storage container. Provide producer name, date of shipment, batch/lot number, weight, and independent lab test reference number on containers with aggregate.

• Shotblasting equipment capable of removing all loose, disintegrated concrete, dirt, paint, oil, asphalt, laitance, carbonation, and curing materials from the deck surface.

• Sandblasting equipment capable of removing all oxidation, dirt, paint, oil, and asphalt from the metal expansion joints.

• Provide a self-propelled vacuum capable of picking up dust and other loose material from the shotblasting and sandblasting operation.

• Provide air compressors capable of producing a minimum of 180 cubic feet per minute and 80 pounds per square inch of clean, dry compressed air and equipped with an oil/water separator to remove dust and loose material.

• Do not use scarifiers, milling machines, or sandblasting instead of shot-blasting, unless accepted by the Structure Control Engineer.

• An epoxy distribution system capable of accurate and complete mixing of the epoxy resin and hardening agent, verification of the mix ratio, and uniform and accurate distribution of the epoxy materials at the specified rate on 100% of the work area. Provide equipment approved by the epoxy-based overlay manufacturer. Equip the distribution system with a cumulative type meter that can read the resin compound discharge to the nearest 0.1 gallon.

• A mechanical aggregate spreader capable of uniform and accurate application of the dry aggregate over 100% of the work area.

• Provide a self-propelled vacuum truck;

• An air compressor capable of producing oil free and moisture free compressed air to remove all dust and loose material.

• Hand tools to facilitate the placement of the surface treatment as specified in this specification and the manufacturer’s recommendations.

Representative.

• Provide calibrated containers for proper proportioning of the base and hardening components.

• Provide a clean, dry container large enough to blend and mix the proper proportions of base and hardening components.

• Provide a powered, paddle-type mixer for blending the base and hardening components.

• Provide squeegees, rollers, or brooms suitable for applying the mixed epoxy-based resin on the bridge deck surface at the specified application rate as specified in Table C.

• Provide shovels, hand spreaders, and other hand tools suitable for applying the aggregate at the specified rate.

• Provide brooms or air compressors equipped with an oil/water separator to remove excess aggregate after each layer of the overlay has cured.

in the presence of the Representative. Record locations of all areas determined to be unsound and provide documentation to the Representative. Remove unsound concrete and repair the areas as specified in Section 1040 and as directed. Do not use patching material containing magnesium phosphate. Do not apply epoxy overlay on concrete surfaces or repairs less than 28 days of age. Perform pull tests to determine the suitability of the concrete surface according to ASTM C1583. Select locations to perform testing at a minimum of one location per span per lane or maximum of 4, 000 square feet per lane, whichever is smaller. Include at least one test on newly repaired deck areas. The minimum acceptable bond strength on normal weight concrete cannot average less than 250 pounds per square inch. No more than 24 hours before overlay placement begins, clean the bridge deck surface by s hotblasting all surfaces to remove all curing compounds, loosely bonded mortar, surface carbonation, and deleterious material. Comply with the International Concrete Repair Institute (ICRI) standard for Concrete Surface Preparation (CSP) Level 5-7. Provide the necessary concrete surface profile chips to visually verify the surface preparation. Before shotblasting the entire deck surface, a test area is required. Perform shotblasting on a 5- foot by 5-foot test area. In the presence of the Representative, verify that ICRI, CSP Level 5-7 has been achieved. Do not proceed with production shotblasting until test area is accepted. After shotblasting, vacuum sweep or air wash all surfaces to remove all dust, debris, and deleterious material.

In areas inaccessible by the shot blasting equipment use sandblasting, walk behind grinders, or both to prepare the surface to the satisfaction of the manufacturer and Representative. Remove existing pavement markings. Avoid excessive removal of concrete. Trace amounts of tightly adhering paint in the bottom of the texturing grooves may remain as accepted. If cracks are present, remove loose material with compressed air and pre-treat cracks 1/4 inch or greater in width with the mixed binder. Do not overfill cracks. If cracks are overfilled shotblast or grind the material to make it flush with the adjacent pavement after the binder material is cured. Install the epoxy overlay after the binder in the pretreated cracks has gelled. Construct the epoxy overlay so the final surface of the overlay is as shown on the standard drawings for expansion joints and dams. Shot blasting or concrete grinders may be used to create the proper profile. Prepare the concrete surface to provide a profile on both sides of the joint as specified in Section 501.3(o).

strip should not exceed 100 square feet . Use the test strip for equipment calibration and establishing procedures and techniques for the actual overlay placement on the bridge deck. Before placement and after priming the distribution pumps, verify the accuracy of the resin compound cumulative meter by performing a volumetric yield test. In the presence of the Representative, perform a volumetric yield test by discharging 1 gallon of the resin compound into a 1 gallon measuring device. The cumulative meter is required to show a discharge of 1 gallon. Cover exposed areas not receiving overlay, such as curbs, sidewalks, railings, parapets, inlets, expansion dams, and along limits between adjacent lanes, if phasing application, or daily termination point with suitable coverings. In phased construction, place joints between phases in neat lines parallel to the centerline of roadway. Stagger and overlap joints a minimum of 2 inches between successive layers so no ridges appear. The deck surface must be dry before the application of the epoxy overlay. Do not place overlay if visible moisture is present on the concrete surface. Affix a sheet of transparent plastic to indicate the presence of moisture for a minimum of 2 hours depending on temperature, cloud cover, and conditions according to ASTM D4263 (modified to a minimum of 2 hours). Use equipment to continuously mix, meter, and monitor the b inder. If recommended by the binder manufacturer, use a heated metering pump. Mix the binder according to the manufacturer’s recommendations. Hand squeegee the mixed binder onto the prepared pavement surface using a serrated edge squeegee at uniform application rates as specified Table C.

Table C Epoxy Overlay Application Rates Course Epoxy Rate Aggregate Rate* 1 Not less than 0.22 gal./sq. yd Not less than 10 lbs./sq. yd 2+ Not less than 0.45 gal./sq. yd Not less than 14.5 lbs./sq. yd *Apply aggregate to completely cover the epoxy

Immediately after the binder application, mechanically spread the aggregate onto the wet, uncured binder at a uniform rate as specified in Table C. Do not allow loose aggregate or excessive dust onto any part of the adjacent, active travel lanes. Hand spreading aggregate is allowed as a secondary method if mechanized equipment cannot be used due to access or geometry, as accepted. Completely cover the wet, uncured binder with aggregate to achieve a uniform surface with no exposed binder remaining visible on the surface. Spread the aggregate without displacing the wet binder film during placement. Remove excess aggregate from each course after the course has completely cured. Use brooms, vacuums, compressed air free from oil and water, or other approved methods to remove the excess aggregate. Do not remove excess aggregate until removal can be performed without tearing or damaging the surface. Minimize walking or standing on the binder. Perform adhesion testing according to ASTM C1583 on the final layer. Test results will be the average of three tests on a test patch not less than 4.5 square feet. The minimum tensile adhesion strength cannot average less than 250 pounds per square inch. Perform a test patch at the same frequency as required for

the initial pull tests conducted on the prepared concrete surface. Test each area at least 24 hours after the indicated minimum cure time for the second course. If a failure occurs on an adhesion test, perform additional adhesion testing immediately before and immediately after the failed area. Continue testing until satisfactory test results are achieved. Remove and replace the failed area(s) at no additional cost to the Department.

during the cure period. Cure each course for the minimum cure period as specified in Table D unless longer periods are recommended by the manufacturer. Cure times are based on the average temperature of deck surface, resin, and aggregate components.

Table D Curing Times Course 60F- 64F 65F-69F 70F-74F 75F-79F 80F-84F 85F + 1 4 hours 3 hours 2.5 hours 2 hours 1.5 hours 1 hour 2+ 6.5 hours 5 hours 4 hours 3 hours 3 hours 3 hours

contaminated aggregate is mixed with virgin aggregate, all the aggregate in the container will be considered contaminated and not acceptable for use in the epoxy overlay. Between 30 and 45 days after placing the epoxy overlay , reclaim loose aggregate using a vacuum sweeper. Completely clean scuppers and expansion dams of accumulated aggregate. Use means of cleaning that does not damage neoprene glands in strip seal expansion dams. This reclaimed aggregate cannot be reused.

accepted QC plan and the manufacturer’s requirements. Do not place epoxy overlays from October 1 to April 30, unless allowed in writing by the District Executive. Do not apply the overlay at surface, air, or resin and aggregate component temperatures lower than 60F. Do not apply the epoxy -based concrete overlay if the temperature is expected to drop below 55F w ithin 8 hours after application or if the mixed epoxy-based resin gels in less than 10 minutes.

If temperatures fall below 60F, the Representative will require a longer curing period. If, at any time during the curing period, the temperature falls below 50F, the work may be considered unsatisfactory and rejected. Protect freshly applied overlays from sudden or unexpected rain. Stop all application operations if it starts to rain. The Representative may order removal and replacement of any material damaged by rainfall or contractor operations that cannot be satisfactorily repaired. Locations identified by the Representative that did not receive a uniform and sufficient application of aggregate will be considered defective work. Remove and replace as directed. Remove and replace epoxy overlays with an epoxy application rate calculated less than 0.18 gallon per square yard in Course 1 or less than 0.36 gallon per square yard in Course 2. Remove the rejected or damaged epoxy overlay in rectangular sections by micromilling or saw cutting to the top of the concrete deck surface. Remove and replace at no additional cost to the Department.

Table E Acceptance and Payment Factor for Epoxy Overlays

Payment Factor Calculated Application Rates of Epoxy for Course 1 (gal./sq. yd.)

Calculated Application Rates of Epoxy for Course 2 (gal./sq. yd.) 100% payment ≥ 0.22 and ≥ 0.45 80% payment < 0.22 but ≥ 0.18 or < 0.45 but ≥ 0.36

1046.4MEASUREMENT AND PAYMENT—Square Yard

Payment includes surface preparation, furnishing, applying all courses, and final cleaning. Repairs to the bridge deck will be paid separately for type of concrete bridge deck repair as indicated.