1047POLYESTER POLYMER CONCRETE (PPC) OVERLAY

1047.1DESCRIPTION—This work is construction of a one course wearing surface of Polyester Polymer

Concrete (PPC) on in-service bridge decks. The indicated or specified depth of the wearing surface is the minimum.

1047.2MATERIALS—Provide PPC consisting of polyester resin binder and aggregates with a compatible

primer meeting the component and composite material properties specified. Supply components collectively through the same provider, qualified as defined within this Section and referred to as the System Provider.

consisting of a resin, initiator, and promoter. Provide a primer conforming to Table A. Store components according to the System Provider’s recommendations. Provide initiator for the methacrylate resin consisting of a metal drier and peroxide. Provide resin and initiator pre-mixed from the System Provider. Do not store containers and measuring devices in a manner that allows leakage or spilling to contact the containers or materials of the other.

TABLE A HMWM Primer Requirements Property Requirement Test Method Apparent Viscosity*, cps, max 25 ASTM D2196, Test Method A (Brookfield RVT with UL adapter, 50 RPM) Volatile Content*, %, max 30 ASTM D2369 Specific Gravity* at 77F, min 0.90 ASTM D1963-85 (1996) Flash Point, F, min 180 ASTM D3278 Vapor Pressure* at 77F, mm Hg, max 1.0 ASTM D323 PPC Saturated Surface-Dry Bond Strength (Adhesive) at 24h ± 15 min, and 70F ± 1F, psi

CalTrans Test 551, Part 5 (with initiated PPC at 12% resin content by weight of the dry aggregate), primed surface NOTES: *Perform test before initiator is added

• Be an unsaturated isophthalic polyester-styrene co-polymer.

• Contain at least 1% by weight gamma- methacryloxypropyltrimethoxysilane, an organosilane ester silane coupler.

• Be used with a promoter that is compatible with suitable methyl ethyl ketone peroxide (MEKP) and cumene hydroperoxide (CHP) initiators.

• Meet the required values for the material properties as specified in Table B.

TABLE B Polyester Resin Binder Requirements Property Requirement Test Method Apparent Viscosity*, cps 75 - 200 ASTM D2196, Test Method A (RVT No.1 Spindle, 20 RPM) Specific Gravity* at 77F 1.05 to 1.10 ASTM D1963-85 (1996) Elongation, %, min. 35 ASTM D638, Type I specimen, thickness 0.25 ± 0.03” at Rate = 0.45 inch/minute. Sample conditioning according to ASTM D618 and Condition 18/25/50+5/70 Tensile Strength, psi, min. 2,500 ASTM D638, Type I specimen, thickness 0.25 ± 0.03” at Rate = 0.45 inch/minute. Sample conditioning according to ASTM D618 and Condition 18/25/50+5/70. NOTES: *Perform test before initiator is added

TABLE C Aggregate Requirements Property Requirement Test Method Fine aggregate composition Natural sand only - Weighted Average Absorption, %, max. 1.0 AASHTO T 84 and AASHTO T 85 Moisture Content by Percent of Aggregate Absorption, at time of mixing with polyester resin, %, max.

0.5AASHTO T 255

Mohs Hardness, min. 7 -

TABLE D Aggregate Gradation Sieve Size Percent Passing (Min – Max) 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

the dry aggregate. Accelerators or inhibitors may be required to achieve proper setting time of PPC. Use as recommended by the overlay System Provider. Provide PPC composite mixture conforming to the requirements in Table E.

TABLE E PPC Composite Mixture Design Requirements Property Requirement Test Method PCC Saturated-Surface Dry Bond Strength (Modulus of Rupture), without primer* (at 24 h ± 15 min and 70 ± 1F), psi, min. 500 CalTrans Test 551, Part 5 Surface Abrasion Resistance (Abrasion Loss), g, max 2 CalTrans Test 550 Modulus of Elasticity, ksi 1,000 to 2,000 ASTM C469 Chloride Permeability (Charge Passed), coulombs, max. 200 ASTM C1202 NOTES: *Initiated PPC mixture tested at 12% resin content by weight of dry aggregates.

• Commercial-quality blast sand required.

• Have at least 95% passing the No. 8 sieve and at least 95% retained on the No. 20 sieve when tested according to AASHTO T 27.

• Must be dry at the time of application.

• Material components are supplied collectively through the System Provider. Aggregates to be supplied by the System Provider and delivered in packaging to the site clean and dry.

certification, provide independent testing for the HMWM primer, PPC resin, aggregate, and PPC mixture to verify compliance with the material requirements as specified in Tables A, B, C, D, and E. Provide independent testing for the aggregate and PPC mixture from an AASHTO certified laboratory . Provide i ndependent testing for HMWM primer, PPC resin from an ISO certified laboratory. Perform testing within 12 months of furnishing materials to the project.

1047.3CONSTRUCTION

no PPC installation experience, list a minimum of three projects demonstrating bridge deck or latex overlay placement experience.

overlay system on at least five projects of similar size and scope within the last 5 years.

provided technical support on at least five projects of similar size and scope within the last 5 years.

Plan for approval a minimum of 30 calendar days before material placement. The onsite System Provider's Technical Representative is required to review and approve the plan. Deviations from the approved QC Plan are to be approved by the Representative. Discuss the QC Plan at the pre-placement meeting. Deviation from the approved QC Plan will be cause for immediate suspension of operations. The QC Plan is to include key personnel, equipment, materials, mixing procedures, safety, proposed methods of installation and operation, and the following:

1.a QC Plan Administrator. Provide name of person having full authority to institute action necessary for the successful operation of the QC Plan. The QC Plan Administrator is responsible for the following:

1.a.1 Procedures. Identify and provide procedures in the QC Plan for the following:

• Safety Procedures.

• Documenting the storage procedures for PPC resin, HMWM primer and aggregates.

• Documenting areas and quantities used of PPC resin and aggregate at each site.

• Documenting the temperature of each component tank with an infrared thermometer before mixing.

• Moisture control methods of aggregate.

• Cleaning and maintenance schedule for machinery and equipment.

• Corrective actions for unsatisfactory construction practices and deviations from the specifications.

1.a.2 Field Work. Perform required field QC sampling, testing and recordkeeping according to the QC Plan and contract documents.

1.a.3 Recordkeeping. Maintain and make available upon request, complete records of sampling, testing, corrective actions, and QC inspection results.

1.b System Provider’s Technical Representative. Provide name of person r esponsible for the following:

1.b.1 Training. Train and provide recommendations to construction personnel in the safe handling and proper application of materials before placing the PPC overlay.

1.b.2 Required Site Visits.

• Onsite for the trial application and for the first 3 days of installation.

• For installers with no previous PPC placement experience, the System Provider’s Technical Representative is required to be onsite for the trial application and the entire placement to ensure proper installation.

• Onsite when corrective action is required.

1.c Placement Plan. Section of QC Plan that includes the following.

1.c.1 Overlay System.

• Safety Data Sheets (SDS)

• Data Sheets from the Manufacturer and System Provider outlining requirements for storage, handling, and mixing of PPC components, HMWM resin, and aggregates.

• Data Sheets from the Manufacturer and System Provider including requirements and procedures for surface preparation, application/installation, curing, cure times, site cleanup, cleanup of mixing and placement equipment, and disposal of materials including HMWM resin, PPC and containers.

• Test reports for overlay system.

• Mix Design.

1.c.2 Placement Schedule.

• Provide schedule for each structure receiving overlay.

• Provide placement sequence for each structure. Include paving lengths, widths, directions, and phase joint locations. Cold joints between passes must be within 6 inches of the indicated line striping or centered within a lane. Limit joints as much as practical. Do not add joints, other than those indicated, unless approved.

1.c.3 Equipment. Provide description of equipment for the following:

• Surface preparation including grinding and shot blasting.

• Applying HMWM primer resin.

• Sketch showing complete details of supports for finishing equipment.

• Measuring, mixing, placing, and finishing.

• Applying surface finish sand.

1.c.4 Placement Operations.

• Chain of command if unforeseen circumstances during construction occur.

• Procedures for surface preparation, application/installation, finishing, and curing.

• Method of protecting and finishing around bridge drains.

• Method of protecting and finishing along parapets.

• Method for controlling, measuring, and maintaining overlay thickness, profile, surface tolerance, and texturing.

• Environmental BMPs required to ensure that the overlay materials do not leave the site (including protective measures at inlets, scuppers, barrier drains, etc.).

a minimum of 14 calendar days before material placement. The QC Plan Administrator, System Provider’s Technical Representative, and Contractor’s Representative are to attend the pre- placement meeting.

the manufacturer’s recommendations. Materials not stored properly will be rejected. Materials that exceed the manufacturer’s recommended shelf life will be rejected. Materials are to have a minimum shelf life of 12 months. Store liquid materials out of direct sunlight and at temperatures less than 80F. Store aggregates in a clean, dry location away from moisture. Applicable fire codes may require special storage facilities for some components of the overlay system. Obtain and post at the storage areas the SDS, Product Data Sheet, and other information from the System Provider regarding the safe practices for the storage, handling, disposal of materials, and health hazards. Include the System Provider's name, date of manufacture, batch/lot number, trade name, quantity, and mixing ratio printed on the label for each storage container with binder components and primer. Include the producer name, date of shipment, batch/lot number, weight and independent lab test reference number for containers with aggregate as supersack. All materials must be delivered in their original containers with the manufacturer’s label.

System Provider’s recommendation, or when the anticipated weather conditions would prevent the proper application of the surface treatment. During surface preparation and overlay application, provide shielding as required and directed to protect adjacent traffic from rebound, dust, and construction activities. During overlay application, provide suitable coverings (i.e. heavy duty drop cloths) as needed to protect exposed areas not to receive overlay, such as curbs, sidewalks, parapets, etc. Clean and/or repair damage or defacement resulting from this application to the satisfaction of the Representative.

the overlay system according to the Systems Provider’s recommendations.

adequately prepare the bridge deck substrate. Provide a self-propelled vacuum capable of picking up dust and other loose material from the shotblasting or sandblasting operation. Provide equipment to supply compressed air free of oil and moisture for final surface preparation.

concrete or by a Continuous Automated Mixer.

2.a Portable Concrete Mechanical Mixer. Provide portable concrete mixer appropriately sized for proposed batches, as recommended by the System Provider.

2.b Continuous Automated Mixer . Provide continuous mixer appropriately sized for proposed batches, as recommended by the System Provider. Provide continuous mixer capable of handling polyester binder resin and catalyst while sufficiently mixing catalyzed resin with dry aggregate and maintaining proper ratios to achieve set/cure times within the specified limits. Provide continuous mixer equipped with an automatic metering device that measures and records aggregate and resin volumes, at least every five minutes, including time and date. Submit recorded volumes at the end of the work shift. Have a visible readout gage that displays volumes of aggregate and resin being recorded.

slip-form paving machine. Do not use roller screeds.

3.a Vibratory Screed. Use a vibratory screed riding on preset forms or rails.

3.b Self-Propelled Slip-Form Paving Machine. Use a self-propelled slip-form paving machine, which is modified or specifically built to effectively place PPC. Equip paving machine with a vibrating pan to consolidate and finish PPC. Fit paving machine with hydraulically controlled grade automation to establish the finished profile to match grade when placing lanes adjacent to previously placed PPC. Have sufficient engine power and weight to provide adequate vibration of the finishing pan while maintaining consistent forward placement speed. Be capable of both forward and reverse motion under its own power.

surface to demonstrate proper initial set time and the effectiveness of the surface preparation, mixing, placing, and finishing equipment proposed. Prepare the surface for the trial application the same as the structure to receive overlay. Place each trial application at least 10 feet long at the indicated overlay thickness and at a profile grade and paving width similar to the structure(s) to receive overlay. Perform trial applications at approved locations. If the cleaning practice, materials, installation, finishing and/or texturing are not acceptable, remove the failed trial application and reinstall the trial application at no additional cost to the Department until satisfactory results are obtained. Provide as many trial applications required to demonstrate the ability to construct an acceptable trial overlay section and perform the remaining work. The installer, System Provider and/or proposed equipment/ techniques may be rejected if not shown to be acceptable after three (3) failed trial applications. Test the trial application as specified in Section 1047.3(i). Repair bond test locations according to the System Provider’s recommendations.

concrete bridge deck cracks to locate potential reflective cracks in the wearing surface. Prepare the surface to the following requirements: Clean areas that will be in contact with the PPC overlay by shot blasting, or abrasive sandblasting if the shot blaster cannot access certain areas, to remove grease, slurry, oils, paint, dirt, debris, curing compound, rust, membrane, asphalt, weak surface mortar or other contaminants that could interfere with the proper adhesion of the overlay system. Shot blast no more than 24 hours before placement of PPC. Perform scarification, if indicated, before shot blasting. For existing bridge decks, do not begin cleaning for a minimum of 28 days after unsound areas have been repaired as specified in Section 1040. For new bridge decks, do not begin

cleaning for a minimum of 28 days after deck placement. Do not allow dust created during cleaning operations to interfere with traffic. Satisfactorily remove and contain contaminants. Determine the size of shot, flow of shot, forward speed of shot blast machine and number of passes necessary to provide a surface free of weak or loose surface mortar, exposing the aggregates within the substrate concrete and visibly changing the color of the substrate concrete. Exposed mortar after cleaning operations is considered adequate for bond when the mortar has open pores, is sound and is firmly bonded to the coarse aggregate. Do not expose cleaned surfaces to traffic unless approved. If contamination occurs to the concrete substrate after cleaning, clean again as directed and according to the System Provider’s recommendations before placing the overlay at no additional cost to the Department. The cleaned concrete substrate is to be dry at the time of application of the primer and overlay. Clean steel surfaces that will be in contact with PPC according to SSPC-SP10.

placement of new substrate or substrate repairs. Before application of primer and PPC overlay, and the surface is free of water, moisture, and is visibly dry, perform moisture test according to ASTM D4263 modified for 2 hours to verify dryness. Do not place primer or PPC unless t he substrate surface temperature is between 40-100F.

HMWM prime coat . Mix and apply primer according to the System Provider’s recommendations. Apply primer within 5 minutes of mixing initiator and resin at a rate of approximately 90- 100 SF/gal or as recommended by the System Provider. Apply primer by flooding and uniformly spreading to completely cover surfaces to receive overlay, including adjacent vertical surfaces. Avoid heavy application that results in excess puddling. Remove or distribute excess material to meet the recommended application rate. Reapply primer to areas that appear visibly dry before overlay placement.

15 minutes and within 2 hours of placing the primer. Place PPC before gelling or within 15 minutes following addition of the initiator, whichever occurs first, or as recommended by the System Provider. An initial set time between 30 minutes and 90 minutes is required for PPC. The initial set is when the in-place PPC cannot be deformed by pressing with a finger. If the initial set is not within 30-90 minutes, remove and replace PPC at no additional cost to the Department. Place, consolidate, and finish PPC using placement equipment as specified in Section 1047.3(e) to the minimum thickness, grade, and cross-section indicated. Termination edges of the overlay may require application and finishing by hand trowel due to obstructions such as curbs or scuppers. Adequately isolate expansion joints before placing PPC. Unarmored joints may be sawed within four hours after placing PPC, if approved. The exact time of sawing will be determined by the System Provider.

of at least 2.2 LB/SY by broadcasting, immediately after the overlay placement before gelling. Provide adequate pavement friction. Ensure the completed overlay surface is free of smooth or glassy areas such as those resulting from insufficient quantities of abrasive finish sand. Repair surface defects as recommended by the System Provider and approved by the Representative.

PPC is still workable, perform straightedge testing and surface correction as specified in Section 501.3(k)3. After the straightedge testing and surface corrections have been completed and before the PPC becomes nonplastic, manually texture/tine the surface as specified in Section 501.3(k)4 if mechanical texturing is not indicated. Terminate texturing 12 inches from gutterlines and scuppers. Terminate texturing within 5 inches, but no closer than 3 inches of bridge joints. Do not overlap tines. After the PPC has hardened, test the surface again as specified in Section 501.3(o). Resound the deck if directed. When mechanical texturing is indicated, perform mechanical texturing as specified in Section 1001.3(k)6.f, except do not begin grooving operations until directed, until a minimum of 24 hours after placement, the PPC has cured as specified in Section 1047.3(h)5, and until the surface tolerance has been checked and high points are removed as specified in Section 501.3(o). Remove high spots by diamond grinding. Do not remove high spots until a minimum of 24 hours after placement.

a minimum reading of 3,000 pounds per square inch is achieved on a properly calibrated Schmidt hammer every 10 feet of deck longitudinally.

the Representative based on vertical axis bond tests.

24 hours and 72 hours after each day’s placement of the overlay in the presence of the Representative. Perform a minimum of one vertical pull bond test on each bridge or day’s placement, whichever is smaller, at a location or locations as designated. If multiple tests are taken in a span, the test result is the average of the tests for that span. The required minimum bond strength between the PPC overlay and substrate is 250 pounds per square inch. If the initial vertical pull bond test results do not meet the minimum requirement of 250 pounds per square inch, perform up to three additional vertical pull bond tests per bridge or day’s placement where the minimum requirement of 250 p ounds per square inch was not met. After additional testing, if the average of the test results for a bridge or day’s placement do not meet the minimum requirement of 250 pounds per s quare inch, the bond between the substrate and PPC overlay in each bridge or day’s placement not meeting this requirement is considered defective work, and the PPC overlay must be removed and replaced at no additional cost to the Department. Repair bond test locations with PPC according to the System Provider’s recommendations.

variations in substrate profile to meet the desired grade and cross -section as indicated. The minimum required thickness is 1 inch. Remove and replace areas where t he minimum required thickness was not attained at no additional cost to the Department.

If PPC overlay exhibits cracking or surface tears, perform an investigation with the Representative to determine the type, source, and extent of cracking. Measure the width, depth, and length of each crack and establish the locations of the ends of each crack with respect to permanent reference points. Coring may be necessary if crack depths cannot be accurately determined using a mechanical probe. If coring is required, obtain two cores at each location or as directed. S ubmit for analysis one core to an independent laboratory and one core to the LTS to determine extent of cracking and if the cracks are structural or non-structural. Remove and replace areas of structural cracks. If the investigation indicates the type of cracking to be nonstructural cracks (plastic shrinkage, drying shrinkage, temperature related, or surface tears caused by finishing and texturing) repair visible surface cracks and tears greater than 1/ 8-inch depth and from 0.007 inch to 0.016-inch width at no additional cost to the Department. Use HMWM penetrating crack sealer from the same manufacturer of the PPC overlay system to repair the surface cracks and tears. Completely fill cracks until flush with surface of PPC overlay. Immediately following the application of the HMWM resin, coat the wetted surface with surface finishing sand for abrasive finish. Submit a Corrective Action Plan that includes, at a minimum, the proposed HMWM crack sealing material data sheet from the System Provider and conditions for use, including ambient and substrate temperature and moisture conditions. Do not perform crack sealing before the Corrective Action Plan has been accepted by the Representative and System Provider. Keep cracks clean, covered, and dry until the crack sealing operation is performed to the satisfaction of the Representative. Unless directed, remove and replace wearing surface deficient in surface tolerance as specified in Section 501.3(o); failing to bond to the substrate; exhibiting nonstructural cracks or tears greater than 1/4-inch depth and greater than 0.016-inch width; or showing surface defects resulting from the effects of rain, improper finish, improper cure, or honeycombing, that cannot be repaired. Use repair materials and finishing methods for surface defects in the PPC overlay according to those used for the installation of the overlay.

1047.4MEASUREMENT AND PAYMENT—Square Yard.

The unit price includes the System Provider’s Technical Representative’s reviews and site visits.