THIN BONDED POLYMER OVERLAY
PART 1 GENERAL
1.1SECTION INCLUDES
A.Thin bonded polymer overlay system applied to concrete bridge decks and
approach slabs
B.Removal of existing polymer overlay from concrete bridge decks and
approach slabs
C.Repair of damaged areas of a polymer overlay system
1.2RELATED SECTIONS Not Used
1.3REFERENCES
A.ASTM C 88: Soundness of Aggregates by Use of Sodium Sulfate or
Magnesium Sulfate
B.ASTM C 131: Resistance to Degradation of Small-Size Coarse Aggregate
by Abrasion and Impact in the Los Angeles Machine
C.ASTM C 566: Total Evaporable Moisture Content of Aggregate by Drying
D.ASTM C 579: Compressive Strength of Chemical-Resistant Mortars,
Grouts, Monolithic Surfacings, and Polymer Concretes
E.ASTM C 881: Epoxy-Resin-Base Bonding Systems for Concrete
F.ASTM C 1583: Tensile Strength of Concrete Surfaces and the Bond
Strength or Tensile Strength of Concrete Repair and Overlay Materials by Direct Tension (Pull-off Method)
G.ASTM D 570: Water Absorption of Plastics
H.ASTM D 638: Tensile Properties of Plastics
I.ASTM D 790: Flexural Properties of Unreinforced and Reinforced Plastics
and Electrical Insulating Materials
Thin Bonded Polymer Overlay
J.ASTM D 2240: Rubber Property – Durometer Hardness
K.ASTM D 4285: Indicating Oil or Water in Compressed Air
L.ASTM D 5821: Determining the Percentage of Fractured Particles in
Coarse Aggregate
M.ASTM D 7428: Resistance of Fine Aggregate to Degradation by Abrasion
in the Micro-Deval Apparatus
N.ASTM E 274: Skid Resistance of Paved Surfaces Using a Full-Scale Tire
O.ASTM E 1621: Elemental Analysis by Wavelength Dispersive X-Ray
Fluorescence Spectrometry
P.International Concrete Repair Institute (ICRI)
1.4DEFINITIONS
A.Polymer Overlay System – A thin bonded polymer overlay applied as a
wearing surface consisting of a two-part polymer resin broadcasted with aggregate to refusal before it cures and includes a healer/sealer primer where applicable.
B.Thin Bonded Polymer Overlay, Type I – Consists of a polymer overlay
system without healer/sealer primer.
C.Thin Bonded Polymer Overlay, Type III – Consists of a polymer overlay
system with a healer/sealer primer.
D.Installer – The entity preparing the surface and installing and finishing the
polymer overlay system
E.Provider – The manufacturer furnishing the polymer overlay system
1.5SUBMITTALS
A.Provider Qualifications for review
1.Include at least the following:
a.Company name
b.Name, phone number and experience of the Provider’s
Technical Support Representative
Thin Bonded Polymer Overlay
c.List of projects using the submitted products with at least
four years of satisfactory performance under similar environmental conditions as the project in which it is to be applied. List the following for each project: 1) Project name 2) Bridge locations (state routes, structures numbers and mile posts) 3) Scope of work 4) Products used 5) Approximate date of the system opening to traffic
B.Materials for review
1.Include at least the following:
a.Manufacturer’s Product Data Sheets and recommended
installation instructions
b.Material Safety Data Sheets
c.The Provider's certification stating that the provider is the
sole provider of the components of the polymer overlay system and that the components: 1) Comply with this Section 2) Are fully compatible with one another
d.The Installer’s certification with the Provider’s written
concurrence that the polymer overlay system is fully compatible with all deck repair materials 1) Include cure duration recommended for the deck repair material before application of the polymer resin.
2.Certified test report for information from an independent nationally
recognized laboratory stating that the polymer resins in the polymer overlay system components meet the requirements in this Section
a.Test results must be from within a three year period of the
submittal.
3.Certified Test Report for information from an AASHTO accredited
testing laboratory confirming the compliance of the aggregate material with the test requirements of this Section
a.Test results must be from within a one year period of the
submittal.
4.Manufacturer’s product data sheets for steel shot media, for
information
C.Method for existing polymer overlay removal for information
1.Include equipment information and details
D.Safety plan for polymer overlay removal and thin bonded polymer overlay
installation activities for information.
Thin Bonded Polymer Overlay
E.Method for mixing the polymer resins for information
1.The Provider’s written concurrence that the selected mixing method
is acceptable and compatible with the polymer overlay system.
a.Include description of provider proposed equipment.
2.Mixing ratio of the polymer resins.
F.A warranty letter stating that the Installer guarantees the polymer overlay
system against material and installation defects incurred under traffic for a period of 5 years.
1.The guarantee period starts on the date of Physical Completion or
written documentation of the partial acceptance of the thin bonded polymer overlay.
2.Include in the letter:
a.State Project Pin Number
b.State Project Name
c.State Structure Numbers
d.Contractor, Provider, and Installer Name
3.Defects (performance failures) include:
a.Spalling: Broken or missing pieces of polymer overlay
system
b.Scaling: Visible, exposed, rough surface texture resulting
from a loss of aggregate or resin
c.Delamination: Visible or audible debonding of the polymer
overlay system at the bond line (interface) with the existing bridge receiving surface
d.Cracking: Visible cracks not reflected from a crack in the
existing deck
e.Loss of skid resistance: Skid resistance less than 40 as
measured according to ASTM E 274
4.The guarantee covers 100 percent of the polymer overlay system
materials and installation costs including removal and replacement of the polymer overlay system for failed sections.
5.The Department will notify the Installer of defects to be repaired
during the guarantee period.
a.Submit detailed plans and procedures of corrective work
according to Provider’s recommendations and obtain the Department’s authorization before commencing work.
b.Perform corrective work within 60 days of notification unless
stated otherwise.
Thin Bonded Polymer Overlay
1.6QUALITY CONTROL
A.Technical Support Representative
1.Provide a Technical Support Representative from the Provider
onsite during surface preparation and application of the polymer overlay system on the first day the polymer overlay system is installed on a structure.
a.The Technical Support Representative must have a
minimum of 3 years of experience with the system and with guiding and assisting installers in the polymer overlay system installation.
b.The Technical Support Representative will instruct the
workers in proper mixing, application technique, safety precautions, traffic opening time, and environmental requirements.
c.The Technical Support Representative must be available for
consultation but not necessarily present at the job site for the remaining work.
d.The Department reserves the right to require the Technical
Support Representative to be onsite if at any time the Engineer is concerned with the product installation quality.
1.7DELIVERY, STORAGE, AND HANDLING
A.Polymer Resin
1.Identify the containers as Part A and Part B and plainly mark with:
a.Manufacturer’s name
b.Manufacturer’s address
c.Name of the product
d.Mixing proportions and instructions
e.Lot and batch numbers
f.Date of manufacture
g.Quantity
2.Transport to and store on the job site in a dry, weather protected
environment away from moisture, and within the maintained temperature range of 60 to 100 degrees F and according to Provider’s recommended installation instructions.
B.Broadcast Aggregate
1.Store aggregate in a clean, dry location, protected from rain and
other moisture sources.
2.Protect the aggregate from contaminants on the job site.
Thin Bonded Polymer Overlay
C.Handling Liquid Materials
1.Use protective gloves, clothing, boots, and goggles when directly
exposed to the material.
2.Provide manufacturer’s safety data sheets to workers and
inspectors.
PART 2 PRODUCTS
2.1POLYMER OVERLAY SYSTEM
A.Use a thin bonded polymer overlay system that chemically cures to
provide an impervious wearing surface consisting of the following:
1.Healer/Sealer primer for Thin Bonded Polymer Overlay, Type III
2.Polymer Resin
3.Broadcast Aggregate
B.Healer/Sealer primer, when applicable
1.Compatible with the repair materials and the polymer resin.
C.Polymer Resin
1.Two-part Epoxy-Urethane Co-Polymer that meets the requirements
of Table 1.
2.Free of fillers, volatile solvents, and external/conventional
flexibilizers.
Table 1 PHYSICAL PROPERTIES OF THE CURED POLYMER RESIN Property Value Method Compressive Strength, min. psi 5,000 ASTM C 579 (Method B) Tensile Strength, min. psi 2,000 ASTM D 638 Tensile Elongation, min. percent 30 ASTM D 638 Water Absorption, max. percent by wt. 1.0 ASTM D 570 Shore D Hardness, min. 77°F 60-75 ASTM D 2240 Gel Time @ 73°F +/- 3°F, minutes 15-45 ASTM C 881 Adhesion to Concrete 100% failure in ASTM C 1583 concrete Flexural Yield Strength, min. psi 3,000 ASTM D 790 Percent Solids 100
Thin Bonded Polymer Overlay
D.Broadcast Aggregate
1.Thoroughly washed and kiln dried to maximum moisture content of
0.2 percent by weight according to ASTM C 566.
a.Do not use recycled or reused aggregate for the first layer of
application. 1) Refer to this Section, Paragraph 3.3 E2.
2.Use basalt aggregate meeting the properties in Table 2 and the
gradation in Table 3, or use calcined bauxite aggregate meeting the properties in Table 4 and the gradation in Table 5.
Table 2 BASALT AGGREGATE PROPERTIES Magnesium Sulfate Soundness, 15% max. ASTM C 88 (5 cycles) LA Abrasion, Grade D, 20.0% max. ASTM C 131 Micro Deval Abrasion, 7.0% max. ASTM D 7428 Mohs Scale Hardness 7.0 min.
Table 3 BASALT AGGREGATE GRADATION Sieve Size Percent Passing 0.187 inch; No.4 100 0.078 inch; No.10* 10 – 35 0.033 inch; No.20 0 – 10 0.024 inch; No.30 0 – 0.2 * 100 percent of the aggregate retained on the #10 sieve has at least one mechanically fractured face according to ASTM D 5821.
Table 4 CALCINED BAUXITE AGGREGATE PROPERTIES Magnesium Sulfate Soundness, 15% max. ASTM C 88 (5 cycles) LA Abrasion, Grade D, 20.0% max. ASTM C 131 Micro Deval Abrasion, 3.0% max. ASTM D 7428 Mohs Scale Hardness 8.0 min. Aluminum Oxide, ASTM E 1621 85.0% min.
Thin Bonded Polymer Overlay
Table 5 CALCINED BAUXITE AGGREGATE GRADATION Sieve Size Percent Passing 0.187 inch; No.4 100 0.046 inch; No.16* 0-5 0.024 inch; No.30 0 – 0.2 * 100 percent of the aggregate has at least one mechanically fractured face for materials being retained on the #16 sieve according to ASTM D 5821.
2.2EQUIPMENT
A.Polymer Overlay Removal
1.Diamond grinding
a.Provide equipment utilizing diamond blades mounted on a
self-propelled machine designed for grinding and texturing pavement.
b.Hand held and small walk behind diamond grinders may be
used in areas not accessible by larger equipment.
2.Heating and scraping
a.Provide equipment capable of heating and scraping off the
existing polymer overlay system
B.Metered Mixing
1.Use equipment capable of metering, mixing, and distributing the
polymer resin.
a.Use equipment that features positive displacement
volumetric metering pumps controlled by a hydraulic power unit.
b.Use motionless, in-line mixing.
2.Use equipment that is approved by the Provider.
C.Hand Mixing
1.Use equipment that is approved by the Provider.
D.Polymer Resin Application
1.Use new 3/16 inch notched squeegee blades for the first layer on
each structure.
a.Replace notched squeegee if coverage rate does not meet
Provider’s recommendations.
Thin Bonded Polymer Overlay
E.Broadcasting Aggregate
1.Use mechanical equipment capable of dispensing the aggregate
onto the deck in a uniform manner as required by the Provider and as specified.
F.Sandblaster/Air Compressor
1.Verify air is free of water and oil according to ASTM D 4285.
2.3SHOT BLASTING
A.Use S-390 or larger steel shot media.
PART 3 EXECUTION
3.1POLYMER OVERLAY REMOVAL
A.Diamond grinding
1.Create a surface in a parallel, corduroy-type texture consisting of
grooves with the following dimensions:
a.Width: 1/16 to ¼ inch
b.Depth: 1/16 inch
c.Spacing: 1/16 to ¼ inch
2.Limit deviations to an ⅛ inch from the lower edge of a 10 ft
straightedge after grinding.
3.The textured pattern is not required in locations where hand held
and walk behind diamond grinders are used.
B.Heating and scraping
1.Do not damage the concrete substrate.
2.Polymer overlay residue remaining after the heating and scraping
operation must be thin enough to be fully removed during surface preparation.
3.Difficult to remove resin within tining may remain.
3.2SURFACE PREPARATION
A.Remove paint markings, visible grease, oils, and other surface
contaminants prior to shot-blasting.
1.Follow manufacturer recommendations when using solvents to
remove contaminants.
2.Complete deck repairs before shot-blasting.
Thin Bonded Polymer Overlay
B.Shot-blast concrete surface to produce a surface relief that meets the ICRI
Surface Preparation CSP 5-7.
1.Use sandblasting equipment or mechanical grinders only in areas
that cannot be reached with steel shot-blasting.
2.Refer to http://www.udot.utah.gov/go/standardsreferences for a
CSP Examples document.
C.Remove dust or debris just before application of the resin with
compressed air.
D.Protect expansion joints, cold joints, grates, drains and other elements
which may not perform adequately if in contact with hardened resin.
E.Do not allow traffic on the deck that has been shot-blasted.
1.Only allow the polymer overlay system equipment on cleaned
surfaces.
3.3APPLICATION
A.Limitations
1.Do not apply the polymer overlay system when it has rained within
24 hours or is expected to rain within 8 hours of application.
2.Verify the concrete substrate is dry before applying the polymer
overlay system.
a.Measure moisture content with an electronic concrete
moisture meter at three locations on the bridge deck to be covered by the polymer overlay system. 1) Take measurements at the beginning, middle, and end of the coverage area.
b.Measure moisture content with a concrete moisture meter at
each structural pothole patch location to be covered by the polymer overlay system.
c.Do not apply the polymer overlay system if one or more
measurements exceed 4.0 percent.
3.Apply when the outside air temperature is above 50 degrees F and
will remain above 50 degrees F per the manufacturer's recommended cure time.
4.Application over new surfaces
a.Allow newly placed concrete to cure for at least 28 calendar
days before beginning installation of polymer overlay system.
b.Allow newly placed rapid setting mortar materials to cure for
at least eight hours, or as recommended by the rapid setting mortar manufacturer, before beginning installation of polymer overlay system. Thin Bonded Polymer Overlay
5.Application to bridges constructed offline and moved into their final
location by self propelled modular transporters (SPMT)
a.Apply the polymer overlay system no sooner than 30
calendar days after setting the bridge in its final location.
B.Mixing Polymer Resin
1.Condition resin material to the proper temperature according to the
Provider’s recommendations.
2.Use metered mixing equipment to measure and mix the polymer
resin components as recommended by the Provider.
a.Maintain mix ratios according to the Provider's
recommendations.
b.Hand mixing polymer resin may be performed in repair areas
and areas with limited access.
3.Mix polymer resin immediately before dispensing.
4.Verify the mix ratio by volumetric sampling immediately before
beginning the application.
a.Use containers with graduated markings with not less than 5
gallon capacity.
b.Remove the static mixer and dispense each component into
separate containers. 1) Dispense at least five gallons of the primary component for ratio comparison. 2) Uncontaminated samples may be returned to the reservoirs they were originally dispensed from.
c.The Engineer or Technical Support Representative may
request additional sampling.
C.Application of Polymer Resin
1.Apply healer/sealer primer according to the Provider’s
recommended installation instructions when placing a Thin Bonded Polymer Overlay, Type III.
a.Apply polymer resin while the healer/sealer primer is still
wet.
2.Evenly distribute the polymer resin at the rate recommended by the
Provider.
D.Broadcasting Aggregate
1.Broadcast the aggregate before the polymer begins to gel.
a.Do not exceed the maximum time limits in Table 6 between
the application of polymer resin and broadcasting the aggregate, unless otherwise directed by the provider’s technical representative.
Thin Bonded Polymer Overlay
Table 6 Time Limits Temperature Maximum Time Above 90°F 10 minutes 80°F to 90°F 15 minutes 70°F to 80°F 20 minutes 60°F to 70°F 25 minutes 50°F to 60°F 35 minutes
2.Cover the surface until no wet spots remain.
a.Continue to broadcast aggregate over individual wet spots.
b.Do not place piles of aggregate.
3.Drop the aggregate vertically.
a.Do not project aggregate toward live traffic.
E.Remove Excess Aggregate
1.Completely remove excess and loose aggregate by vacuum or with
compressed air after the overlay has hardened and before applying subsequent layers.
a.Remove dust and debris with compressed air.
2.Do not reuse removed excess aggregate for subsequent layers
unless the following criteria is met:
a.Aggregate is removed directly into containers
b.Aggregate is screened to required gradation specified in
Table 3 and Table 5
c.Aggregate is stored free of contaminants
F.Apply Successive Layer of Overlay
1.Provide at least two layers.
2.Longitudinal Joints in the Overlay
a.Stagger and overlap joints between successive layers 6 to
12 inches so that no ridges appear between two adjacent lanes.
b.Maintain straight construction joints between adjacent
placements and layers.
3.Provide a total overlay thickness of at least 3/8 inch when using
Basalt aggregate.
G.Traffic
1.Do not allow vehicles on the polymer overlay while it is curing.
2.Traffic may be allowed on the final layer or on non-final layers after
the resin has cured, as determined by the Provider
a.Remove excess and loose aggregate before allowing traffic
on the thin bonded polymer overlay system.
Thin Bonded Polymer Overlay
b.Brush blast the surface with shot blast according to the
Provider’s recommendations before applying additional layers when traffic has been allowed on the cured surface between layers.
H.Final Cleanup
1.Remove excess and loose aggregate by vacuum or sweeper truck
two weeks after traffic has been on the polymer overlay.
2.Completely remove aggregate from joints.
3.4POLYMER OVERLAY REPAIR
A.Locate and mark polymer overlay repair areas as shown and in the
presence of the Engineer.
1.Delaminated areas
a.Sound the polymer overlay around repair area for
delamination of the polymer overlay to determine repair limits.
2.Polished areas
a.Polished areas are identified as areas where minimal
aggregate remains.
b.Treat gouges which reduce the overall thickness of the
polymer overlay to less than 1/8 inch as polished areas.
3.Square off and mark the edges of polymer overlay system repair
area six inches beyond the determined limits and parallel to the travel lane.
B.Saw cut ½ inch deep saw cut along the marked edges of repair areas.
C.Remove existing polymer overlay within the repair area according to this
Section, Article 3.1.
D.Prepare the deck surface within the repair area according to this Section,
Article 3.2.
E.Apply the polymer overlay system within the repair area according to this
Section, Article 3.3 and Article 3.4.
3.5PROTECTION
A.Prevent sandblasting material and debris from falling into waterways,
pedestrian areas, traffic areas, or onto railroad tracks.
END OF SECTION
Thin Bonded Polymer Overlay
Utah revises spec sections through supplementals and new editions. We check this one every week and email you the day it changes. Free, no account.
Source: Utah Standard Specifications for Road and Bridge Construction, 2026 Edition. Pages 1028–1040 of 1,331.
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