SECTION 243—EPOXY -RESIN SYSTEMS
243.01 Description
These specifications cover epoxy-resin systems to be used for all applications requiring bonding of various materials or as patching or overlay of concrete slabs.
243.02 Detail Requirements
Epoxy-resin materials shall conform to the applicable requirements of Table II-19 and Table II-21. Type EP-3B EP-3T EP-4 EP-5 EP-6 EP-7 Property Max. Max. Max. Max. Max. Max. Epoxide equivalent 245 220 225 270 245 270 TABLE II-19 Requirements: Component A 243.02 TABLE II-21 Requirements: Mixed Epoxy Systems Property Min Max Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Pot Life/ Gel Time at 75° F 40 65 40 65 35 55 35 55 20 30 20 40 15 45 Tensile Strength (psi) at 75° F , 7 days 3,000 2,000 1,500 400 2,000 Tensile elongation (%) at 75° F , 7 days 1 5 5 30 30 Water absorption (Max %) 0.8 0.8 0.8 0.8 0.8 0.8 0.8 2 inch cubes, compressive strength (psi) dry, min 3 hours 24 hours 48 hours, wet, min 6,000 7,000 4,000 4,000 1,000 5,000 3,000 3,000 3,000 3,000 2,500 Ash content (%) 20 30 20 30 0.5 0.5 5 15 5 0.5 Viscosity Poises 40 100 40 150 20 40 10 25 7 25 Spindle No. 4 4 3 3 Gel 3 Speed 10 or 20 10 or 20 20 20 20 V olatile content (max. %) 6.0 3.0 3.0 3.0 20.0 3.0 Type EP-3B Red EP-3T Gray EP-4 Straw EP-51,2 Straw EP-6 Lt. Gray CTE Black EP-7 Brown/Straw 243.02
a.Epoxy Systems:
1.Types EP-3B and EP-3T shall be 100 percent reactive high-build coatings designed as a two-coat (minimum) system for protection of concrete exposed to splash zones and tidal water. T ype EP-3B shall be the prime or base coat, and T ype EP-3T shall be the finish or topcoat.
2.Types EP-4, EP-5, and EP-6 shall be moisture-insensitive systems designed for structural bonding, sealing, and grouting of dry, damp, or wet structural material free from standing wa- ter. Mortar shall be prepared by mixing 2 parts by volume of loose oven-dried sand to 1 part of premixed T ype EP-4 or EP-5 epoxy; however, T ype EP-6 shall be prepared by mixing 0.6 parts by volume of loose oven dried sand to 1 part of premixed EP-6 epoxy. Mortars shall be mixed to a uniform consistency. T ype EP-4 shall be a high-modulus, rigid, general purpose adhesive with a tensile elongation of 1 to 3 percent. T ype EP-4, low viscosity, shall be used to seal rigid cracks. T ype EP-5 shall be a low-modulus patching, sealing, and overlay adhesive with an elongation of at least 10 percent. When used as a penetrating sealer and to repair nonrigid cracks, T ype EP-5 shall be of a low viscosity. T ype EP-6 shall be a low-modulus, nonsagging, flexible adhesive with an elongation of at least 5 percent. T ype EP-6 shall be used for bonding or repairing damp and underwater surfaces where a nonsagging, low-modulus material is required.
3.Type EP-7 shall be used for epoxy concrete overlays on bridge decks and high friction surface treatments on roads.
b.Classes: Epoxy resin shall be formulated for use at specific temperatures. Three classes of systems are defined according to the range of temperatures for which they are suited. The controlling tem - perature shall be that of the surface of the hardened concrete to which the bonding system is applied. Where unusual curing rates are desired, and with the Engineer’ s approval, a class of bonding agent may be used at a temperature other than that for which it is normally intended. The class and gel temperature shall be as follows:
1.Class A: for use with ambient air and surface temperatures less than 40 degrees F
2.Class B: for use with ambient air and surface temperatures greater than or equal to 40 degrees F and less than or equal to 60 degrees F
3.Class C: for use with ambient air and surface temperatures greater than 60 degrees F
c.Mixing Epoxy: Epoxy resin shall be furnished in two components for combining in accordance with the manufacturer’ s instructions immediately prior to use. Component A shall conform to Table II-19. Component B shall contain one or more hardening agents that, when mixed with Component A, will cause the system to polymerize and harden to conform to Table II-21. The Department will permit the use of thixotropic agents in accordance with the manufacturer’ s recommendations to control viscosity. The Contractor shall only use complete units as packaged by the manufacturer if the mixture proportion of Component A to Component B exceeds 2:1. 243.03 Contents of the separate packages containing Component A and Component B shall be thoroughly stirred prior to use. The same paddle shall not be used to stir Component A that is used to stir Com- ponent B. The Contractor shall dispose of solvents used for cleaning in accordance with applicable policies and procedures of the Virginia Department of Waste Management. Components A and B shall be stored between 65 degrees F and 80 degrees F for at least 2 hours before use. Epoxy com- ponents may be heated in hot water or by indirect heat prior to mixing to bring them to the required temperature. Solvents and thinners shall not be used except for cleaning equipment. Mixing of epoxy components shall be in accordance with the manufacturer’ s instructions. When mineral fillers are specified, they shall be inert and nonsettling or readily dispersible. Mate- rials showing a permanent increase in viscosity or the settling of pigments that cannot be readily dispersed with a paddle shall be replaced at the Contractor’ s expense. At least 95 percent of the filler shall pass the No. 300 sieve.
d.Aggregates: Aggregate for surface application work shall be nonfriable, nonpolishing, clean, and free from surface moisture. The Contractor shall use silica sand having a well-rounded particle shape. Aggregate for epoxy concrete overlay shall be angular grained silica sand or basalt having less than 0.2 percent moisture, and free of dirt, clay, asphalt and other foreign or organic mate - rials. Aggregates that will be exposed to traffic shall have a Mohs scale hardness of at least 7. In surface applications, the aggregate shall be applied on the epoxy surface in excess of the amount necessary to cover the surface, shall be sprinkled or dropped vertically in such a manner that the level of epoxy mixture is not disturbed, and shall be applied within 5 minutes after application of the epoxy. At temperatures below 70 degrees F , a maximum of 10 minutes will be allowed. The grading analysis of the fine aggregate (silica sand) shall conform to the requirements of Table II-22. Grading D aggregate shall be used in Class I waterproofing and other skid-resistant applications. Grading E aggregate shall be used in epoxy patching mortars and loop detector sealants Grading F aggregate shall be used in epoxy concrete overlay. Aggregates shall be oven dried.
243.03 Handling and Storing Materials
The Contractor or supplier shall furnish the two components of the epoxy-resin system in separate con - tainers that are nonreactive with the materials. The size of the containers shall be such that the recom - mended proportions of the final mixture can be obtained by combining one container of Component A with one container of Component B. When less than one complete unit is used, each component shall be measured within ±2 percent of the volume required. Batches of less than 6 fluid ounces shall be measured within ±1 percent. TABLE II-22 Fine Aggregate (Silica Sand) Grading Amounts Finer Than Each Laboratory Sieve (Sieve Opening) (% by Weight) No. 4 No. 8 No.16 No. 20 No. 30 No. 40 No. 100 D Min 100 30-70 Max 5 Max 1 E Min 100 99 ± 1 95 ± 5 Max 10 F Min 100 30-75 Max 5 Max 1 243.03 Containers shall be identified as “Component A—Contains Epoxy Resin” and “Component B—Contains Hardener” and shall show the type, class, and mixing directions. Each container shall be marked with the name of the manufacturer; class, batch, or lot number; date of packaging; date of shelf life expiration; pigmentation, if any; and the quantity contained in pounds and gallons.
243.04 Acceptance
Shipments of less than 15 gallons may be accepted upon certification. The Contractor shall submit to the Engineer a certification from the manufacturer that Components A and B conform to these specifica - tions. The certification shall consist of a statement by the manufacturer that Components A and B have been sampled and tested according to the requirements herein. The certification shall be signed by an authorized agent of the manufacturer and contain actual results of tests performed in accordance with the methods specified herein. The Department will take at least one random test sample of each component from each batch or lot number for shipments of 15 gallons or more. The quantity of Component A required to react with 1 quart of Component B will be a sufficient sample for the tests specified. Components shall be furnished in as few different batches or lots as possible. Tests for the cited characteristics will be performed in accordance with the following methods: Characteristics1 Test Method1 VTM-115, Model DV -II Brookfield Viscometer VTM-115 test conditions: Determinations to be made at: Viscosity Class A, 32°F Class B, 50°F Class C, 77°F Epoxide equivalent ASTM D1652 ASTM D1259, Method B, for mixed system V olatile content ASTM D1259 test conditions: Sample cured 4 days at room temperature and weighed on previously weighed metal foil. Filler content AASHTO T -111, on Component A Ash content ASTM D482 AASHTO T237 AASHTO T237 test conditions: Determinations to be made at: Pot life2 Class A , 32°F Class B, 50°F Class C, 75°F Tensile strength ASTM D638 Bond strength VTM-41 Compressive strength VTM-41 Water absorption ASTM D570 Thermal shear VTM-42
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Source: Road and Bridge Specifications, 2020 Edition. Pages 288–292 of 1,065. View official source ↗