505-BSP-03 Polyester Polymer Concrete Overlay

7/27/2019 505-BSP-03 Polyester Polymer Concrete Overlay

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Polyester Polymer Concrete Overlay

1.0 Description. This work shall consist of constructing a wearing surface of polyester polymer

concrete on a prepared surface in accordance with these specifications as shown on the plans or

as directed by the engineer. Polyester polymer concrete shall be composed of the following three

components polyester resin binder, high molecular weight methacrylate (HMWM resin andaggregate.

2.0 Materials.

2.1 Primer. The prepared surface shall recei!e a wa"#free low odor, high molecular weight

methacrylate prime coat. The primer shall comply with the following re$uirements%

High Molecular Weight Methacrylate (HMWM) esin

Property e!uirement "est Metho#

&iscosity ' .)* Pa#s, ma"imum

(+rookfield &T with -adapter, * PM at //deg. 0

12TM 3 )456

2pecific 7ra!ity ' .5, minimum

(at // deg. 0

12TM 3 48/*

&olatile 9ontent ' : percent, ma"imum 12TM 3 ):65

0lash Point ' 4; deg. 0, minimum 12TM 3 :)/;

&apor Pressure ' 4. mm Hg, ma"imum

(at // deg. 0

12TM 3 :):

Tack 0ree Time 8 minutes, ma"imum

(at // deg. 0

12TM9 6/5

P99 2aturated 2urface#3ry

+ond 2trength

* psi, minimum

()8 hrs at /


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2.2.1.2 &'sorption. The aggregate absorption shall not e"ceed one percent as determined by

112HT@ T ;*.

2.2.1. Moisture Content. 1t the time of mi"ing with the resin, the moisture content of the

aggregate, as determined by 112HT@ T )**, shall not e"ceed one half of the aggregate

absorption.

2.2.1. "emperature. The aggregate temperature shall be between 8* deg. 0 and 4 deg. 0 at

the time of mi"ing.

2.2.1.* Com'ine# +ra#ation. 1ggregate for polyester polymer concrete shall comply with the

following re$uirements%

Com'ine# &ggregate

%ieve %i,e 1-2 Ma$. Percent Passing -/ Ma$. Percent Passing

AB 4 4:=;B ;: 4 4

C8 6* ;) 6) ;*

C; 8* 68 8* 6/

C46 )/ 8; )5 *

C: 4) : 46 :6

C* 6 4/ * )

C4 / /

C) # : :

2.2.1. ine &ggregate. The fine aggregate shall consist of natural sand.

2.2.2 inishing %an#. The sand for abrasi!e finish shall be commercial $uality blast sand

ha!ing at least 5* percent passing the ?o. ; sie!e and at least 5* percent retained on the ?o. )sie!e when tested in accordance with 112HT@ T )/. The absorption of the sand shall not

e"ceed 4D when tested in accordance with 112HT@ T ;8.

2. Polyester esin in#er. The resin shall be an unsaturated isophthalic#styrene co#polymer

conforming to the following re$uirements%

Polyester esin in#er

Property e!uirement "est Metho#&iscosity ' ./* to .) Pa#s

(&T, ?o. 4 2pindle, ) PM at // deg.

0

12TM 3 )456

2pecific 7ra!ity ' 4.* to 4.4

(at // deg. 0

12TM 3 48/*

Elongation :* percent, minimum

(Type > at .8*B=min.

12TM 3 6:;


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Thickness F G at .8*B=min.

Thickness F G


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2. "raining. The contractor shall arrange to ha!e the material supplier furnish technical

ser!ice related to application of material and health and safety training for personnel who are to

handle the polyester polymer concrete and the HMWM resin prime coat.

2.5 "echnical %upport. The materials supplier shall ha!e a representati!e onsite during

placement of the polyester polymer concrete.

.0 Mi$ Design. The contractor shall prepare and submit the polyester polymer concrete mi"

design and mi"ing procedures to the 9onstruction and Materials 3i!ision for appro!al. The mi"design shall include a recommended initiator percentage for the e"pected application

temperature. The 9ontractor shall not begin ordering materials for application of the polyester

polymer concrete until the polyester polymer concrete mi" design and mi"ing procedures are

appro!ed.

.0 Construction.

.1 %ur3ace Preparation. The concrete surface shall be prepared by remo!ing all materialwhich may act as bond breaker between the surface and the polyester polymer concrete.

.1.1 6e7 ri#ge Dec8s. @n new concrete decks, the surface shall be gi!en a !ery rough

te"ture while still plastic by use of a wire comb or other appro!ed te"turing de!ice which will

produce a bondable surface acceptable to the engineer.

.1.2 9$isting ri#ge Dec8s. @n e"isting concrete decks, the surface shall be uniformly

scarified in accordance with 2ec )46. The surface shall be scarified to an appro"imate depth of

G inch. The scarifier shall not produce a polish or slick surface. 1ny epo"y patches encounteredshall be completely remo!ed to sound, natural concrete. Polyester polymer concrete or other

patching material, appro!ed by the engineer, may be used to repair the deck. 2urfaces of

concrete patches placed in the deck after scarifying shall be te"tured to an appro"imate depth ofG inch before placing the o!erlay.

.1. 9$isting ri#ge Dec8s Containing Wearing %ur3ace. @n e"isting concrete decks withan e"isting wearing surface, the wearing surface shall be remo!ed prior to placing the polyester

polymer concrete. The e"posed concrete surface shall meet the re$uirements contained in 2ec

8.4.) of this specification.

.1. emoving Contaminates. The te"tured or scarified deck shall be sand blasted followed

by an air blast. The sand blasting shall remo!e all dirt, oil and other foreign materials, as well as

any unsound concrete or laitance from the surface and edges against which new polyesterpolymer concrete is to be placed. The compressor shall be e$uipped to pre!ent oil in the air

supply. 1ny loose or foreign material detected on the concrete surface prior to placement of the

polyester polymer concrete shall be remo!ed by sand or air blasting. The concrete surface mayre$uire rete"turing where penetration of foreign material is e!ident. ?o contamination of the

rete"tured or scarified concrete surface shall be permitted. With appro!al from the engineer, the

contractor may use automatic shot blasting units in lieu of sand blasting. The automatic shot

blasting units shall be self propelled and include a !acuum to reco!er spent abrasi!e. The


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abrasi!e shall be steel shot. Magnetic rollers shall be used to remo!e any spent shot remaining

on the deck after !acuuming. 9leaned surfaces shall not be e"posed to !ehicular or pedestrian

traffic other than that re$uired by the o!erlay operation.

.1.* %teel %ur3aces. 1ll steel surfaces that will be in contact with the o!erlay shall be cleaned

in accordance with 22P9#2P4, ?ear White +last 9leaning, e"cept that wet blasting methodsshall not be allowed.

*.0 &pplication o3 Prime Coat. @ne coat of HMWM prime coat shall be applied to theprepared concrete and steel surfaces immediately before placing the polyester polymer concrete.

The prime coat shall be uniformly applied to completely co!er the surface to recei!e the o!erlay.

The area recei!ing the prime coat shall be dry and had no e"posure to any moisture within the

past )8 hours. Prior to applying the prime coat, the surface shall be cleaned with compressed airto remo!e accumulated dust and any other loose material.

*.1 %ur3ace "emperature. The concrete bridge deck surface shall be between * deg. 0 and

4 deg. 0 when applying the prime coat.

*.2 elative Humi#ity. Polyester polymer concrete shall not be placed when the relati!ehumidity is abo!e 5 percent.

*. Curing. Polyester polymer concrete shall be placed immediately after the prime coat isapplied to the bridge deck.

*. Prime Coat Contaminate#. >f the primed surface becomes contaminated, the contaminated

area shall be cleaned by abrasi!e blasting and re#primed at no additional e"pense to thedepartment.

.0 Placement o3 Polyester Polymer Concrete.

.1 Placement "ime. The polyester polymer concrete shall be placed on the prime coat within

two hours of placing the prime coat.

.2 %ur3ace "emperature. The surface temperature of the area to recei!e polyester polymer

concrete shall be the same as specified in 2ection *.4 of this special pro!ision.

. Mi$ing 9!uipment. The concrete shall be !olumetrically mi"ed at the bridge site by a

continuous mi"er in accordance with 2ec *4.

..1 atching 4n3ormation. The continuous mi"er shall be e$uipped with a metering de!ice

that automatically measures and records the aggregate !olumes and corresponding resin

!olumes. The !olumes shall be recorded at no greater than fi!e minute inter!als along with thetime and date of each recording. 1 printout of the recordings shall be furnished to the engineer at

the end of each shift. eadout gages shall be !isible to the Engineer at all times.


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..2 Mi$ture Consistency. The concrete discharged from the mi"er shall be uniform in

composition and consistency. Mi"ing capability shall be such that initial and final finishing

operations can proceed at a steady pace.

. Contamination. The 9ontractor shall pre!ent any cleaning chemicals from reaching the

polyester polymer concrete mi" during the mi"ing operation

.* #ition o3 4nitiator. Polyester polymer concrete shall be placed prior to gelling and within

4* minutes following the addition of initiator, whiche!er occurs first. Polyester polymerconcrete that is not placed within this time shall be discarded.

. &mount o3 Polyester esin. The polyester resin binder in the polyester polymer concrete

shall be 4) percent


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10.0 Metho# o3 Measurement. 0inal measurement will not be made e"cept for authoriNed

changes during construction or where appreciable errors are found in the contract $uantity.Where re$uired, the area of polyester polymer concrete will be measured to the nearest 4.

s$uare yards of accepted, in#place polyester polymer concrete. The re!ision or correction will be

computed and added to or deducted from the contract $uantity.

11.0 asis o3 Payment. The contract unit price for polyester polymer concrete will be full

compensation for all materials and other items entering into the construction of the polyesterpolymer concrete. The accepted $uantity of polyester polymer concrete will be paid for at the

contract unit price.

Documents

505-BSP-03 Polyester Polymer Concrete Overlay