SHRP PRODUCT 2035A

yellow pavement stripe on black background

SHRP PRODUCT 2035A:
Rapid Bridge Deck Rehabilitation Manual
Michael Sprinkel

Product Summary
Product Use and Evaluation
Contacts/Champions
Reference List of Project Use
Guidelines for the Use of Rapid Set® Cement in Latex-Modified Concrete Overlays

Source:	SHRP Implementation Coordinator
	FHWA, Office of Technical Applications
	400 7th Street, SW
	Washington, D.C. 20590
Expert:	Michael M. Sprinkel
	Virginia Transportation Research Council
	530 Edgemont Road
	Charlottesville, VA 22903
Champion:	Michael M. Sprinkel
Champion:	Virginia Transportation Research Council
	530 Edgemont Road
	Charlottesville, VA 22903

Product Summary
The manual describes the various rehabilitation techniques that can be used to protect and repair decks with a minimum of inconvenience to the traveling public. Very-early-strength patching and overlay systems that can be installed within an 8 hour time frame such as at night include polymer concrete and latex modified concrete prepared with special blended cement. A 3-hour curing period can be adequate depending on temperature.

A typical construction sequence is:

Close bridge at 9 P.M.
Complete milling and shotblasting at 11 P.M.
Complete concrete placement by 2 A.M.
Open lane to traffic by 5 A.M.

Systems that can be installed within 24 hours or during weekends include silica fume concrete and LMC made with Type III cement. Curing periods of 18 to 36 hours can be adequate depending on temperature.

A typical construction sequence is:

Close lane at 9 P.M. Friday night.
Complete milling and shotblasting by 6 A.M.
Complete concrete placement by 11 A.M.
Open lane to traffic at 5 A.M. Sunday or Monday depending on temperature and job requirements.

Typical construction activities are shown in Figures 44 through 47. Cost data is shown in Table 33. The special blended cement required for the very-early-strength latex-modified overlay costs 4 times more and the Type III cement used in the high early strength latex-modified overlay costs 20 percent more than types I and II cements used in the conventional LMC overlays. These cements increase the cubic yard cost of the concrete by approximately $90 and $7 respectively. These costs are more than offset by the reduced cost of traffic control. Because of the large savings in the cost of traffic control rapid deck rehabilitation can be done at as little as one third the cost of conventional rehabilitation. DOTs that spend $5 million per year on deck rehabilitation can save up to $3 million per year.

Figure 44. A milling machine rapidly removes old concrete surface prior to preparing the surface for concrete overlay.

Figure 44. Photograph of milling machine in operation

Figure 45. Shotblasting is used to rapidly clean the concrete surface prior to placing overlay.

Figure 45. Photograph of shotblasting operation

Figure 46. Very-early-strength latex modified concrete overlay is placed using conventional equipment. Because a special blended cement is used, the overlay can receive traffic in as little as 3 hours depending on temperature.

Figure 46. Photograph of placement of very-early-strength latex modified concrete overlay.

Figure 47. High-early-strength latex modified concrete overlay is placed using conventional overlay placement equipment. Because Type III cement is used, the overlay can receive traffic in less than 24 hours.

Figure 47. Photograph of high early strength latex modified concrete overlay being placed.

Table 33. Cost of Bridge Deck Protective Treatments ($/yd²)

	Epoxy Overlay	Very-Early-Strength LMC Overlay	High-Early-Strength LMC Overlay	Conventional LMC Concrete Overlay
Treatment	24	65	61	61
Misc.	0	23	23	23
Traffic	8	8	8	46
Total	32	96	92	130
Life (years)	15	30	30	30
Life Cycle	47	96	92	130

Product Use and Evaluation
The results of a questionnaire survey on use of the manual follows. The survey showed that the manual is the most used product to come from the SHRP research on concrete assessment and rehabilitation.

Figure 48. Results of Survey of DOT Use of Product 2035A

Figure 48. U.S. map indicating DOT use of Product 2035A

Table 34. Result of Survey of DOT Use of Product 2035

Alabama - Hawaii

Product Evaluation Product Use

State P
L
A
N
N
E
D O
N
-
G
O
I
N
G C
O
M
P
L
E
T
E I
N
-
U
S
E R
E
J
E
C
T
E
D N
O

I
N
T
E
R
E
S
T Comments (attach extra pages as needed) Contact Person Phone Number

AL

AK

AZ

AR X X Lynn Austin 501-569-2192

CA

CO X

CT

DE

DC

FL

GA X C. Baumgard 404-363-7561

HI

Idaho - Minnesota

Product Evaluation Product Use

State P
L
A
N
N
E
D O
N
-
G
O
I
N
G C
O
M
P
L
E
T
E I
N
-
U
S
E R
E
J
E
C
T
E
D N
O

I
N
T
E
R
E
S
T Comments (attach extra pages as needed) Contact Person Phone Number

ID

IL X Gary Kowalski 217-785-2914

IN X

IA X

KS X X Scherschligt 785-296-3761

KY

LA

ME X

MD X X R. Healy 410-545-8063

MA

MI

MN X P. Rowecamp 612-582-1149

Mississippi - Nova Scotia, Canada

Product Evaluation Product Use

State P
L
A
N
N
E
D O
N
-
G
O
I
N
G C
O
M
P
L
E
T
E I
N
-
U
S
E R
E
J
E
C
T
E
D N
O

I
N
T
E
R
E
S
T Comments (attach extra pages as needed) Contact Person Phone Number

MS

MO X X Roger Schwartze 573-751-4671

MT X

NE

NV X R. K. Moore 702-888-7520

NH

NJ X

NM X Jim Camp 505-827-5532

NY X F. Naret 518-485-1386

NC

ND

Nova Scotia,
Canada

Ohio - Wyoming

Product Evaluation Product Use

State P
L
A
N
N
E
D O
N
-
G
O
I
N
G C
O
M
P
L
E
T
E I
N
-
U
S
E R
E
J
E
C
T
E
D N
O

I
N
T
E
R
E
S
T Comments (attach extra pages as needed) Contact Person Phone Number

OH

OK

OR X Keith Johnston 503-986-3053

PA X

PR

RI

SC

SD

TN

TX X Randy Cox 512-416-2189

UT

VT

VA X Michael Sprinkel 804-293-1941

WA X X Tom Roper 360-705-7213

WV X

WI

WY

Contacts/Champions

Ushakant Ghandi	PA DOT	610-791-6034
Casimir (Cas) Bognacki	NY/NJ Port Authority	201-216-2964
Park Thompson	VA DOT	540-332-9104
Bill Rogers	NC DOT	919-250-4037
Jerry Bond	KY DOT	502-564-4556
Butch Meyers	KY DOT	502-367-6411
Mike Shelton	VA DOT	540-899-4293

Reference List of Project Use

See also the web site for the AASHTO Technology Implementation Group