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yellow pavement stripe on black background		 AASHTO Innovative Highway Technologies Concrete Assessment and Rehabilitation

SHRP PRODUCT 2035B:
Guide Specifications for Polymer Concrete Bridge Deck Overlays
Michael Sprinkel

Product Summary
Product Use and Evaluation
Market Penetration of Polymer Concrete Overlays
Reference List of Project Use

TAMMS Flexolith Epoxy Applications
E-Bond 526 Multicoat Epoxy Application
Polycarb, List of Completed Projects
Sikadur Epoxy Broadcast Overlay System
Transpo, List of Completed Projects
Reichhold, List of Installations
Degadur, List of Installations

Guide Specifications for Polymer Concrete Bridge Deck Overlays

Source: AASHTO
444 N. Capitol Street
Suite 225
Washington, D.C. 20001
Expert: Michael Sprinkel
Virginia Transportation Research Council
530 Edgemont Road
Charlottesville, VA 22903
Champion: Michael Sprinkel
Virginia Transportation Research Council
530 Edgemont Road
Charlottesville, VA 22903

Product Summary
The guide provides generic specifications that can be used to construct multiple-layer, slurry and premixed polymer overlays. Overlays are constructed with epoxy, unsaturated polyester styrene and methacrylate and graded aggregates. Overlays are used to provide an economical skid resistant weaving and protective system for bridge decks. Polymer overlays are particularly suited for installations during off peak traffic periods such as at night and can be constructed in situations where it is necessary to minimize lane closures and traffic disruption. Typical construction activities are illustrated in Figures 49 through 52. Cost data from 79 overlay projects is shown in Table 1. Because of large savings in the cost of traffic control, polymer overlays can be installed at one third the cost of hydraulic cement concrete overlays based on a life cycle analysis. DOTs that spend $5 million per year on concrete overlays can save $3 million using polymer overlays.

Figure 49. The first step toward the successful placement of a polymer concrete overlay is to shotblast the concrete surface. Shotblasting equipment is available in a range of sizes. Units that blast a strip 230 mm wide and a strip 1.8 m wide are shown.

Figure 49. Photo of shotblasting operation

Figure 50. A multiple-layer epoxy overlay consists of two layers of epoxy and aggregate. An epoxy mixture is spread over the deck with notched squeegees. Basalt aggregate is here broadcast to excess from the back of a dump truck.

Figure 50. Photo of workers placing exopy mixture overlay

Figure 51. Methyl methacrylate aggregate slurry mixed with mortar mixers is applied to a shotblasted surface that was primed at least 1 hour earlier with a methyl methacrylate primer. The primer must be cured prior to placement of the slurry. The overlay should be struck off with gage rakes set to provide a layer of slurry 5 mm thick.

Figure 51. Photo of application of methyl methacrylate aggregate slurry mixed with mortar mixers

Figure 52. Premixed polyester styrene resin concrete may be consolidated and struck off with a transverse vibrating screed. The overlay is typically 6 to 25 mm thick.

Figure 52. Photo of application of premixed polyester styrene resin concrete

Cost of Bridge Deck Protective Treatments ($/yd2)

  Epoxy Overlay Concrete Overlay
Treatment  24  61 
Misc.  0  23 
Traffic  8  46 
Total  32  130 
Life (years)  15  30 
Life Cycle  47  130 

Product Use and Evaluation
The results of a questionnaire survey on use of the product are shown in Figure 53 and Table 35. The survey showed the polymer overlay guide to be one of the most used products to come from SHRP research on concrete assessment and rehabilitation.

Figure 53. Results of Survey of DOT Use of Product 2035B

Figure 53. U.S. map showing DOT use of Product 2035B.


Table 35. Results of Questionnaire Survey of All the States

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      
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       Ron Temmee 573-526-3030
MT X                
NE                  
NV       X       R. K. Moore 702-888-7520
NH                  
NJ                  
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                  
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           X      
WY                  


Table 36. Market Penetration of Polymer Concrete Overlays

Year E-bond SIKA POLYCARB TAMMS TRANSPO REICHHOLD Degadur TOTAL
90 0 3 3 4 2 3 1 16
91 19 15 4 6 0 6 8 58
92 6 5 6 4 4 6 4 35
93 9 17 7 0 1 9 3 46
94 10 9 8 4 0 22 7 60
95 12 12 5 1 3 7 4 44
96 1 1 6 3 3 17 1 32
97 13 4 14 2 4 17 0 54
98 8 1 7 1 5 10 0 32
99 - - 9 - 6 24 0 39
Before SHRP 2 8 56 22 12 23 16 139
Lead State 69 44 10 7 4 0 1 135
Total 80 75 125 47 40 144 44 555
Since 1990 78 67 69 25 28 121 28 416


Reference List of Project Use

TAMMS Flexolith Epoxy Applications

YEAR PROJECT LOCATION
1976 Route M-44, Bridge over the Grand River Grand Rapids, MI
1976 Route 106 & 107 Southbound Roadway Hicksville, NY
1979 Monroeville Mall Access Bridge over Route 22 Monroeville, PA
1979 Bayou Macon Bridge, Route LA572 (Franklin Parish) Chase, LA
1983 Brooklyn Bridge Brooklyn, NY
1984 Queensboro (59th Street) Bridge New York, NY
1984 Remington Street Bridge Baltimore, MD
1984 Clakamas River Bridge - Highway 99 Oregon City, OR
1984 Red Deer River Bridge Sundrie, Alberta, Canada
1985 Yakima River Bridge - Route 82 Ellensburg, WA
1985 Thousand Islands Bridge Thousand Islands, NY
1985 Crows Nest River Bridge Highway No. 3, Frank, Alberta
1986 Edgewood Avenue - Route 17 Milwaukee, WI
1986 Route 16 over Route 170 Columbus, OH
1986 Jonesport River Bridge Jonesport, ME
1986 Steel Orthotropic Bridge Sidewalk Hanover Street bridge
1986 Lackawanna/Luzerne Counties Moosic, PA
  L.R. 439, Route 52  
1986 Strawberry Creek Bridge Kinuso, Alberta, Canada
  Highway 2  
1986 Dawson Bridge City of Edmonton, Alberta, Canada
1987 Carvell Corner Overpass/Hwy. 16W Alberta
1987 Bow River Bridge at Canmore Alberta
1989 Greenpoint Avenue Bridge New York
1990 Harlem Avenue Bridge Chicago, IL
1990-1992 Tobin Bridge, Route 1 Boston, MA
1990 State Route 35 Jackson, OH (18 Bridges)
1990-1991 Pleasant Valley Overpass, Highway 16 British Columbia, Canada
1991 Henry Hudson Bridge New York, NY
1991 Joseph T. Can Bridge (Steel Grid) New Haven, CT
1991 Maybey Bridge Brooklyn, MD
1991 Pennsylvania Turnpike Overpass Somerset, PA
1991 State Route 52 Ripley, OH (6 Bridges)
1991 207th Street Bridge New York City
1992 Cleveland Bridge Project Cleveland, OH (12 Bridges)
1992 City Island Bridge (Steel Grid) New York City
1992 Akron Bridge Project Akron, OH (6 Bridges)
1992 Queensboro (59th Street) Bridge - Lower Level Brooklyn, NY
1994 Kosciuszko Bridge New York City
1994 Polaski Bridge New York City
1994 Smithfield Street Bridge Pittsburgh, PA
1994 Georgia Bridge Georgia, VT
1995 Bragga Bridge Fall River, MS
1996 Corbin Bridge Huntingdon, PA
1996 Montana Bridges Various Locations
1996 Santiam River (Jefferson) Bridge Marion, OR
1997 Route 58 Bridge Mecklenburg County, VA
1997 Corbin Suspension Bridge Huntingdon, PA
1998 Main Street and Norwood Bridges City of Winnipeg

E-Bond 526 Multicoat Epoxy Application

See also the web site for the AASHTO Technology Implementation Group