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49 1. NCHRP SYNTHESIS 39-11: PERFORMANCE OF THIN POLYMER OVERLAYS FOR BRIDGE DECKS Introduction/Background: The National Cooperative Highway Research Program (NCHRP) has requested that a synthesis of polymer overlays for concrete bridge decks be conducted. Thin polymer overlays (TPOs), also referred to as polymer con- crete or polymer mortar overlays, which consist of a polymer binder; e.g., epoxies, polyesters, or methacrylates, and aggre- gates are constructed with a thickness of no more than 1.0 in. They have the advantages of (1) adding very little dead load; (2) very fast cure times; (3) shallow depths that eliminate need for raising approach slabs; (4) transition from overlaid lane to non-overlaid lane during construction; (5) low permeability, (6) long-lasting wearing surface; and (7) frictional resistance. Many TPOs have been installed and it is critically important to summarize their performance in one document. The intent of this synthesis is to summarize the history and performance of thin polymer overlays over the past 20 years and specifically: ⢠Summarize the research, specifications, and procedures ⢠Summarize the performance data based on field applications ⢠Determine the primary factors that influence the performance of these overlays Your assistance in responding to this questionnaire is very important to the success of this effort to produce the most accurate and complete synthesis possible. We are asking you to complete the Agency Questionnaire below. As well, there is an attached TPO Questionnaire asking for information on specific TPOs you have completed. If your agency used its own forces to install a TPO, there are some additional questions on this questionnaire relating to Agency-as-Installer. These questionnaires can be completed on-line. Please save and email back the completed questionnaires to David Whit- ney, whose email address is below. We particularly appreciate any comments you may have. Please provide any unpublished reports or documents that you may have related to TPOs. Please feel free to contact either of us if you have any questions or comments that you would like to discuss: David W. Fowler David W. Whitney Professor Manager, Construction Materials University of Texas at Austin Research Lab dwf@mail.utexas.edu University of Texas at Austin 512 232 2575 dpwhitney@mail.utexas.edu 512 471 4529 APPENDIX A Questionnaires
50 Thin Polymer Overlays AGENCY QUESTIONNAIRE 1. In which state are you employed? 2. Your name: _____________________Phone: _______________ Email: ______________________ 3. What is your organization?   State DOT   Other public transportation agency 4. Has your agency constructed one or more thin polymer overlays (TPO)? (See the cover letter for a more complete description of TPO.)   Yes (Please continue to question 5.)   No (If no, you are finished with the survey. Your time and attention are sincerely appreciated. Please send the form back to the email address at the end of the questionnaire.) 5. In what year did you construct your first TPO? 6. How many TPOs has your agency constructed? (Normally one TPO is defined as one bridge; if more than one type TPO is used on a bridge, each type would be a separate TPO.) 7. What was the last year that you constructed a TPO? 8. Do you plan to construct TPOs in the future?   Yes   NoâIf no, skip to question 12. 9. For what reasons will you construct TPOs (check all that apply)?   To improve skid resistance.   To extend life of deck.   To surface bridge deck that has been repaired due to spalling or cracking.   To provide a uniform surface for appearance.   To waterproof the deck. 10. What resin systems will you specify? 11. What method of installation will you specify? 12. If you do not plan to construct additional TPOs, please indicate the reason:   Too expensive   Poor performance   Other (please indicate): Please indicate why TPOs were used originally.
51 Please save and email back the completed questionnaire to David Whitney, dpwhitney@mail.utexas.edu. For specific TPO projects you have completed, we most appreciate you filling out the TPO questionnaire, also attached to the transmittal email. 2. QUESTIONNAIRE TO AGENCIES Information on each TPO Please complete the following questions for each TPO your agency has constructed. This can be accomplished by copying the following questionnaire and filling it in as many times as needed. We request that you complete one of the following question- naires for each different TPO if possible. We need to determine the performance of different polymer systems on different types of bridge decks subjected to different environmental conditions during application and during the life of the TPO. If you are not able to provide information on each TPO, please provide as much information as possible. Feel free to call us if you would like to discuss the information. Information on original bridge deck 13. State in which TPO is located: 14. Bridge reference name/number/location: __________________ Year constructed ______________ 15. Bridge structure:   Prestressed girders   Prestressed box beams   Steel beams   Other (describe): _______________________________________________________________ 16. Substrate was  concrete  steel (If steel go to question 23.) 17. Deck concrete actual compressive strength ________ psi or NA  18. Coarse aggregate in deck concrete:   Limestone  Silica gravel  Basalt   Other 19. Fine aggregate in deck concrete:   Silica sand  Limestone fines   Other 20. Actual air content: in original deck concrete % or NA  21. Condition of deck at time of TPO placement (check all that apply):   Sound, no spalls  Low surface friction   Corrosion:  Less than 10% of area  10â25% of area  Over 25%   Delaminated:  Less than 10% of area  10â25% of area  Over 25%   Alkali-silica/alkali-carbonate reaction distress:  Yes  No
52 22. Deicing salt application:  None  Moderate  Heavy  Magnesium chloride 23. Prior deck repairs:  No  Yes If yes, briefly describe Polymer overlay: 24. Year installed: 25. Was bridge kept in service during TPO installation?  yes  no 26. Contractor contact information Please send Questionnaire B to them, or check the box , if you prefer that we send it to him. Researchers send?  27. Number of lanes: ___________ Length: ________ ft. Area of TPO: ________ sq. yd. 28. Nominal thickness: ______ in. 29. Monomer/resin system:  Acrylic;  Epoxy;  Polyester  Other: 30. Resin supplier: ___________________ 31. Aggregate type: __________________ Environment at time of placement: 32. Moisture:  Dry for previous 2 weeks;  Rain during previous 2 weeks;   Rain during previous 3 days.  Other: 33. Air Temperature:  Below 50°F  50 to 70°F  70 to 85°F  Over 85°F 34. Surface preparation: Sand blast  Shot blast  Milling  Hydro blast   Other: 35. Approximate depth removed: _____ in. Application method: 36. Monomer/resin system mixing method:  Hand  In line mixing 37. Method of application:   Resin system mixed and sprayed on deck followed by broadcasting aggregate   Resin system mixed and poured on deck followed by broadcasting aggregate   Resin system and aggregate premixed and applied to deck   Other:
53 38. Thickness control:   Gauge rakes used to control thickness   Screed guides used with screed or paver to control thickness   Self-leveling (notched squeegees, brooms or rollers used to spread polymer) 39. Number of layers: 40. Curing method:  Ambient conditions  Insulating blankets   Other: 41. Original cost: $ _________ /sq. yd. Other information 42. Estimated additional TPO life prior to significant repairs or removal: ___________years 43. Do you have original specifications:  Yes  No If yes, please attach a copy of the construction specifications. 44. Describe any problems/spalling/cracking and repairs that have been made in the TPO. If you have reports on the TPO installation and/or evaluation please attach. 45. The purpose of the overlay for this bridge was (check all that apply):   Restore frictional resistance. (If so, please give the change in frictional resistance, before and after TPO, if known.)   Provide impermeable surface on sound deck   Provide impermeable surface on deteriorated deck which has been repaired   Restore surface on steel deck   Other: __________________________________________ 46. Please indicate any recommended changes in your specifications. Please save your completed form and email back to David Whitney at dpwhitney@mail.utexas.edu. Thank you for your time in this survey. If your agency was an installer on this TPO, please complete the following questions.
54 Agency-as-Installer Questions For agencies whose own forces have performed TPO installations, please complete the following questions for each TPO your local agency forces have installed. This can be accomplished by copying the following questionnaire and filling it in as many times as needed. We request that you complete one of the following questionnaires for each different TPO if possible. We need to determine the performance of different polymer systems on different types of bridge decks subjected to different environmental conditions during application and during the life of the TPO. If you are not able to provide information on each TPO, please provide as much information as possible. Feel free to call us if you would like to discuss the information. 47. Name of unit: __________________ Your name: ___________________ 48. Unitâs location: _______________________________________________ 49. Phone: _________________________ Email: _______________________ 50. Name/location of bridge: _______________________________________ 51. Owner: _____________________________________________________ 52. Substrate was  concrete  steel (If steel, go to question 10.) 53. Condition of bridge at time of placement:   Sound condition  Minor spalling/cracking  Moderate spalling/cracking. 54. Had bridge been previously repaired?  Yes  No 55. Did you perform substrate repairs as part of the overlay project?  Yes  No. If âyes,â what type of repair material was used? 56. Surface preparation:  sand blast  shot blast  milling  hydro blast   Other: ___________________________________________________ 57. Overlay application: Resin/monomer system: _______________________________________ Mixing method: ______________________________________________ Application method:___________________________________________ Number of layers: ________________ Thickness: ___________________ in. Type of aggregate: ____________________________________________ Method of finishing:___________________________________________ Curing method: _________________ Ambient temperature __________°F 58. Problems encountered:_________________________________________ 59. Recommended changes in specifications/procedures: Please save your completed form and email back to David Whitney at dpwhitney@mail.utexas.edu. Thank you for your time in this survey.
55 3. CONTRACTOR QUESTIONNAIRE NCHRP Synthesis 39-11: Performance of Thin Polymer Overlays for Bridge Decks Introduction/Background: The National Cooperative Highway Research Program (NCHRP) has requested that a synthesis of polymer overlays for concrete bridge decks be conducted. Thin polymer overlays (TPOs), also referred to as polymer con- crete or polymer mortar overlays, which consist of a polymer binder; e.g., epoxies, polyesters, or methacrylates, and aggre- gates are constructed with a thickness of no more than 1.0 in. They have the advantages of (1) adding very little dead load; (2) very fast cure times; (3) shallow depths that eliminate need for raising approach slabs; (4) transition from overlaid lane to non-overlaid lane during construction; (5) low permeability, (6) long-lasting wearing surface; and (7) frictional resistance. Many TPOs have been installed and it is critically important to summarize their performance in one document. The intent of this synthesis is to summarize the history and performance of thin polymer overlays over the past 20 years and specifically: ⢠Summarize the research, specifications, and procedures ⢠Summarize the performance data based on field applications ⢠Determine the primary factors that influence the performance of these overlays Your assistance in responding to this questionnaire is very important to the success of this effort to produce the most accurate and complete synthesis possible. As a contractor, we are asking you to complete the attached questionnaire. We particularly appreciate any comments you may have and would request that you provide any reports or documents that you may have related to TPOs. Please feel free to contact either of us if you have any questions or comments that you would like to discuss: David W. Fowler David W. Whitney Professor Manager, Construction Materials University of Texas at Austin Research Lab dwf@mail.utexas.edu University of Texas at Austin 512 232 2575 dpwhitney@mail.utexas.edu 512 471 4529 Contractor Questionnaire Please complete the following questions for each TPO you have installed. This can be accomplished by copying the follow- ing questionnaire and filling it in as many times as needed. We request that you complete one of the following questionnaires for each different TPO if possible. We need to determine the performance of different polymer systems on different types of bridge decks subjected to different environmental conditions during application and during the life of the TPO. If you are not able to provide information on each TPO, please provide as much information as possible. Feel free to call us if you would like to discuss the information. 1. Name of firm: ______________Your name: ________________________ 2. Location: _________________ 3. Phone: ____________________E-mail: ___________________________ 4. Name/location of bridge: _____ 5. Owner: ___________________ 6. Substrate was  concrete  steel (If steel, go to question 10.) 7. Condition of bridge at time of placement:   Sound condition  Minor spalling/cracking  Moderate spalling/cracking.
56 8. Had bridge been previously repaired?  Yes  No 9. Did you perform repairs as part of your contract?  Yes  No If âyes,â what type of repair material was used? 10. Surface preparation:  sand blast  shot blast  milling  hydro blast Other: ____________________ 11. Overlay application: Resin/monomer system: _______________________________________ Mixing method: _____________________________________________ Application method:___________________________________________ Number of layers: ___________Thickness: ________________________ in. Type of aggregate: ____________________________________________ Method of finishing:___________________________________________ Curing method: ____________Ambient temperature ________________°F 12. Problems encountered: 13. Recommended changes in specifications/procedures: Please save your completed form and email back to David Whitney at dpwhitney@mail.utexas.edu. Thank you for your time in this survey. 4. MATERIAL SUPPLIER QUESTIONNAIRE NCHRP Synthesis 39-11: Performance of Thin Polymer Overlays for Bridge Decks Introduction/Background: The National Cooperative Highway Research Program (NCHRP) has requested that a synthesis of polymer overlays for concrete bridge decks be conducted. Thin polymer overlays (TPOs), also referred to as polymer con- crete or polymer mortar overlays, which consist of a polymer binder; e.g., epoxies, polyesters, or methacrylates, and aggre- gates are constructed with a thickness of no more than 1.0 in. They have the advantages of (1) adding very little dead load; (2) very fast cure times; (3) shallow depths that eliminate need for raising approach slabs; (4) transition from overlaid lane to non-overlaid lane during construction; (5) low permeability, (6) long-lasting wearing surface; and (7) frictional resistance. Many TPOs have been installed and it is critically important to summarize their performance in one document. The intent of this synthesis is to summarize the history and performance of thin polymer overlays over the past 20 years and specifically: ⢠Summarize the research, specifications, and procedures ⢠Summarize the performance data based on field applications ⢠Determine the primary factors that influence the performance of these overlays Your assistance in responding to this questionnaire is very important to the success of this effort to produce the most accurate and complete synthesis possible. As a material supplier, we are asking you to complete the attached questionnaire. We particularly appreciate any comments you may have and request that you provide any reports or documents that you
57 may have related to TPOs. Please feel free to contact either of us if you have any questions or comments that you would like to discuss: David W. Fowler David W. Whitney Professor Manager, Construction Materials University of Texas at Austin Research Lab dwf@mail.utexas.edu University of Texas at Austin 512 232 2575 dpwhitney@mail.utexas.edu 512 471 4529
58 4. Material Supplier Questionnaire Your name: ____________________ Company: ____________________ Phone: _____________________ E-mail: ______________________ How many years have you supplied resins? _________________________ Provide information on each resin system you furnish for TPOs: Resin No. 1: Type:  Epoxy  Acrylic  P/S  Other: _____________________ Viscosity @ 75°F _______________ cps Tensile elongation (ASTM D638) __ % Gel time ______________________ min. and cure time _____________min @ 75°F Is cured polymer breathable (allows moisture vapor out of concrete)?   Yes  No Date first installed as TPO: Approximately how many bridges? States used: Resin No. 2: Type:  Epoxy  Acrylic  P/S  Other: _____________________ Viscosity @ 75°F _______________ cps Tensile elongation (ASTM D638) __ % Gel time ______________________ min. and cure time _____________min @ 75°F Is cured polymer breathable (allows moisture vapor out of concrete)?   Yes  No Date first installed as TPO: Approximately how many bridges? States used: Please save your completed form and email back to David Whitney at dpwhitney@mail.utexas.edu. Thank you for your time in this survey.
