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Epoxy Applications
Transportation
                     Concrete Repair: Bridges and
                               Tunnels




                                      ChemCo Systems
Epoxy Applications



Transportation   Civil uses

                      Major roles:
                       • Repair and Protection

                        • Infrastructure Renovation
                            – Bridges & Tunnels
                            – Airports
                            – Rail

                        • Structural Rehabilitation
                          – Commercial, Industrial & Residential
                          – Public & Private Sectors
                                                               ChemCo Systems
Epoxy Applications



Transportation   Corrosion = spalling
                                      Iron oxide (corrosion product
                                      commonly called rust)
                                      occupies about 7 times the
                                      volume of a similar mass of
                                      steel. The formation of rust
                                      generates high internal forces
                                      leading to spalling.

                                      Spalling is more common in
                                      applications with insufficient
                                      cover (depth of concrete over
                                      the steel reinforcement).




                                                        ChemCo Systems
Epoxy Applications



Transportation   Salt: tough on steel and concrete




                                                     ChemCo Systems
Epoxy Applications



Transportation   Monitor crack movement (strain gauge)




                                                         ChemCo Systems
Epoxy Applications



Transportation   History of Epoxies

                     1936            First epoxy patents

                     1940s-50s       Bakelight introduces commercial
                                      applications (electrical and jewelry)



                     1948            First use as construction
                                      adhesive (hardened-to-hardened
                                      concrete bonding)

                     1954            Caltrans uses bonding agent for
                                      traffic markers



                                                                              ChemCo Systems
Epoxy Applications



Transportation    History of Epoxies

                      late 1950s     Patching, bolt grouting, crack injection and
                                      overlays more common.

                      1959           U.S. Army Corp of Engineers issues
                                      specification

                      1959           PG&E dam successfully repaired using
                                      meter/mix pump and structural epoxy from
                                      Adhesive Engineering


                      1978           ASTM* C881 spec. published
                                        *American Society of Testing and Materials




                                                                                     ChemCo Systems
Epoxy Applications



Transportation   Specification for civil engineering

                  ASTM C881
                    Standard U.S. specification for epoxy bonding
                    systems for concrete
                   AASHTO* M-235 used by U.S. transportation

                    design engineers as specification for epoxy bonding

                      AASHTO M235 = ASTM C881

                          *American Association of State Highway and Transportation Officials




                                                                                                ChemCo Systems
Epoxy Applications



Transportation
                 Properties: Viscosity
                 measure of a material’s resistance to flow—common unit is
                 centipoise (cps)


                  Water               =           1 cps

                  Motor Oil       =                100 - 500 cps
                         (similar to some unfilled epoxies)

                  Peanut Butter =                250,000 cps
                         (similar to some epoxy pastes)


                                                                    ChemCo Systems
Epoxy Applications



Transportation
                      Properties: Modulus of Elasticity
                      Ratio of stress to strain




                      High modulus  rigid or stiff
                        • Structural uses
                              – High creep resistance


                      Low modulus  flexible
                        • Impact resistant, less brittle



                                                           ChemCo Systems
Epoxy Applications



Transportation   Properties: Coefficient of Thermal Expansion
                 (Thermal Compatibility {ASTM D648})
                 Materials change in size at                           Filled epoxies behave more like
                 varying rates upon being heated                        concrete or steel
                 or cooled                                                     •       Aggregate gradation is key criteria
                 Neat epoxies expand/contract at
                                                                                       for filled epoxies (gap-grading is
                                                                                       helpful)
                 a higher rate than steel or
                 concrete                                               Important factor for thick layers and
                                                                        bulk applications

                                                          EFFECT of BOND LINE STRESSES
                             50

                             45         NEAT EPOXY (SAND FREE)


                             40

                             35

                             30

                             25
                                                                                        MAXIMUM EPOXY SAND LOAD
                             20
                                  AGGREGATE/BINDER
                                  RATIO EFFECT ON THE
                             15   THERMAL COEFFICIENT OF
                                  EXPANSION FOR AN EPOXY SYSTEM.
                             10

                             5
                                                             CONCRETE 10x6-6

                             0      1        2        3          4      5          6        7       8       9



                                                                                                            ChemCo Systems
Epoxy Applications



Transportation   Properties: Heat deflection temperature (HDT)
                    Temperature an adhesive polymer deflects under 3 point
                     load
                    120ºF is minimum value for ASTM C881 load bearing
                     structural use
                    Cold temperature curing may undermine HDT performance
                    Special adhesives available offering higher HDTs for high
                     temperature use
                    Creep is potential problem if use temp > HDT


                         CONSTANT LOAD 264 psi
                                                                          Variable
                                                                           Hot Oil
                                                                             Bath
                                       EPOXY BEAM 1/2”x1/2”x5”




                                                                      ChemCo Systems
Epoxy Applications



Transportation        Properties: Reactions are exothermic


                         Epoxies produce heat during cure
                         Temperature dependent
                         Mass dependent
                         Can undermine product performance in bulk
                          applications
                         Exotherm may increase apparent shrinkage
                          upon cure
                           • Thick cross-sections and bulk uses should
                             consider special low exotherm systems




                                                                     ChemCo Systems
Epoxy Applications



Transportation   Properties: Cure rate vs. temperature


                                      CURE RATE OF EPOXY ADHESIVES


                              160
                              140
                              120                                      Typical epoxy resin
                              100                                      Slower
                               80                                      Faster
                               60
                               40
                               20
                                0
                                      30   40   50       60       70      80      90         100
                                                Cure T e mpe ra ture D e g. F




                                                                                    ChemCo Systems
Epoxy Applications



Transportation                        Advantages


                     Low shrinkage
                     Tolerates moisture after cure
                     Mechanical and chemical bond
                       • Very high bond strength
                     Cost effective repair vs. complete removal /
                      replacement
                     Chemically inert
                     Long storage life of A and B components
                     Repair is considered permanent


                                                                ChemCo Systems
Epoxy Applications



Transportation
                                      Limitations

                       Thermal incompatibility
                         • Minimal concern with thin glue line
                       Creep
                         • Minimal concern with thin glue line
                       Vapor barrier
                       Proper mixing and ratio is critical
                       Short open time for some formulations
                       Clean-up requires solvents
                       Cure and viscosity is temperature sensitive



                                                                ChemCo Systems
Epoxy Applications



Transportation                        Surface Preparation

                 Clean and free of
                 contaminants (remove loose
                 substrate, laitance, dirt, dust,
                 grease, oils, chemical spills)
                 Metal shot blasting

                 machines, sand blasting,
                 “dust-free” diamond grinding,
                 hydroblast, scarifiers,
                 scabblers
                 Dry--no standing water

                      • Some epoxies are
                        designed for wet or
                        underwater use
                 Prepare surface profile for
                 good mechanical / chemical
                 bonding

                                                            ChemCo Systems
Epoxy Applications



Transportation   Surface prep

                                               Shotblasting




                               Hydroblasting


                                                              ChemCo Systems
Epoxy Applications



Transportation      ASTM Bond Types: I, II, III, IV,V, VI, VII


                   ASTM C-881 (or AASHTO M-235)
                      Crack Repair – pressure injection or gravity feed
                       (Types I & IV)
                      Concrete Bonding (Types II & V)
                      Low mod overlays and spall/joint repair (Type III)

                      Segmental Bridge Adhesives      (Types VI & VII)




                                                                 ChemCo Systems
Epoxy Applications



Transportation                Non-ASTM Specification Uses

                    Miscellaneous Epoxy Products
                      • Base plate grouts
                      • Mortars for patching
                      • Coatings
                      • Control joints and wire loops
                            – Airport runway lighting (see right)
                            – Traffic control
                      • High strength grouts
                      • Polymer concrete
                      • Handicapped access warning strip adhesives
                     Adhesive Anchoring (ICC-ES/AC308)
                     External Structural Strengthening


                                                                     ChemCo Systems
Epoxy Applications



Transportation
                               ASTM C-881 used in crack repair


                      Type I – Non-load bearing, bond hardened
                       concrete to hardened concrete

                      Type IV – Load bearing, bond hardened concrete
                       to hardened concrete




                                                             ChemCo Systems
Epoxy Applications



Transportation                        Why Repair Cracks?




                  Extend structural lifespan   Fix spalls due to freeze/thaw
                                                cycles, unrepaired cracks,
                 Repair settling from poor
                                                steel corrosion
                 soils
                                                Stop leakage in fluid
                 Earthquake damage repair
                                                containing structures (see
                 Cracked member unable to      above)
                 transfer design load           Cracks are unsightly in
                                                architectural concrete
                                                                   ChemCo Systems
Epoxy Applications



Transportation              Crack Treatment Considerations

                                           Some moving cracks may re-
                                            appear after injection

                                           Cracks with hydrostatic pressure
                                            (i.e., running water) are frequently
                                            epoxy treated, but may also be
                                            candidates for urethane grouting if
                                            non-structural

                                           Vertical / Overhead applications –
                                            Injection technique

                                           Horizontal applications – Gravity-
                                            feed or injection

                                           Voids and honeycombed concrete
                                            may require special low exotherm
                                            epoxy
                                                                   ChemCo Systems
Epoxy Applications



Transportation   Crack Treatment Considerations
                 (for reinforced concrete used in structural applications)


                  ACI 224 guidelines for crack width




                  Exposure condition                      Tolerable crack width (in.)   Tolerable crack width (mm)

                  Dry air or protective membrane                       0.016                       0.41

                  Humidity, moist air, soil                            0.012                       0.30

                  De-icing chemicals                                   0.007                       0.18

                  Seawater and seawater spray:                         0.006                       0.15
                  Wetting and drying

                  Water retaining structures (excluding                0.004                       0.10
                  pressure pipes)




                                                                                                 ChemCo Systems
Epoxy Applications



Transportation   Restore monolithic strength




                                               ChemCo Systems
Epoxy Applications



Transportation                        Structural Crack Repairs




                                                                 ChemCo Systems
Epoxy Applications



Transportation   Injection: beams and columns




                                                ChemCo Systems
Epoxy Applications



Transportation   Injection--tunnels




                                      ChemCo Systems
Epoxy Applications



Transportation   Injection--Rail




                                      ChemCo Systems
Epoxy Applications



Transportation   Injection--airports




                                       ChemCo Systems
Epoxy Applications



Transportation   Injection--bridges




                                      ChemCo Systems
Epoxy Applications



Transportation   Injection: pile caps



                                        Mass pours
                                        (large volume
                                        single pours)
                                        can develop
                                        severe cracks
                                        associated
                                        with high heat
                                        buildup during
                                        cure




                                          ChemCo Systems
Epoxy Applications



Transportation           Bridge--Gravity Feed Crack Repair


                                                 For concrete decks with
                                                high amounts of small
                                                crack networks
                                                Gravity feed

                                                Very low viscosity
                                                systems use epoxies and
                                                HMWM (methacrylates)
                                                Open to traffic in 5 hrs

                                                Restore monolithic
                                                integrity to deck
                                                Protect reinforcing steel
                                                from corrosion
                                                Also available in special
                                                long potlife version




                                                            ChemCo Systems
Epoxy Applications



Transportation                 Spray Applied – Gravity feed




                                                              ChemCo Systems
Epoxy Applications



Transportation                        QC Check: Taking Cores




                                                               ChemCo Systems
Epoxy Applications



Transportation                         Visual Inspection




                       Can penetrate cracks as
                      small as 0.002” (0.05 mm)
                                                           ChemCo Systems
Epoxy Applications



Transportation   ASTM Standard C-881 (continued)

                      Type II – Non-load bearing, bond freshly mixed
                       concrete to hardened concrete
                      Type V – Load bearing, bonding freshly mixed
                       concrete to hardened concrete

                      Typical Applications:
                        • Introduction of newly poured concrete for
                          large area repairs.
                        • Primers for overlays (Type III) & patch repairs
                          with epoxy and cementitious mortars.


                                                                 ChemCo Systems
Epoxy Applications



Transportation                        Concrete Bonding

                    Requirements for “fresh to hardened”
                      • Achieve monolithic structural bond of new
                        material to old concrete
                      • Epoxy must have proper viscosity to maintain
                        uniform film thickness of 20 mils
                      • Epoxy must be tacky when new concrete or
                        new material is placed




                                                              ChemCo Systems
Epoxy Applications



Transportation             Bonding: Hardened to Hardened




                                                      ChemCo Systems
Epoxy Applications



Transportation                        Trowel Applied




                                                       ChemCo Systems
Epoxy Applications



Transportation                        Set Precast Panel




                                                          ChemCo Systems
Epoxy Applications



Transportation              Spray Applied Concrete Bonder




                                                       ChemCo Systems
Epoxy Applications



Transportation            Fresh Concrete Pour (over epoxy)




                                                       ChemCo Systems
Epoxy Applications



Transportation   Bridge deck overlay delamination repair




                 Modification of structural crack injection practices
                 Observed more frequently in climates with high cold-to-hot temp

                 ranges (Canada and parts of China)
                 Fill voids between overlay and structural slab

                 Considerable savings compared to replacement of deck overlay




                                                                     ChemCo Systems
Epoxy Applications



Transportation   ASTM Standard C881
                 (cont.)
                Type III – Bond skid
                 resistant materials to
                 hardened concrete
                 (low modulus)
                  • Binders in epoxy
                    mortars used on
                    traffic bearing
                    surfaces (overlays)
                  • Impact resistant joint
                    nosing repair on
                    bridge decks
                  • Handicapped access
                    warning strips

                                             ChemCo Systems
Epoxy Applications



Transportation    Polymer Overlays
                     What is an Overlay?
                      • A resurfacing of an existing horizontal surface
                        (bridge deck or parking structure)

                     Function of overlay
                       • Protects structure
                       • Provides non-skid surface
                       • Extends life of the structure

                     Properties
                       • Low modulus.
                       • Medium viscosity.
                       • Excellent adhesive properties.
                       • Long term abrasion resistance.
                                                                ChemCo Systems
Epoxy Applications



Transportation   Broadcast overlay




                                      ChemCo Systems
Epoxy Applications



Transportation   Seed with aggregate to excess




                                                 ChemCo Systems
Epoxy Applications



Transportation   Completed thin overlay




                                          ChemCo Systems
Epoxy Applications



Transportation   ASTM Standard C-881 (continued)
                 Segmental bridges


                      Type VI – Bonding / sealing segmental precast
                       elements with internal tendons (temporary post
                       tensioning applied)
                        • Normal Set
                      Type VII – For use as a nonstress carrying sealer
                       for segmental precast elements (temporary post
                       tensioning not applied)
                        • Slow Set




                                                                ChemCo Systems
Epoxy Applications



Transportation
                     Segmental Bridges


                      Technology first developed in France
                       and Switzerland in the 1940’s
                      Early projects left segment joints dry
                      Epoxies used since early 1970’s for
                       sealing segments
                      ASBI (American Segmental
                       Bridge Institute)
                        • Developed a standard epoxy
                          specification




                                                                ChemCo Systems
Epoxy Applications



Transportation   Functions of Epoxy Resin (Segmental use)

                    Lubricant - allows segments to slide easily into
                     place during construction
                    Distributes compressive/shear stresses across
                     each joint
                    Provides water-tight seal between segments
                    Prevents loss of cementitious grout at joints when
                     pumped through cable ducts
                    Specific temperature ranges often used




                                                               ChemCo Systems
Epoxy Applications



Transportation                        Apply by Hand




                                                      ChemCo Systems
Epoxy Applications



Transportation                        Place Segments




                                                       ChemCo Systems
Epoxy Applications



Transportation                        Epoxy Squeeze-Out




                                                          ChemCo Systems
Epoxy Applications



Transportation   External strengthening


                         Early applications used steel plate
                         Change in use
                         Used in seismic upgrades
                         Steel and fiberglass forms used on columns
                               Steel saddles on beams
                         Epoxy resin and hand-applied composite fiber
                          wrapping technologies are popular today
                               Fabrics are glass or carbon fiber




                                                                    ChemCo Systems
Epoxy Applications



Transportation
                     Why add Strengthening?




                      Insufficient reinforcement
                      Corrosion of reinforcement
                      Change in use
                      Excessive deflections
                      Structural/Fire damage
                      Seismic upgrade




                                                    ChemCo Systems
Epoxy Applications



Transportation   Failed columns




                                      ChemCo Systems
Epoxy Applications



Transportation   Beam damage




                                      ChemCo Systems
Epoxy Applications



Transportation   External fixes: Stitching




                                      Mid 1960s drawing from US Army Corp of Engineers




                                                                                         ChemCo Systems
Epoxy Applications



Transportation                        Plate strengthening
                                       used with epoxy injection




                                                                   ChemCo Systems
Epoxy Applications



Transportation   Steel saddle (3-sides) over concrete beam
                                      used with epoxy injection




                                                                  ChemCo Systems
Epoxy Applications



Transportation   Column grouting Steel (or rigid fiberglass)   jackets




                                                                     ChemCo Systems
Epoxy Applications



Transportation                        Composite Systems




                                                          ChemCo Systems
Epoxy Applications



Transportation                        Bridge Column Upgrade




                       Applying fairing epoxy to corner




                                                              ChemCo Systems
Epoxy Applications



Transportation   Test substrate adhesion (after surface prep)




                           ASTM D4541
                           (Elcometer)



                                                                ChemCo Systems
Epoxy Applications



Transportation                        Prime Substrate




                                                        ChemCo Systems
Epoxy Applications



Transportation                   Saturate Fabric – Wet Lay-Up




                                                            ChemCo Systems
Epoxy Applications



Transportation                        Apply Saturated Fabric




                                                               ChemCo Systems
Epoxy Applications



Transportation                        Dry Lay-Up




                                                   ChemCo Systems
Epoxy Applications



Transportation       Reinforce Tension Zone with CF strips




                                                Fiberglass bars inset
                                                in pre-cut channels
                                                used in a “stitching”
                                                technique are an
                                                alternative to strips




                                                        ChemCo Systems

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Concrete Repair: Bridges and Tunnels--Epoxies

  • 1. Epoxy Applications Transportation Concrete Repair: Bridges and Tunnels ChemCo Systems
  • 2. Epoxy Applications Transportation Civil uses  Major roles: • Repair and Protection • Infrastructure Renovation – Bridges & Tunnels – Airports – Rail • Structural Rehabilitation – Commercial, Industrial & Residential – Public & Private Sectors ChemCo Systems
  • 3. Epoxy Applications Transportation Corrosion = spalling Iron oxide (corrosion product commonly called rust) occupies about 7 times the volume of a similar mass of steel. The formation of rust generates high internal forces leading to spalling. Spalling is more common in applications with insufficient cover (depth of concrete over the steel reinforcement). ChemCo Systems
  • 4. Epoxy Applications Transportation Salt: tough on steel and concrete ChemCo Systems
  • 5. Epoxy Applications Transportation Monitor crack movement (strain gauge) ChemCo Systems
  • 6. Epoxy Applications Transportation History of Epoxies  1936 First epoxy patents  1940s-50s Bakelight introduces commercial applications (electrical and jewelry)  1948 First use as construction adhesive (hardened-to-hardened concrete bonding)  1954 Caltrans uses bonding agent for traffic markers ChemCo Systems
  • 7. Epoxy Applications Transportation History of Epoxies  late 1950s Patching, bolt grouting, crack injection and overlays more common.  1959 U.S. Army Corp of Engineers issues specification  1959 PG&E dam successfully repaired using meter/mix pump and structural epoxy from Adhesive Engineering  1978 ASTM* C881 spec. published *American Society of Testing and Materials ChemCo Systems
  • 8. Epoxy Applications Transportation Specification for civil engineering ASTM C881 Standard U.S. specification for epoxy bonding systems for concrete  AASHTO* M-235 used by U.S. transportation design engineers as specification for epoxy bonding  AASHTO M235 = ASTM C881 *American Association of State Highway and Transportation Officials ChemCo Systems
  • 9. Epoxy Applications Transportation Properties: Viscosity measure of a material’s resistance to flow—common unit is centipoise (cps) Water = 1 cps Motor Oil = 100 - 500 cps (similar to some unfilled epoxies) Peanut Butter = 250,000 cps (similar to some epoxy pastes) ChemCo Systems
  • 10. Epoxy Applications Transportation Properties: Modulus of Elasticity Ratio of stress to strain  High modulus  rigid or stiff • Structural uses – High creep resistance  Low modulus  flexible • Impact resistant, less brittle ChemCo Systems
  • 11. Epoxy Applications Transportation Properties: Coefficient of Thermal Expansion (Thermal Compatibility {ASTM D648}) Materials change in size at Filled epoxies behave more like varying rates upon being heated concrete or steel or cooled • Aggregate gradation is key criteria Neat epoxies expand/contract at for filled epoxies (gap-grading is helpful) a higher rate than steel or concrete Important factor for thick layers and bulk applications EFFECT of BOND LINE STRESSES 50 45 NEAT EPOXY (SAND FREE) 40 35 30 25 MAXIMUM EPOXY SAND LOAD 20 AGGREGATE/BINDER RATIO EFFECT ON THE 15 THERMAL COEFFICIENT OF EXPANSION FOR AN EPOXY SYSTEM. 10 5 CONCRETE 10x6-6 0 1 2 3 4 5 6 7 8 9 ChemCo Systems
  • 12. Epoxy Applications Transportation Properties: Heat deflection temperature (HDT)  Temperature an adhesive polymer deflects under 3 point load  120ºF is minimum value for ASTM C881 load bearing structural use  Cold temperature curing may undermine HDT performance  Special adhesives available offering higher HDTs for high temperature use  Creep is potential problem if use temp > HDT CONSTANT LOAD 264 psi Variable Hot Oil Bath EPOXY BEAM 1/2”x1/2”x5” ChemCo Systems
  • 13. Epoxy Applications Transportation Properties: Reactions are exothermic  Epoxies produce heat during cure  Temperature dependent  Mass dependent  Can undermine product performance in bulk applications  Exotherm may increase apparent shrinkage upon cure • Thick cross-sections and bulk uses should consider special low exotherm systems ChemCo Systems
  • 14. Epoxy Applications Transportation Properties: Cure rate vs. temperature CURE RATE OF EPOXY ADHESIVES 160 140 120 Typical epoxy resin 100 Slower 80 Faster 60 40 20 0 30 40 50 60 70 80 90 100 Cure T e mpe ra ture D e g. F ChemCo Systems
  • 15. Epoxy Applications Transportation Advantages  Low shrinkage  Tolerates moisture after cure  Mechanical and chemical bond • Very high bond strength  Cost effective repair vs. complete removal / replacement  Chemically inert  Long storage life of A and B components  Repair is considered permanent ChemCo Systems
  • 16. Epoxy Applications Transportation Limitations  Thermal incompatibility • Minimal concern with thin glue line  Creep • Minimal concern with thin glue line  Vapor barrier  Proper mixing and ratio is critical  Short open time for some formulations  Clean-up requires solvents  Cure and viscosity is temperature sensitive ChemCo Systems
  • 17. Epoxy Applications Transportation Surface Preparation Clean and free of contaminants (remove loose substrate, laitance, dirt, dust, grease, oils, chemical spills) Metal shot blasting machines, sand blasting, “dust-free” diamond grinding, hydroblast, scarifiers, scabblers Dry--no standing water • Some epoxies are designed for wet or underwater use Prepare surface profile for good mechanical / chemical bonding ChemCo Systems
  • 18. Epoxy Applications Transportation Surface prep Shotblasting Hydroblasting ChemCo Systems
  • 19. Epoxy Applications Transportation ASTM Bond Types: I, II, III, IV,V, VI, VII ASTM C-881 (or AASHTO M-235)  Crack Repair – pressure injection or gravity feed (Types I & IV)  Concrete Bonding (Types II & V)  Low mod overlays and spall/joint repair (Type III)  Segmental Bridge Adhesives (Types VI & VII) ChemCo Systems
  • 20. Epoxy Applications Transportation Non-ASTM Specification Uses  Miscellaneous Epoxy Products • Base plate grouts • Mortars for patching • Coatings • Control joints and wire loops – Airport runway lighting (see right) – Traffic control • High strength grouts • Polymer concrete • Handicapped access warning strip adhesives  Adhesive Anchoring (ICC-ES/AC308)  External Structural Strengthening ChemCo Systems
  • 21. Epoxy Applications Transportation ASTM C-881 used in crack repair  Type I – Non-load bearing, bond hardened concrete to hardened concrete  Type IV – Load bearing, bond hardened concrete to hardened concrete ChemCo Systems
  • 22. Epoxy Applications Transportation Why Repair Cracks?  Extend structural lifespan Fix spalls due to freeze/thaw cycles, unrepaired cracks, Repair settling from poor steel corrosion soils Stop leakage in fluid Earthquake damage repair containing structures (see Cracked member unable to above) transfer design load Cracks are unsightly in architectural concrete ChemCo Systems
  • 23. Epoxy Applications Transportation Crack Treatment Considerations  Some moving cracks may re- appear after injection  Cracks with hydrostatic pressure (i.e., running water) are frequently epoxy treated, but may also be candidates for urethane grouting if non-structural  Vertical / Overhead applications – Injection technique  Horizontal applications – Gravity- feed or injection  Voids and honeycombed concrete may require special low exotherm epoxy ChemCo Systems
  • 24. Epoxy Applications Transportation Crack Treatment Considerations (for reinforced concrete used in structural applications) ACI 224 guidelines for crack width Exposure condition Tolerable crack width (in.) Tolerable crack width (mm) Dry air or protective membrane 0.016 0.41 Humidity, moist air, soil 0.012 0.30 De-icing chemicals 0.007 0.18 Seawater and seawater spray: 0.006 0.15 Wetting and drying Water retaining structures (excluding 0.004 0.10 pressure pipes) ChemCo Systems
  • 25. Epoxy Applications Transportation Restore monolithic strength ChemCo Systems
  • 26. Epoxy Applications Transportation Structural Crack Repairs ChemCo Systems
  • 27. Epoxy Applications Transportation Injection: beams and columns ChemCo Systems
  • 28. Epoxy Applications Transportation Injection--tunnels ChemCo Systems
  • 29. Epoxy Applications Transportation Injection--Rail ChemCo Systems
  • 30. Epoxy Applications Transportation Injection--airports ChemCo Systems
  • 31. Epoxy Applications Transportation Injection--bridges ChemCo Systems
  • 32. Epoxy Applications Transportation Injection: pile caps Mass pours (large volume single pours) can develop severe cracks associated with high heat buildup during cure ChemCo Systems
  • 33. Epoxy Applications Transportation Bridge--Gravity Feed Crack Repair  For concrete decks with high amounts of small crack networks Gravity feed Very low viscosity systems use epoxies and HMWM (methacrylates) Open to traffic in 5 hrs Restore monolithic integrity to deck Protect reinforcing steel from corrosion Also available in special long potlife version ChemCo Systems
  • 34. Epoxy Applications Transportation Spray Applied – Gravity feed ChemCo Systems
  • 35. Epoxy Applications Transportation QC Check: Taking Cores ChemCo Systems
  • 36. Epoxy Applications Transportation Visual Inspection Can penetrate cracks as small as 0.002” (0.05 mm) ChemCo Systems
  • 37. Epoxy Applications Transportation ASTM Standard C-881 (continued)  Type II – Non-load bearing, bond freshly mixed concrete to hardened concrete  Type V – Load bearing, bonding freshly mixed concrete to hardened concrete  Typical Applications: • Introduction of newly poured concrete for large area repairs. • Primers for overlays (Type III) & patch repairs with epoxy and cementitious mortars. ChemCo Systems
  • 38. Epoxy Applications Transportation Concrete Bonding  Requirements for “fresh to hardened” • Achieve monolithic structural bond of new material to old concrete • Epoxy must have proper viscosity to maintain uniform film thickness of 20 mils • Epoxy must be tacky when new concrete or new material is placed ChemCo Systems
  • 39. Epoxy Applications Transportation Bonding: Hardened to Hardened ChemCo Systems
  • 40. Epoxy Applications Transportation Trowel Applied ChemCo Systems
  • 41. Epoxy Applications Transportation Set Precast Panel ChemCo Systems
  • 42. Epoxy Applications Transportation Spray Applied Concrete Bonder ChemCo Systems
  • 43. Epoxy Applications Transportation Fresh Concrete Pour (over epoxy) ChemCo Systems
  • 44. Epoxy Applications Transportation Bridge deck overlay delamination repair Modification of structural crack injection practices Observed more frequently in climates with high cold-to-hot temp ranges (Canada and parts of China) Fill voids between overlay and structural slab Considerable savings compared to replacement of deck overlay ChemCo Systems
  • 45. Epoxy Applications Transportation ASTM Standard C881 (cont.)  Type III – Bond skid resistant materials to hardened concrete (low modulus) • Binders in epoxy mortars used on traffic bearing surfaces (overlays) • Impact resistant joint nosing repair on bridge decks • Handicapped access warning strips ChemCo Systems
  • 46. Epoxy Applications Transportation Polymer Overlays  What is an Overlay? • A resurfacing of an existing horizontal surface (bridge deck or parking structure)  Function of overlay • Protects structure • Provides non-skid surface • Extends life of the structure  Properties • Low modulus. • Medium viscosity. • Excellent adhesive properties. • Long term abrasion resistance. ChemCo Systems
  • 47. Epoxy Applications Transportation Broadcast overlay ChemCo Systems
  • 48. Epoxy Applications Transportation Seed with aggregate to excess ChemCo Systems
  • 49. Epoxy Applications Transportation Completed thin overlay ChemCo Systems
  • 50. Epoxy Applications Transportation ASTM Standard C-881 (continued) Segmental bridges  Type VI – Bonding / sealing segmental precast elements with internal tendons (temporary post tensioning applied) • Normal Set  Type VII – For use as a nonstress carrying sealer for segmental precast elements (temporary post tensioning not applied) • Slow Set ChemCo Systems
  • 51. Epoxy Applications Transportation Segmental Bridges  Technology first developed in France and Switzerland in the 1940’s  Early projects left segment joints dry  Epoxies used since early 1970’s for sealing segments  ASBI (American Segmental Bridge Institute) • Developed a standard epoxy specification ChemCo Systems
  • 52. Epoxy Applications Transportation Functions of Epoxy Resin (Segmental use)  Lubricant - allows segments to slide easily into place during construction  Distributes compressive/shear stresses across each joint  Provides water-tight seal between segments  Prevents loss of cementitious grout at joints when pumped through cable ducts  Specific temperature ranges often used ChemCo Systems
  • 53. Epoxy Applications Transportation Apply by Hand ChemCo Systems
  • 54. Epoxy Applications Transportation Place Segments ChemCo Systems
  • 55. Epoxy Applications Transportation Epoxy Squeeze-Out ChemCo Systems
  • 56. Epoxy Applications Transportation External strengthening  Early applications used steel plate  Change in use  Used in seismic upgrades  Steel and fiberglass forms used on columns  Steel saddles on beams  Epoxy resin and hand-applied composite fiber wrapping technologies are popular today  Fabrics are glass or carbon fiber ChemCo Systems
  • 57. Epoxy Applications Transportation Why add Strengthening?  Insufficient reinforcement  Corrosion of reinforcement  Change in use  Excessive deflections  Structural/Fire damage  Seismic upgrade ChemCo Systems
  • 58. Epoxy Applications Transportation Failed columns ChemCo Systems
  • 59. Epoxy Applications Transportation Beam damage ChemCo Systems
  • 60. Epoxy Applications Transportation External fixes: Stitching Mid 1960s drawing from US Army Corp of Engineers ChemCo Systems
  • 61. Epoxy Applications Transportation Plate strengthening used with epoxy injection ChemCo Systems
  • 62. Epoxy Applications Transportation Steel saddle (3-sides) over concrete beam used with epoxy injection ChemCo Systems
  • 63. Epoxy Applications Transportation Column grouting Steel (or rigid fiberglass) jackets ChemCo Systems
  • 64. Epoxy Applications Transportation Composite Systems ChemCo Systems
  • 65. Epoxy Applications Transportation Bridge Column Upgrade Applying fairing epoxy to corner ChemCo Systems
  • 66. Epoxy Applications Transportation Test substrate adhesion (after surface prep) ASTM D4541 (Elcometer) ChemCo Systems
  • 67. Epoxy Applications Transportation Prime Substrate ChemCo Systems
  • 68. Epoxy Applications Transportation Saturate Fabric – Wet Lay-Up ChemCo Systems
  • 69. Epoxy Applications Transportation Apply Saturated Fabric ChemCo Systems
  • 70. Epoxy Applications Transportation Dry Lay-Up ChemCo Systems
  • 71. Epoxy Applications Transportation Reinforce Tension Zone with CF strips Fiberglass bars inset in pre-cut channels used in a “stitching” technique are an alternative to strips ChemCo Systems