United States Department of Transportation
i
Polymer concrete bridge deck overlays : Deschutes River Bridge (Biggs) and Maupin Bridge (Maupin) : final report.
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1995-07-01
[PDF-2.15 MB]
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Alternative Title:Polymer concrete bridge deck overlays : Deschutes River Bridge (Biggs) and Maupin Bridge (Maupin).
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Abstract:This report documents the construction and performance of two thin polymer concrete (with polyester/styrene resins) bridge deck overlays. The overlays were constructed in Biggs and Maupin, Oregon in June 1993.
Several problems were encountered during construction the resulted in bare spots and/or rough riding surface. The bare spots could be attributed to the polymer concrete curing before aggregate placement. Maintaining a uniform grade and providing a smooth riding surface was difficult because of bare spot repair, could joints, and joint repair. More than 900 sq. ft. of delamination was noted at the Deschutes River Bridge within six months following construction; 4,500 sq. ft. was noted after 1 1/2 years. More than 2,200 sq. ft. of delamination was noted at the Maupin Bridge after six months; 6,600 sq. ft. was noted after 1 1/2 years. The polymer concrete has broken loose and is easily removed in blocks. Both overlays are scheduled for removal in the fall of 1995.
We recommended that controlled field tests of polymer concrete (with polyester/styrene resins) be required before these products are used extensively by ODOT. When the next polymer concrete overlay is constructed the following recommendations should be followed to aid proper placement:
a) Drains shall be temporarily covered to keep the slurry mix out.
b) All deck striping shall be removed prior to overlay construction.
c) The contractor shall be required to maintain a continuous delivery of materials to the bridge deck during overlay construction. The amount of material available for application should be evenly matched with the number of construction workers.
d) Joint repair shall include the removal of material 12 to 18 inches on each side of the joint. Heavy shot blasting or 1/4-inch diamond grinding shall be used for concrete removal around the joints. The material used to fill the joint shall be feathered in to provide a smooth riding surface.
e) Workers shall not be allowed to walk on the fresh overlay to broadcast the aggregate.
f) The aggregate shall be broadcast from a distance to provide uniform coverage and allow the wind to remove finer particles.
g) The overlay shall be feathered to zero inches at the drains to reduce the possibilities of standing water at the curb line.
h) Final ranking shall be in the direction of traffic.
i) If edge tape (duct tape) is used, it shall be removed as soon as possible (if the mix sets up, edge tape removal may cause delamination).
j) Gauge rakes shall be checked and hooks replaced frequently to maintain the specified minimum thickness of overlay.
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