ACI 548.8M-2007 Specification for Type EM (Epoxy Multi-Layer) Polymer Overlay for Bridge and Parking Garage Decks.pdf

1、Reported by ACI Committee 548ACI 548.8M-07Specification for Type EM(Epoxy Multi-Layer) PolymerOverlay for Bridge andParking Garage DecksAn ACI StandardSpecification for Type EM (Epoxy Multi-Layer) Polymer Overlayfor Bridge and Parking Garage DecksFirst PrintingOctober 2007ISBN 978-0-87031-261-8Ameri

2、can Concrete InstituteAdvancing concrete knowledgeCopyright by the American Concrete Institute, Farmington Hills, MI. All rights reserved. This materialmay not be reproduced or copied, in whole or part, in any printed, mechanical, electronic, film, or otherdistribution and storage media, without the

3、 written consent of ACI.The technical committees responsible for ACI committee reports and standards strive to avoid ambiguities,omissions, and errors in these documents. In spite of these efforts, the users of ACI documents occasionallyfind information or requirements that may be subject to more th

4、an one interpretation or may beincomplete or incorrect. Users who have suggestions for the improvement of ACI documents arerequested to contact ACI. Proper use of this document includes periodically checking for errata atwww.concrete.org/committees/errata.asp for the most up-to-date revisions.ACI co

5、mmittee documents are intended for the use of individuals who are competent to evaluate thesignificance and limitations of its content and recommendations and who will accept responsibility for theapplication of the material it contains. Individuals who use this publication in any way assume all ris

6、k andaccept total responsibility for the application and use of this information.All information in this publication is provided “as is” without warranty of any kind, either express or implied,including but not limited to, the implied warranties of merchantability, fitness for a particular purpose o

7、rnon-infringement.ACI and its members disclaim liability for damages of any kind, including any special, indirect, incidental,or consequential damages, including without limitation, lost revenues or lost profits, which may resultfrom the use of this publication.It is the responsibility of the user o

8、f this document to establish health and safety practices appropriate tothe specific circumstances involved with its use. ACI does not make any representations with regard tohealth and safety issues and the use of this document. The user must determine the applicability of allregulatory limitations b

9、efore applying the document and must comply with all applicable laws and regulations,including but not limited to, United States Occupational Safety and Health Administration (OSHA) healthand safety standards.Order information: ACI documents are available in print, by download, on CD-ROM, through el

10、ectronicsubscription, or reprint and may be obtained by contacting ACI.Most ACI standards and committee reports are gathered together in the annually revised ACI Manual ofConcrete Practice (MCP).American Concrete Institute38800 Country Club DriveFarmington Hills, MI 48331U.S.A.Phone: 248-848-3700Fax

11、: 248-848-3701www.concrete.orgACI 548.8M-07 was adopted September 2007 and published October 2007.Copyright 2007, American Concrete Institute.All rights reserved including rights of reproduction and use in any form or by anymeans, including the making of copies by any photo process, or by electronic

12、 ormechanical device, printed, written, or oral, or recording for sound or visual reproductionor for use in any knowledge or retrieval system or device, unless permission in writingis obtained from the copyright proprietors.548.8M-1Specification for Type EM (Epoxy Multi-Layer) Polymer Overlay for Br

13、idgeand Parking Garage DecksAn ACI StandardReported by ACI Committee 548ACI 548.8M-07This Specification covers epoxy multi-layer (EM) polymer overlay forbridge and parking garage decks. Type EM polymer overlay incorporates alow-modulus epoxy binder and selected aggregate to produce a flexible,skid-r

14、esistant, and waterproof overlay. The overlay may be used for bothnew construction and rehabilitation. The overlay is placed by applying theneat epoxy binder to the surface and broadcasting aggregate. This Specifi-cation includes requirements for chemical components, aggregates, storageand handling,

15、 surface preparation, surface profile, mixing, placement, andfinishing.Keywords: bridge decks; epoxy; multi layer; parking garage decks; polymeroverlay; surface preparation.NOTE TO SPECIFIERThis Specification is incorporated by reference in theProject Specification using the wording in P3 of the Pre

16、faceand including information from the Mandatory Requirementsand Submittals Checklists following the Specification.PREFACEP1. ACI Specification 548.8M is intended to be used byreference or incorporation in its entirety in the ProjectSpecification. Do not copy individual Parts, Sections, Articles,or

17、Paragraphs into the Project Specification, because takingthem out of context may change their meaning.P2. If Sections or Parts of ACI Specification 548.8M arecopied into the Project Specification or any other document,do not refer to them as an ACI Specification, because theSpecification has been al

18、tered.P3. A statement such as the following will serve to makeACI Specification 548.8M a part of the Project Specification:“Work on (Project Title) shall conform to all requirements ofACI 548.8M-07, Specification for Type EM (Epoxy Multi-Layer) Polymer Overlay for Bridge and Parking GarageDecks, pub

19、lished by the American Concrete Institute,Farmington Hills, Michigan, except as modified by ContractDocuments.”P4. Each technical section of ACI Specification 548.8M iswritten in the three-part Section format of the ConstructionSpecifications Institute, as adapted for ACI requirements.The language i

20、s imperative and terse.P5. The Specification is written to the Contractor. When aprovision of this Specification requires action by Contractor,the verb “shall” is used. If Contractor is allowed to exercisean option when limited alternatives are available, thephrasing “either.or” is used. Statements

21、provided in theSpecification as information to Contractor use the verbs“may” or “will.” Informational statements typically identifyactivities or options that “will be taken” or “may be taken”by the Owner or Architect/Engineer.Herschel H. Allen III David W. Fowler Mahmoud M. Reda Taha Donald P. Tragi

22、aneseMilton D. Anderson Robert W. Gaul John R. Robinson Cumaraswamy VipulanandanJohn J. Bartholomew Larry E. Good Donald A. Schmidt Wafeek S. WahbyConstantin Bodea Albert O. Kaeding Qizhong Sheng Harold H. Weber, Jr.James T. Dikeou John R. Milliron Joe Solomon David WhiteHarold (Dan) R. Edwards Brad

23、 Nemunaitis Michael M. Sprinkel David P. WhitneyGarth J. Fallis Richard C. PrusinskiMichael S. StenkoChair548.8M-2 ACI STANDARDCONTENTSPreface, p. 548.8M-1Section 1General, p. 548.8M-21.1Scope1.2Reference standards1.3Reference organizations1.4Submittals1.5Project conditions1.6Labeling, storage, and

24、handling of materials1. 7SafetySection 2Products, p. 548.8M-32.1Epoxy binder2.2Aggregate2.3Polymer overlaySection 3Execution, p. 548.8M-33.1Procedure qualification3.2Surface preparation3.3Mixing epoxy binder3.4Overlay application3.5Curing3.6Excess aggregate removal3.7Joints3.8Open to trafficForeword

25、 to checklists, p. 548.8M-4Mandatory requirements checklist, p. 548.8M-5Submittal checklist, p. 548.8M-5SECTION 1GENERAL1.1Scope1.1.1 This Specification covers materials and proceduresfor constructing a polymer overlay for new construction andfor repair and rehabilitation of bridge and parking garag

26、edecks. Type EM polymer overlay incorporates a low-modulus,multi-component epoxy binder and selected aggregate toproduce a flexible, skid-resistant, and waterproof overlay.This Specification includes requirements for chemicalcomponents, aggregates, storage and handling, surfacepreparation, surface p

27、rofile, mixing, placement, finishing,quality control, and quality assurance.1.1.2 The provisions of this Specification shall governunless otherwise specified in the Contract Documents.1.1.3 UnitsValues stated in SI units are to be regardedas standard.1.2Reference standards1.2.1 ASTM StandardsC566-97

28、 Standard Test Method for Total Evaporable(2004) Moisture Content of Aggregate by DryingC579-01 Standard Test Methods for Compressive Strength(2006) of Chemical-Resistant Mortars, Grouts, Mono-lithic Surfacings, and Polymer ConcretesC778-06 Standard Specification for Standard SandC881/ Standard Spec

29、ification for Epoxy-Resin-BaseC881M-02 Bonding Systems for ConcreteC884/ Standard Test Method for Thermal Compatibility C884M-98 between Concrete and an Epoxy Resin Overlay(2005)C1583-04 Standard Test Method for Tensile Strength ofConcrete Surfaces and the Bond Strength orTensile Strength of Concret

30、e Repair and OverlayMaterials by Direct Tension (Pull-off Method)D638-03 Standard Test Method for Tensile Properties ofPlasticsD2393-86 Standard Test Method for Viscosity of EpoxyResins and Related Components (withdrawn)D3278-96 Standard Test Methods for Flash Point of Liquids (2004)e1 by Small Scal

31、e Closed-Cup ApparatusD4263-83 Standard Test Method for Indicating Moisture (2005) in Concrete by the Plastic Sheet Method1.2.2 SSPC standardsSSPC-SP 10/NACE No. 2, Near White Metal Blast Cleaning1.3Reference organizationsAbbreviations for and complete names and addresses oforganizations issuing doc

32、uments referred to in this Specifi-cation are listed:ASTM International100 Barr Harbor DriveWest Conshohocken, PA 19428www.astm.orgThe Society for Protective Coatings (SSPC)40 24th Street6th FloorPittsburgh, PA 15222-4656www.sspc.org1.4Submittals1.4.1 Submit a certificate of compliance and qualityco

33、ntrol test results verifying conformance to materialspecifications for each manufactured batch of epoxy and lotof aggregate. A lot or batch is a quantity of materialmanufactured at one time and placed into containers.1.4.2 Submit material and product data sufficient for theArchitect/Engineer to eval

34、uate the system, including allinstallation instructions and quality control proceduresrequired to assure an acceptable finished overlay.1.4.3 Submit safety data sheets.1.5Project conditions1.5.1 Cold weather limitsDo not place overlay when thetemperature of the deck or applicable surface and polymer

35、materials is below 15 C unless otherwise recommended bythe material manufacturer and accepted by the Architect/Engineer.1.5.2 Hot weather limitsDo not place overlay if the 70 mLjob site production samples have gel times less than 10 minutesor if the broadcast aggregate will not penetrate the epoxy l

36、ayer.1.5.3 Moisture limitsDo not place the overlay onsurfaces unless they are moisture free when tested in accor-dance with ASTM D4263.SPECIFICATION FOR TYPE EM POLYMER OVERLAY FOR BRIDGE AND PARKING GARAGE DECKS 548.8M-31.6Labeling, storage, and handling of materials1.6.1 LabelingMark product conta

37、iners with thefollowing information:Name of manufacturer;Manufacturers product identification;Material quantity;Manufacturers mixing instructions;Warning for storage and handling; andHazard information.1.6.2 StorageStore epoxy resins and hardeners in anarea that prevents them from getting wet. Store

38、 them awayfrom open flames and other sources of ignition. Store epoxyresins and hardeners at temperatures between 15 and 45 Cunless otherwise recommended by the material manufacturer.Store aggregates in an area that prevents them from getting wet.1.7SafetyHeed all warnings of Material Safety Data Sh

39、eets andmanufacturers labels.SECTION 2PRODUCTS2.1Epoxy binderMulti-component epoxy shall meet the requirements listedin Tables 2.1 and 2.2. All components used for physical testingshall be maintained at 23.0 C (1.0 C) for a minimum of24 hours before mixing, curing, or testing. Do not use epoxysystem

40、s containing solvents and unreactive diluents.2.2AggregateAggregate shall meet the gradation requirements in Table 2.3and have hardness of six or higher on the Mohs hardnessscale. Aggregate shall be angular, shall consist of naturalsilica sand, basalt, or other nonfriable aggregate, and shallcontain

41、 less than 0.2% moisture when tested in accordancewith ASTM C566.2.3Polymer overlayType EM polymer overlay shall meet the requirements ofTable 2.4.SECTION 3EXECUTION3.1Procedure qualification3.1.1 EquipmentRemove deteriorated concrete, grease,dirt, oil, and other contaminants that inhibit bond of th

42、eoverlay with blasters using steel shot or grit abrasives.3.1.2 Quality control procedure qualificationSpecify asurface preparation technique (size and flow of abrasive,forward speed, and number of passes of the blastingmachine) that shall expose coarse aggregate and ensureadhesion of the overlay to

43、 the substrate. Remove all loosematerial to result in a dust-free surface before application.Use this quality control procedure (Sections 3.1.2.1 through3.1.2.6) to determine that the materials, batching, mixing,placing, and curing procedures provide the required adhesion ofthe overlay to the substr

44、ate.3.1.2.1 Test locations will be designated for qualitycontrol to evaluate the range of surface conditions on thearea to be overlaid, including areas with deck repairs, if any.The engineer shall designate one test location to be evaluatedfor each span or 400 m2, whichever is smaller for bridges,an

45、d 400 m2 for parking decks.3.1.2.2 At each test location selected by the Engineer,prepare a minimum surface area of 0.4 m2using the equipmentand procedures proposed for project surface preparation.3.1.2.3 Prepare the surface and apply the overlay atdesignated quality control test locations.3.1.2.4 A

46、pply overlays at quality control test locations atthe same thickness and with the same materials, equipment,personnel, timing, sequence of operations, and curing periodthat will be used on the project.3.1.2.5 Evaluate the test overlays using the proceduredescribed in ASTM C1583, except that the tens

47、ile adhesionevaluation shall not be performed at surface temperaturesabove 27 C. Core through the test overlay to a depth of 10 mmTable 2.1Properties of mixed, uncured epoxy binderProperty Value Test methodViscosity 700 to 2500 mPasASTM D2393 (No. 3 at20 rpm, Brookfield RVT)Gel time at 23 C 15 to 45

48、 minutesASTM C881/C881M(modified 70 mL)Flash point 93 C ASTM D3278Table 2.2Physical properties of cured epoxy binder at 7 daysProperty Value Test methodTensile strength 12 to 34 MPa ASTM D638 (Type I)Tensile elongation 30 to 70% ASTM D638 (Type I)Modulus of elasticity, maximum90 MPa ASTM D638 (Type

49、I)Table 2.3Deck aggregate gradationBroadcast bridge deck aggregate gradationMesh size Percent passing4.75 mm 1002.36 mm 30 to 751.18 mm 0 to 5600 m0 to 1Broadcast parking deck aggregate gradationMesh size Percent passing2.36 mm 1001.18 mm 51 to 75850 m 14 to 50600 m0 to 25425 Table 2.4Properties of Type EM polymer overlayProperty Value Test methodCompressive strength*7 MPa (3 hours)34 MPa (24 hours)ASTM C579, Method BThermalcompatibility*PassASTM C884/C884M, Method BBond strength,*minimum1.7 MPa ASTM C1583*Samples should be m