1、ACI 548.9M-08Reported by ACI Committee 548Specification for Type ES(Epoxy Slurry) Polymer Overlayfor Bridge and Parking Garage DecksAn ACI StandardSpecification for Type ES (Epoxy Slurry) Polymer Overlayfor Bridge and Parking Garage DecksFirst PrintingAugust 2008ISBN 978-0-87031-295-3American Concre
2、te 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 written c
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4、erpretation 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 committee do
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9、ying 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 electronicsu
10、bscription, 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: 248-848-
11、3701www.concrete.orgACI 548.9M-08 was adopted July 1, 2008 and published August 2008.Copyright 2008, 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 ormechanical
12、 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.548.9M-1Specification for Type ES (Epoxy Slurry) Polymer Overlay for Bridge and Parking G
13、arage DecksAn ACI StandardReported by ACI Committee 548ACI 548.9M-08This Specification covers epoxy slurry (ES) overlay for bridge and parkinggarage decks. Type ES polymer overlay incorporates low-modulus epoxy-based slurry and selected aggregate to produce a flexible, skid-resistant,and water-resis
14、tant overlay. The overlay may be used for both newconstruction and rehabilitation. The overlay is placed by applying thepolymer slurry to the surface and broadcasting aggregate. This Specificationincludes requirements for chemical components, aggregates, storage andhandling, surface preparation, sur
15、face profile, mixing, placement,finishing, and quality control.Keywords: aggregate; bridge decks; epoxy; mortar; overlays; parkinggarage decks; polymer; premixed; resin; slurry.CONTENTSSection 1General, p. 548.9M-21.1Scope1.2Reference standards1.3Reference organizations1.4Submittals1.5Project condit
16、ions1.6Labeling, storage, and handling of materials1.7SafetySection 2Products, p. 548.9M-22.1Epoxy binder2.2Aggregate2.3Polymer overlay slurrySection 3Execution, p. 548.9M-33.1Procedure qualification3.2Surface preparation3.3Mixing epoxy binder3.4Overlay application3.5Curing3.6Excess aggregate remova
17、l3.7Joints3.8Open to trafficNotes to Specifier, p. 548.9M-4Foreword to checklists, p. 548.9M-4Mandatory Requirements Checklist, p. 548.9M-5Submittals Checklist, p. 548.9M-5Herschel H. Allen III David W. Fowler Mahmoud M. Reda Taha Donald P. TragianeseMilton D. Anderson Robert W. Gaul John R. Robinso
18、n 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 Nemunaitis Michael M. Sprinkel David P. WhitneyGarth
19、J. Fallis Richard C. PrusinskiMichael S. StenkoChair548.9M-2 ACI STANDARDSECTION 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 garagedecks. Type ES polymer overlay
20、 incorporates a low-modulus epoxy binder, filler, and selected aggregate toproduce a flexible, skid-resistant, and water-resistant overlay.This Specification includes requirements for chemicalcomponents, aggregates, storage and handling, surfacepreparation, surface profile, mixing, placement, finish
21、ing,and quality control.1.1.2 The provisions of this Specification shall governunless otherwise specified in the Contract Documents.1.1.3 UnitsValues are stated in SI units.1.2Reference standards1.2.1 ASTM International standardsC566-97(2004) Test Method for Total EvaporableMoisture Content of Aggre
22、gate byDryingC579-01(2006) Test Methods for CompressiveStrength of Chemical-ResistantMortars, Grouts, MonolithicSurfacings, and Polymer ConcretesC778-06 Specification for Standard SandC881/C881M-02 Specification for Epoxy-Resin-BaseBonding Systems for ConcreteC884/C884M-98(2005) Test Method for Ther
23、mal Compati-bility between Concrete and anEpoxy-Resin OverlayC1583-04 Test Method for Tensile Strength ofConcrete Surfaces and the BondStrength or Tensile Strength ofConcrete Repair and Overlay Materialsby Direct Tension (Pull-off Method)D638-03 Test Method for Tensile Propertiesof PlasticsD2393-86
24、Standard Test Method for Viscosityof Epoxy Resins and RelatedComponents*D3278-96(2004)e1Test Methods for Flash Point ofLiquids by Small Scale Closed-CupApparatusD4263-83(2005) Test Method for Indicating Moisturein Concrete by the Plastic SheetMethod1.2.2 SSPC standardsSSPC-SP 10/NACE No. 2 Near Whit
25、e Metal Blasting1.3Reference organizationsAbbreviations for and complete names and addresses oforganizations issuing documents referred to in this Specificationare listed:ASTM International100 Barr Harbor DriveWest Conshohocken, PA 19428www.astm.orgThe Society for Protective Coatings (SSPC)40 24th S
26、treet, 6th FloorPittsburgh, PA 15222-4656www.sspc.org1.4Submittals1.4.1 Submit a certificate of compliance and qualitycontrol test results, verifying conformance to materialspecifications in Section 2 for each manufactured batch ofepoxy and lot of aggregate. A lot or batch is a quantity ofmaterial m
27、anufactured at one time and placed into containers.1.4.2 Submit materials and product data sufficient for theArchitect/Engineer to evaluate the system including allinstallation instructions and quality control proceduresrequired to ensure an acceptable finished overlay.1.5Project conditions1.5.1 Col
28、d weather limitsDo not place overlay when thetemperature of the deck or applicable surface and polymermaterials is below 15 C unless otherwise recommended by thematerial manufacturer and accepted by the Architect/Engineer.1.5.2 Hot weather limitsDo not place overlay if the 70 mLjob-site production s
29、amples have gel times less than 10 minutesor if the broadcast aggregate will not penetrate the epoxy layer.1.5.3 Moisture limitsDo not place the overlay onsurfaces unless they are moisture-free when tested inaccordance with ASTM D4263.1.6Labeling, storage, and handling of materials1.6.1 LabelingMark
30、 product containers with the following 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 get
31、ting wet. Store 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 on Material
32、 Safety Data Sheets andmanufacturers labels.SECTION 2PRODUCTS2.1Epoxy binderMulti-component epoxy shall meet the requirements listedin Tables 2.1 and 2.2. All components used for physicaltesting shall be maintained at 23.0 1.0 C for a minimumof 24 hours before mixing, curing, or testing. Do not usee
33、poxy systems containing solvents and unreactive diluents.*This document has been withdrawn.SPECIFICATION FOR TYPE ES POLYMER OVERLAY FOR BRIDGE AND PARKING GARAGE DECKS 548.9M-32.2AggregateAggregate shall meet the gradation requirements in Table 2.3and have a hardness of six or higher on the Mohs ha
34、rdnessscale. Aggregate shall be angular and consist of natural silicasand, basalt, or other nonfriable aggregate and shall containless than 0.2% moisture when tested in accordance withASTM C566.2.3Polymer overlay slurryType ES polymer overlay slurry shall meet the requirementsof Table 2.4.SECTION 3E
35、XECUTION3.1Procedure qualification3.1.1 EquipmentRemove deteriorated concrete, grease,dirt, oil, and other contaminants that inhibit bond of theoverlay with blasters using steel shot or grit abrasives.3.1.2 Quality-control procedure qualificationSpecify asurface preparation technique (size, flow of
36、abrasive, forwardspeed, number of passes of the blasting machine) that shallexpose coarse aggregate and ensure adhesion of the overlay tothe substrate. Remove all loose material to result in a dust-freesurface before application. Use this quality-control procedure(Sections 3.1.2.1 through 3.1.2.6) t
37、o determine that thematerials, batching, mixing, placing, and curing proceduresprovide the required adhesion of the overlay to the substrate.3.1.2.1 Test locations will be designated for quality-control tests to evaluate the range of surface conditions onthe area to be overlaid, including areas with
38、 deck repairs, ifany. The Architect/Engineer shall designate one test locationto be evaluated for each span or 400 m2, whichever issmaller, for bridges, and 400 m2 for parking decks.3.1.2.2 At each test location selected by the Architect/Engineer, prepare a minimum surface area of 0.4 m2usingthe equ
39、ipment and procedures proposed for project surfacepreparation.3.1.2.3 Prepare the surface and apply the overlay todesignated quality-control test locations.3.1.2.4 Apply overlays at quality-control test locations atthe same thickness and with the same materials, equipment,personnel, timing, sequence
40、 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 tensile adhesionevaluation shall not be performed at surface temperaturesabove 27 C. Core through the test overlay to a depth of10 3 mm int
41、o the underlying concrete slab. An evaluationshall be an average of three tests at each location within thequality-control test location and have an average minimumpulloff strength of 1.7 MPa.3.1.2.6 If the test results do not meet the required 1.7 MPaaverage pulloff strength, check the surface prep
42、arationprocedures and repeat the tests. If the test results still do notmeet the required 1.7 MPa average pulloff strength, checkthe manufacturers batching, mixing, placing, and curingrequirements, and repeat the test until the required pulloffstrength is achieved.3.1.3 Quality control of surface pr
43、eparationSurfacesprepared for overlay application shall have the same surfaceprofile as accepted test areas in Section 3.1.2.3.2Surface preparation3.2.1 Concrete decksPrepare the overlay area using theapproved surface preparation until the specified substrateconditions have been achieved.3.2.2 Steel
44、 decksPrepare steel surfaces according toSSPC-SP 10/NACE No. 2, resulting in minimum surfaceprofiles of 0.1 mm. If flash rust appears, reblast the surfaceto SSPC-SP 10/NACE No. 2 specifications.Table 2.1Properties of mixed, uncuredepoxy binderProperty Value Test methodViscosity 700 to 2500 mPasASTM
45、D2393 (No. 3 at20 rpm, Brookfield RVT)Gel time at 23 C 15 to 45 minutesASTM C881/C881M(modified 70 mL)Flash point 93 C ASTM D3278Table 2.2Physical properties of curedepoxy binderProperty Value Test methodTensile strength 12 to 34 MPa ASTM D638 (Type I)Tensile elongation 30 to 70% ASTM D638 (Type I)M
46、odulus of elasticity, maximum90 MPa ASTM D638 (Type 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 758
47、50 m 14 to 50600 m0 to 25425 Table 2.4Properties of Type ES 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 made using 2.75 vo
48、lume parts 20-30 sand per ASTM C778, 850 to600 m sieve to one volume part of mixed epoxy.548.9M-4 ACI STANDARD3.2.3 Blasted surface shall be free of dust and other loosematerial that can interfere with the bonding of the overlay.3.2.4 If the Architect/Engineer determines that there hasbeen a deviati
49、on from the accepted surface preparationprocedure, prepare the suspect areas using the acceptedmethod or verify surface preparation in suspect areas usingASTM C1583 procedure.3.2.5 Obtain inspection and acceptance by the Architect/Engineer of patching and surface preparation before placementof the overlay.3.3Mixing epoxy binder3.3.1 Mix the epoxy binder according to the manufacturersinstructions.3.3.2 When continuous mixing is specified, use equipmentthat continually meters, mixes, and dispenses the epoxy binder.3.3.3 T
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