ACI 548.5R-2016 Guide for Polymer Concrete Overlays.pdf

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1、Guide for Polymer Concrete OverlaysReported by ACI Committee 548ACI 548.5R-16First PrintingJanuary 2016ISBN: 978-1-942727-39-2Guide for Polymer Concrete OverlaysCopyright by the American Concrete Institute, Farmington Hills, MI. All rights reserved. This material may not be reproduced or copied, in

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11、crete Institute38800 Country Club DriveFarmington Hills, MI 48331Phone: +1.248.848.3700Fax: +1.248.848.3701www.concrete.orgThis guide provides an overview of thin (less than 1 in. 25 mm thick) polymer concrete overlays for concrete and steel substrates. Emphasis is placed on their use in the transpo

12、rtation sector, specif-ically for bridge decks and parking garages. Surface preparation, application, quality control, and safety aspects are included.Keywords: aggregate; bridge deck; epoxy; high friction surface; methyl methacrylate; mortar; overlay; parking garage decks; polyester; polymer concre

13、te; premixed; resin; skid resistance; slurry.CONTENTSCHAPTER 1INTRODUCTION, p. 21.1General, p. 21.2History of polymer concrete overlays, p. 21.3Scope, p. 2CHAPTER 2DEFINITIONS, p. 3CHAPTER 3POLYMER BINDERS, p. 33.1General, p. 33.2Properties of polymer binders, p. 33.3Epoxies, p. 43.4Polyesters, p. 5

14、3.5Methacrylates, p. 5CHAPTER 4POLYMER CONCRETE, p. 64.1General, p. 64.2Aggregates, p. 64.3Properties of polymer concrete, p. 6CHAPTER 5SURFACE PREPARATION, p. 75.1General, p. 75.2Concrete surfaces, p. 75.3Steel surfaces, p. 85.4Evaluation of surface preparation, p. 9CHAPTER 6APPLICATION OF POLYMER

15、CONCRETE OVERLAYS, p. 96.1General, p. 96.2Multiple-layer overlay, p. 106.3Premixed or slurry overlays, p. 11Brad Nemunaitis, Chair Mahmoud M. Reda Taha, SecretaryACI 548.5R-16Guide for Polymer Concrete OverlaysReported by ACI Committee 548Ashraf I. AhmedMohammad A. AlhassanJacques A. BertrandConstan

16、tin BodeaChris DavisDavid W. FowlerQuentin L. HibbenAlbert O. KaedingJohn R. MillironMyles A. MurryJoseph A. Nuciforo JrJohn R. RobinsonMichael L. SchmidtJoe SolomonMichael M. SprinkelMichael S. StenkoDonald P. TragianeseWafeek S. WahbyDavid WhiteRichard E. WollmershauserConsulting MembersMilton D.

17、AndersonLu AnqiCraig A. BallingerJohn J. BartholomewShashi P. BhatnagerZhi-Yuan ChenLech CzarneckiHarold (Dan) R. EdwardsLarry J. FarrellJack J. FontanaGeorge HoreczkoDavid P. HuBert Paul KriekemansDeon KrugerWilliam LeeTroy D. MadeleyHenry N. Marsh JrPeter MendisPeter J. MossYoshihiko OhamaKelly M.

18、 PageHamid SaadatmaneshDonald A. SchmidtMeyer SteinbergHarold H. Weber JrACI Committee Reports, Guides, and Commentaries are intended for guidance in planning, designing, executing, and inspecting construction. This document is intended for the use of individuals who are competent to evaluate the si

19、gnificance and limitations of its content and recommendations and who will accept responsibility for the application of the material it contains. The American Concrete Institute disclaims any and all responsibility for the stated principles. The Institute shall not be liable for any loss or damage a

20、rising therefrom.Reference to this document shall not be made in contract documents. If items found in this document are desired by the Architect/Engineer to be a part of the contract documents, they shall be restated in mandatory language for incorporation by the Architect/Engineer.ACI 548.5R-16 su

21、persedes ACI 548.5R-94(98) and was adopted and published January 2016Copyright 2016, American Concrete Institute.All rights reserved including rights of reproduction and use in any form or by any means, including the making of copies by any photo process, or by electronic or mechanical device, print

22、ed, written, or oral, or recording for sound or visual reproduc-tion or for use in any knowledge or retrieval system or device, unless permission in writing is obtained from the copyright proprietors.1CHAPTER 7QUALITY CONTROL, p. 137.1Quality control needs, p. 13CHAPTER 8STORAGE, HANDLING, AND SAFET

23、Y, p. 138.1General, p. 138.2Storage, p. 138.3Handling and safety, p. 13CHAPTER 9REFERENCES, p. 14Authored documents, p. 14CHAPTER 1INTRODUCTION1.1GeneralReinforced concrete, steel grid, and steel orthotropic decks are constantly exposed to deicing salts and other environ-mental factors such as acid

24、rain and pollution chemicals. Escalating costs of preservation and replacement of bridges and parking garage decks have promoted construction and maintenance options such as high-density concrete overlays, latex-modified concrete overlays, membrane/asphalt overlays, cathodic-protection systems, epox

25、y-coated reinforcing bars, and thin polymer concrete (PC) overlays (Mo et al. 2012).Each option has advantages and disadvantages that should be analyzed before a choice is made. Costs vary by region with the availability of materials and experienced contractors. In addition, the life expectancies of

26、 these options are different.Bridges and parking garage decks contain structural elements that are susceptible to premature failures due to moisture, chlorides, freezing and thawing, and wear from high traffic volumes.1.1.1 AdvantagesCompared with other overlay systems, PC overlays are cost effectiv

27、e on a life cycle cost basis (Kim and Lee 2013). Rapid-cure characteristics of PC overlays minimize disruptions, reduce traffic-control costs, and ease the inconvenience of scheduling repairs. With dead load of only 2 to 6 lb/ft2(9.8 to 29.3 kg/m2), PC overlays result in greater live-load capacity t

28、han heavier conventional systems. This is a critical factor to be considered for aging structures. At application thicknesses of 3/8 to 1 in. (10 to 25 mm), PC overlays do not require modification of expansion joints or drainage structures. They are highly resistant to the penetra-tion of water and

29、exhibit better chloride-intrusion resistance than other types of concrete overlays. In addition, they offer a high skid resistance and wearing resistance for both concrete and steel deck protection (Lopez-Anido et al. 1998; Wang et al. 2013). PC overlays can be installed without special-ized equipme

30、nt; however, technical expertise is required. Maintaining quality control is important, and proper surface preparation requires close attention.1.1.2 DisadvantagesA disadvantage associated with PC overlays is that they must be applied to dry surfaces. The workability and curing rate of PC overlays a

31、re dependent on the substrate, material, and ambient temperatures. Polymer overlays are not intended to provide resistance to reflective cracking.1.2History of polymer concrete overlaysPolymer concrete (PC) overlays date back to the 1950s, with original systems consisting of a single layer of coal-t

32、ar epoxy evenly spread over the substrate and broadcast with aggregate. These overlays were relatively porous and did not stand up well to heavy traffic. In the early 1960s, oil-extended epoxy came into use in an attempt to improve resistance to water penetration. By the mid-1970s, low- and medium-m

33、odulus 100 percent solids epoxy formulas were introduced, and many of these systems continue to be used successfully today.By the mid-1960s, single- and double-layer polymer broadcast systems and polyester resins, and methyl meth-acrylate overlays were introduced. The first premixed and screeded pol

34、ymer and aggregate systems also appeared at this time. Thicker PC overlays and brittle materials were used, frequently exhibiting cohesive failure in the concrete. Through trial and error, resin formulations were modified to provide better thermal compatibility and improved physical properties. Resi

35、stance to chemical and mechanical attack, corrosion resistance, and performance under adverse instal-lation conditions have also been the subject of extensive development. For instance, Whiting (1991) showed, using field measurements, that corrosion current in reinforced concrete bridge deck substra

36、tes is decreased when a low-permeability overlay (for example, latex-modified concrete overlay) was installed. Virmani (1992) showed that electri-cally conductive PC overlays can be used as secondary anodes to distribute cathodic protection current across the concrete surface and provide a skid- and

37、 water-resistant surface. PC overlays have been shown to be successful, though some problems still exist. Many of these problems are the result of inadequate surface preparation, improper application tech-niques, or inappropriate selection of polymer materials.There have been many improvements in PC

38、 materials and technology. PC overlays are now generally specified with flexible resins and high-friction wear-resistant aggregates. Workmanship and inspection techniques have also improved as designers, inspectors, and applicators have gained experi-ence related to the causes and prevention of PC o

39、verlay defects continues to improve. Some of the best practices on PC over-lays have been reported by Fowler and Whitney (2011).1.3ScopeThis guide is intended to aid in the proper selection and application of PC overlays for structures in the transpor-tation industry, focusing primarily on bridge an

40、d parking garage decks. Materials discussed are epoxies, polyesters, and methacrylates for application on either concrete or steel surfaces.In general, these overlays are used for the protection of the substrate and are designed to be compatible without causing stress. The low permeability of PC ove

41、rlays makes them resistant to the penetration of water and provides protec-tion against chloride penetration. Overlays are designed to minimize deterioration from repeated thermal expansion and contraction (Fowler et al. 2001). In addition to describing the characteristics of PC overlays, this guide

42、 includes chap-American Concrete Institute Copyrighted Material www.concrete.org2 GUIDE FOR POLYMER CONCRETE OVERLAYS (ACI 548.5R-16)ters on surface preparation, application, quality control, and handling and safety. The information should allow the reader to select materials for a given application

43、 and may serve as the basis for the preparation of overlay specifications.CHAPTER 2DEFINITIONSPlease refer to the latest version of ACI Concrete Termi-nology (https:/www.concrete.org/store/productdetail.aspx?ItemID=CT13) for a comprehensive list of definitions. Definitions provided herein complement

44、 that resource.A/B componentindividual parts of a polymer binder system; components typically consist of resin and curing agent (also known as a hardener).broadcastto scatter over a wide area by hand or mechanical method.catalystsubstance that markedly speeds up the curing of a binder when added in

45、minor pressive strengthmeasured maximum resistance of a concrete or mortar specimen to axial loading; expressed as force per unit cross-sectional area.crosslinkingjoining of preformed linear polymer chains to each other to form three-dimensional networks.cure timeinterval after mixing in which a pol

46、ymer concrete system develops the required strengthflexibilizeradditive that gives a rigid plastic flexability.gel timetime interval after mixing that a liquid material exhibits a significant viscosity increase.high-molecular-weight methacrylatelow-viscosity substituted methacrylate monomer that is

47、characterized by low volatility.initiatorsubstance capable of causing the polymeriza-tion of a monomer by a chain reaction mechanism.methyl methacrylatelow-viscosity methacrylate monomer that is characterized by high volatility.monomerorganic liquid of relatively low molecular weight that creates a

48、solid polymer by reacting with itself, other compounds of low molecular weight, or both.organic peroxidessources of free radicals used in polymerization and crosslinking.polyestergroup of resins, mainly produced by reaction of unsaturated dibasic acids with dihydroxy alcohols; commonly dissolved in

49、a vinyl group monomer such as styrene.promotersreducing agent compounds added to the monomer system to cause the decomposition of the peroxide initiators in the system (often called accelerators).reflective crackingphenomenon where cracks form in the overlay directly over existing cracks in the substrate.ruttingformation of a depression in the overlay.scarificationprocess of scratching, cutting, or chipping the existing concrete surface for the purpose of cleaning and texturing it.sensitizationact, process, or res