POLYESTER POLYMER CONCRETEIndian Roads Congress Accredited (March 2012)

DDR Global Infrastructure Pvt. Ltd.

Rajesh Oberoi, P.E. (California, USA)

WALIA INTERNATIONAL MACHINES CORPORATION408, Vishwadeep, District Centre, Janak Puri, New Delhi – 110058

Ph # 011-25546044, 25521275, E-mail : waliaintl@yahoo.comWebsite : www.waliainternational.com

Introduction

DDR Global Infrastructure Pvt. Ltd.

RAJESH OBEROIP.E. (Civil) State of California,

USAB.Tech. (Civil), 1981, IIT,

Kanpur, IndiaM.S. (Civil), 1985, Univ. of

Massachussetts, Amherst, MA, USA

Why Polyester Concrete for Overlays in India? Proven technology with a track record

of 30+ years ELIMINATES Maintenance Cost Provides almost 100% protection

against chloride intrusion Provides high skid resistance Quick return to service in less than 2

hrs Can be placed in one lift from 25mm –

300 mm Exceptional Bond Strength Used in EXTREME CLIMATIC

CONDITIONS with Altitude, Marine/Coastal, Humid, Freeze-Thaw and Desert Environments

Polyester

Concrete

Bond line

Break line

What is Polyester Concrete?A very durable composite

material made of hardened polyester resin, coarse aggregate and sand.

The polyester resin serves as the binding agent - similar to hydrated Portland Cement in PCC.

Engineered Material with Consistent Properties.

Polyester

Concrete

Bond line

Break line

Polyester Concrete backgroundFirst use of current system 1983 – Thomson

Creek & Beaver Creek Bridges, Yreka, California, USA

1985/86 Highway overlay I-80 (10 lane miles), California, USA

5 million m2 (55 million ft2) surface in place on BRIDGES ALONE in 20 States in the USA equates to approximately 1,500 km of single lane

TODAY – An average of 2 tenders/month are advertised in just one State (California)

What is Polyester Concrete?POLYSTER POLYMER

CONCRETE (PPC 1121)PORTLAND CEMENT

CONCRETE

WATER

POLYESTER POLYMER RESIN (Unsaturated IsophthalicPoly-Styrene Co-Polymer)

CEMENT

SAND IS383

SANDIS383

AGGREGATENatural,10mm Down, River

Borne

AGGREGATECrushed, 26.5mm Down

Approved by FHWA in year 1988

AASHTO Guide Specifications - 1995

Indian Roads Congress Accredited - 2012

Polyester Concrete use in USA

30+ Years of Proven Performance

Polyester Polymer Concrete Overlay Placed in 1983

These Pictures were taken in

July 2011

Polyester Concrete Properties Thermal coefficient of expansion – 14.6 x 10-6

deg CLower modulus equals less stressHigher tensile and flexural strengthHigh abrasion resistanceExcellent bond strength (composite)Very low permeability to water and chloridesFast setting – traffic in about 2 hours

Key Engineering Properties

 Polyester Polymer

Concrete (PPC 1121)

Portland Cement(8-Bags)

Chloride Permeability,Coulombs 0 – 200 1,000 - 3,000

Compressive Strength 565 Kg/cm2 490 Kg/cm2

24-hr Early Strength 280 Kg/cm2 105 Kg/cm2

Flexural Strength 155 Kg/cm2 55 Kg/cm2

Modulus of Elasticity(E) 7000 - 14000 Mpa 21000 - 35000

Mpa

Abrasion 0.25mm/year 4.0 mm/year

Open to Traffic 2 - 4 Hours 3 - 7 Days

PERMEABILITY

Signature ProjectsPolyester Polymer Concrete Overlays

San Francisco-Oakland Bay Bridge, CA- 300,000 ADT

Richmond San Rafael Bridge, CA- 80,000 ADT

Benicia Martinez Bridge, CA – 100,000 ADTVincent Thomas Bridge, Long Beach, CA-

35,000 ADTSouth Grand Island Bridge Buffalo, NY-

40,000 ADTMcCullough Memorial Bridge, Oregon-

20,000 ADT

Richmond-San Rafael BridgeExtreme Coastal/Marine EnvironmentBuilt in 1956, 8.85 KM, Upper & Lower Decks – 3 Lanes on Each DeckLeft Lane - GrindedRight Lane - Overlain by PPCMiddle Lane - Original,

Damaged, Potholed, patched

1 KM long critical link, Niagara Falls and Buffalo, NY was overlaid with Polyester Concrete.

Completed: night and full weekend closures

Largest polyester project to date on East Coast

Tough winter weather conditions

Overlay applied to newly replaced precast deck system to protect thin 100 mm concrete deck section

South Grand Island Bridge, NYExtreme Winter Conditions

San Francisco - Oakland Bay BridgeExtreme Coastal/Marine Environment

Built in 1936 Total Length = 7.18 km Deck Surface overlaid with 25 mm Thick

PPC Total of 110,000 Square Meters One of the busiest bridges in the US 300,000+ vehicles per day 5 lanes on the upper and lower deck

Polyester Concrete at AirportsPolyester Concrete has been used at airports across the country for spall and concrete repairs:

�San Diego International Airport �Southern CA Logistics Airport �Marine Corps Air Station Pendleton �Sacramento International Airport �Niagara Falls Guard Station Airport �Denver International Airport �Dallas Fort Worth International Airport �Los Angeles International Airport

�PPC 1121 - High Resistance to Jet Fuel/Aviation Hydraulic Fluids

Skid DataMarina Viaduct

Measured Skid Resistance in 1991 Friction Coefficient = 0.4

Measured Skid Resistance in 2010Measured by Towed-Trailer Skid Test Friction Coefficient = 0.4

Polyester Overlay Construction:Step 1 (If Required): Remove/Grinding existing asphalt or

concrete overlay/coating by micro-millingStep 2: Find & Repair spalls or unsound concreteStep 3: Surface Preparation/ShotblastingStep 4: Apply HMWM Resin Prime CoatStep 5: Mix and PaveStep 6: Finish, Tine, sprinkle dry sand, Open to Traffic!

Polyester Overlay Construction:Step 1 (If Required): Remove existing asphalt

or concrete overlay/coating by micromilling Construction Keys:

Use specialized equipment to prevent damage to concrete deck (Caltrans Micromill spec) 6mm tooth spacing Hand removal near metal joints Remove slurry seals, chip seals etc. Potholing may be needed to determine existing overlay thickness

Polyester Overlay Construction:Step 2: Find & Repair spalls or unsound

concreteConstruction Keys:

Sawcut edges square Remove only unsound material May be placed during overlay Sandblast or shotblast, blow w/ air

Polyester Overlay Construction:Step 3: Surface

Preparation/Shotblasting Construction Keys

The objective is a surface free of loose material, laitance, previous coatings or oils.

Utilize shotblasting machines Reblast if too much primer

applied in previous shift Remove traffic stripe or buttons

prior to shotblasting Should be blown off with high

pressure air after shotblasting

Polyester Overlay Construction:Step 4: Apply HMWM Resin

Prime CoatConstruction Keys:

Minimize puddling Place overlay within 15 mins of

placing primer and/or before primer gels

Can be applied with sprayer or rollers

Paving equipment may drive on prime coat

Deck surface temperature between 0 to 350C

Dry deck surface conditions

Polyester Overlay Construction: Step 5: Mix and Pave

Construction Keys Volumetric mixer ensures best product consistency Paver should have grade control & should consolidate overlay Polyester concrete should be thoroughly mixed and should be

applied within 3-5 minutes of mixing

Polyester Overlay Construction: Step 6: Finish, Tine, Apply Sand,

Open to Traffic! Construction Keys:

Edges should be tapered, joints/ends may require hand finishing

Expansion joints must be blocked out or sawcut within 4 hours

Sand should be applied uniformly, with additional sand for wet or glossy looking areas

Tining should be applied by paving machine or shortly after

Paving may be opened to traffic after Schmidt hammer reading of 24 or greater

Polyester Concrete Spall Repair

Step 1: Determine limits, sawcut rectangular

Step 2: Chip and remove unsound concrete, prep and blow clean

Step 3: Apply HMWM prime coat

Step 4: Place and finish polyester concrete, apply sand

Summary Polymer Concrete Overlay 30+ years of Proven performance. Used in EXTREME CLIMATIC CONDITIONS with Altitude,

Marine/Coastal, Humid, Freeze-Thaw and Desert Environments ELIMINATES almost 100% Maintenance Cost High Strength – Flexural, Tensile, and Compressive Strength 100% Seals bridge deck surfaces against chloride intrusion,

Extremely low permeability to seal the deck Superior adhesion, Exceptional Bond Strength Placement temperature - 00 C to 350 C Performance Temperature: -500 C to +500 C Open to traffic quickly – in 2 hours Provides high skid resistance Thermal coefficient of expansion – compatible to PCC Lower modulus and higher creep equals less stress Excellent abrasion resistance – 16 Times Portland Cement

Concrete Thin composite - minimizing dead load/clearance issues Improves ride quality and drainage MULTIPLE USES APPLICATION – ONE MATERIAL

WHAT ABOUT THE COST?OVER A LIFE OF 30 YEARS

Polyester Polymer Concrete

Overlay (25 mm)

Conventional Overlay on Concrete

(Typical 65-100mm)

Rs. 4,500/Sq. m. Rs. 60,000/Sq. m.

Rs. 1.25 Cr/Km Lane Length

Rs. 21 Cr/Km Lane Length