1. 1. POLYESTER POLYMER CONCRETE Indian Roads Congress Accredited (March 2012) DDR Global Infrastructure Pvt. Ltd. Rajesh Oberoi, P.E. (California, USA) WALIA INTERNATIONAL MACHINES CORPORATION 408, Vishwadeep, District Centre, Janak Puri, New Delhi 110058 Ph # 011-25546044, 25521275, E-mail : waliaintl@yahoo.com Website : www.waliainternational.com
2. 2. Introduction DDR Global Infrastructure Pvt. Ltd. RAJESH OBEROI P.E. (Civil) State of California, USA B.Tech. (Civil), 1981, IIT, Kanpur, India M.S. (Civil), 1985, Univ. of Massachussetts, Amherst, MA, USA
3. 3. 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
4. 4. 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
5. 5. Polyester Concrete background First 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)
6. 6. What is Polyester Concrete? POLYSTER POLYMER CONCRETE (PPC 1121) PORTLAND CEMENT CONCRETE WATER POLYESTER POLYMER RESIN (Unsaturated Isophthalic Poly-Styrene Co-Polymer) CEMENT SAND IS383 SAND IS383 AGGREGATE Natural,10mm Down, River Borne AGGREGATE Crushed, 26.5mm Down
7. 7. Approved by FHWA in year 1988
8. 8. AASHTO Guide Specifications - 1995
9. 9. Indian Roads Congress Accredited - 2012
10. 10. Polyester Concrete use in USA
11. 11. 30+ Years of Proven Performance Polyester Polymer Concrete Overlay Placed in 1983 These Pictures were taken in July 2011
12. 12. Polyester Concrete Properties Thermal coefficient of expansion 14.6 x 10-6 deg C Lower modulus equals less stress Higher tensile and flexural strength High abrasion resistance Excellent bond strength (composite) Very low permeability to water and chlorides Fast setting traffic in about 2 hours
13. 13. 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
14. 14. PERMEABILITY
15. 15. Signature Projects Polyester 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 ADT Vincent Thomas Bridge, Long Beach, CA- 35,000 ADT South Grand Island Bridge Buffalo, NY- 40,000 ADT McCullough Memorial Bridge, Oregon- 20,000 ADT
16. 16. Richmond-San Rafael Bridge Extreme Coastal/Marine Environment Built in 1956, 8.85 KM, Upper & Lower Decks 3 Lanes on Each Deck Left Lane - Grinded Right Lane - Overlain by PPC Middle Lane - Original, Damaged, Potholed, patched
17. 17. 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, NY Extreme Winter Conditions
18. 18. San Francisco - Oakland Bay Bridge Extreme 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
19. 19. Polyester Concrete at Airports Polyester 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
20. 20. Skid Data Marina Viaduct Measured Skid Resistance in 1991 Friction Coefficient = 0.4 Measured Skid Resistance in 2010 Measured by Towed-Trailer Skid Test Friction Coefficient = 0.4
21. 21. Polyester Overlay Construction: Step 1 (If Required): Remove/Grinding existing asphalt or concrete overlay/coating by micro-milling Step 2: Find & Repair spalls or unsound concrete Step 3: Surface Preparation/Shotblasting Step 4: Apply HMWM Resin Prime Coat Step 5: Mix and Pave Step 6: Finish, Tine, sprinkle dry sand, Open to Traffic!
22. 22. 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
23. 23. Polyester Overlay Construction: Step 2: Find & Repair spalls or unsound concrete Construction Keys: Sawcut edges square Remove only unsound material May be placed during overlay Sandblast or shotblast, blow w/ air
24. 24. 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
25. 25. Polyester Overlay Construction: Step 4: Apply HMWM Resin Prime Coat Construction 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
26. 26. 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
27. 27. 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
28. 28. 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
29. 29. 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
30. 30. 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