SECTION [INSERT NUMBER]: RAPID-SET POLYMER PAVEMENT REPAIR
PART 1: GENERAL
1.1 SCOPE
A. This work consists of the rapid structural repair of Portland Cement Concrete (PCC) and Asphalt Concrete (AC) pavements, bridge decks, and industrial floors using a rapid-curing polyurethane resin system. B. The system is engineered to penetrate structural cracks and to be "percolated" over pre-placed, dry aggregates for deep spall restoration.
1.2 REFERENCES
-
AASHTO T84/T85: Specific Gravity and Absorption of Fine/Coarse Aggregates.
-
ASTM C33: Standard Specification for Concrete Aggregates.
-
ASTM C39: Compressive Strength of Cylindrical Concrete Specimens.
-
ASTM D412: Tensile Properties of Vulcanized Rubber and Elastomers.
-
ASTM D624: Tear Strength of Conventional Vulcanized Rubber.
-
ASTM D2240: Durometer Hardness (Shore D).
-
ASTM D2393: Viscosity of Epoxy and Related Resins.
1.3 SUBMITTALS
A. Technical Procedures: Submit detailed protocols for storage, handling, safety (SDS), and mechanical dispensing. B. Trial Installation: If required by the Engineer, the Contractor shall install a trial section to demonstrate batching accuracy, pump calibration, and finishing techniques.
PART 2: MATERIALS
2.1 RAPID-SETTING POLYURETHANE (Percol® Elastic Cement AC)
The resin shall be a two-component, 100% solids system mixed at a 1:1 volume ratio.
Physical Properties (Cured):
2.2 PRE-PLACED AGGREGATE
Aggregate shall be clean, kiln-dried, and conform to ASTM C33.
-
Depth < 1.5": 1/4" Aggregate.
-
Depth 1.5" to 3": 1/2" Aggregate.
-
Depth > 3": 1" Aggregate.
-
Moisture Content: Shall not exceed 0.5% (one-half of the aggregate's absorption).
2.3 SKID-RESISTANT AGGREGATE
Topping sand shall be commercial-quality dry blast sand (No. 4 to No. 16 mesh).
PART 3: EXECUTION
3.1 SURFACE PREPARATION
A. General: The substrate must be clean, sound, and 100% dry. All oil, grease, paint, and laitance must be removed via abrasive blasting. B. Moisture Protocol: Pavement must be dry for at least 24 hours. For emergency repairs in damp conditions, a heat lance or hot air must be used to ensure the bond interface is bone-dry. C. Edges: Spalls exceeding 1 sq. ft. must be saw-cut to a minimum depth of 3/4" with a vertical or undercut edge.
3.2 PLACEMENT TEMPERATURE
A. Ambient: 0°F to 100°F. B. Material: Resin components must be maintained between 50°F and 85°F. For applications below 40°F, pre-heat aggregate and resin to 60°F+.
3.3 MIXING & DISPENSING
A. Mechanical: Use only manufacturer-approved metering/dispensing equipment. Hand-mixing is prohibited. B. Calibration: Pump calibration must ensure a mix ratio accuracy within ±5%.
3.4 INSTALLATION
A. Spall Repair: Pre-fill spall with dry aggregate to grade. Flood with resin until the aggregate is completely saturated. B. Crack Repair: Flood prepared cracks to refusal. C. Finishing: Strike off to grade. Immediately broadcast skid-resistant sand (minimum 0.8 lbs/sq. yd) before the resin gels.
3.5 TRAFFIC RETURN
Traffic may resume once the resin has cured sufficiently to prevent aggregate loss.
-
70°F: ~15 minutes.
-
50°F: ~40 minutes.
-
30°F: ~70 minutes.
PART 4: MEASUREMENT & PAYMENT
A. Volume Basis: Rapid-setting urethane repairs shall be measured by the total volume (gallons) of resin binder used in the work, exclusive of waste and trial sections. B. Unit Price: The contract price per gallon shall include all labor, tools, equipment, aggregate, and incidentals required to complete the repair as specified.
