ARMY TM 5-822-9

AIR FORCE AFM 88-6, Chap. 10

DEPARTMENTS OF THE ARMY

AND THE AIR FORCE

TECHNICAL MANUAL

REPAIR OF RIGID PAVEMENTS,USING EPOXY RESIN GROUTS,MORTARS, AND CONCRETES

DEPARTMENTS OF THE ARMY, AND THE AIR FORCEJANUARY 1989

TM 5-822-9/AFM 88-6, Chap. 10

REPRODUCTION AUTHORIZATION/RESTRICTIONS

This manual has been prepared by or for the Government and is public

property and not subject to copyright.

Reprints or republications of this manual should include a credit substan-

tially as follows: “Joint Departments of the Army and the Air Force, USA,

TM 5-822-9/AFM 88-6, Chapter 10, Repair of Rigid Pavements Using

Epoxy Resin Grouts, Mortars, and Concretes, 20 January 1989.”

*This manual supersedes TM 5-822-9, dated January 1978.

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A

TM 5-822-9/AFM 88-6, Chap.10*

TECHNICAL MANUAL HEADQUARTERS

No. 5-822-9 DEPARTMENTS OF THE ARMY

AIR FORCE MANUAL AND THE AIR FORCE

NO. 88-6, CHAPTER 10 WASHINGTON, DC, 20 January 1989

REPAIR OF RIGID PAVEMENTS USING EPOXY RESINGROUTS, MORTARS, AND CONCRETES

Paragraph PagePURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1APPROVED EPOXY MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2EFFECTIVE TEMPERATURE AND CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2AGGREGATES FOR EPOXY RESIN CONCRETES AND MORTARS . . . . . . . . . . . . . . . 8 3SAMPLING AND TESTING EPOXY RESINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3TRIAL BATCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3FIELD MIXING AND BATCH SIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 4PROCEDURES FOR CONDITIONS 1 AND 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 4PROCEDURE FOR CONDITION 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4PROCEDURE FOR CONDITION 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 6PROCEDURE FOR CONDITION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 6PROCEDURE FOR CONDITION 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 8PROCEDURE FOR CONDITION 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 9PROTECTION OF REPAIRED AREAS FROM WEATHER AND TRAFFIC . . . . . . . . . . 18 9CLEANING OF EQUIPMENT AND TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 9SAFETY AND HEALTH PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 9INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 10APPENDIX A: REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1APPENDIX B: INSPECTION, SAMPLING, AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

1. Purpose. This manual presents materials, cri- f. Epoxy resin grout. The product obtained byteria, and procedures for rapid repair of uncon- combining a filler with the epoxy resin system. Thetrolled cracks and spalls in rigid pavements by using filler and the epoxy resin system are obtained fromepoxy resin grouts, mortars, and concretes. This the formulator.guidance is applicable to the repair of rigid g. Epoxy resin mortar. The product obtained bypavements on roads and airfields. combining a fine aggregate with the epoxy resin2. References. Appendix A contains a list of system.references used in this document. h. Epoxy resin concrete. The product obtained3. Definitions. a. Epoxy resin. The resin by combining both fine and coarse aggregate withcomponent of a thermosetting polymer which the epoxy resin system.contains epoxy groups principally responsible for its 4. General. Expedient methods of repairing un-polymerization. controlled cracks and spalls in rigid pavements are

b. Epoxy resin system. The product resulting often required to minimize the time a pavement isfrom the combination of all the components sup- closed to traffic. Approved epoxy resins, describedplied for use as an epoxy resin system. herein, provide binding agents particularly suitable

c. Binder. The cementitious part of a grout, for use in this type of work where a high degree ofmortar, or concrete that binds the aggregate or bond in a short period of time is needed. The highfiller into a cohesive mass. strengths obtainable in a short curing time usually

d. Component. A constituent that is intended to permit regular traffic on the pavements within 24 tobe combined with one or more other constituents to 48 hours after the repair, depending uponform the epoxy resin system. temperature conditions. The epoxy resins specified

e. Filler. A finely divided solid, predominantly react most favorably when air and surfacepassing the No. 200 sieve, that is used to improve temperatures are in the range of 70 degrees F tocertain properties of the epoxy resin system or to 100 degrees F, but satisfactory results can bereduce cost. obtained at temperatures as low as 40 degrees F, if

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proper conditions are provided as described herein.Generally pavement repairs with epoxy materialsshall not be initiated unless the air and pavementtemperatures are above 40 degrees F and rising.Class A epoxy resin shall be used if the temperatureis below 40 degrees F.5. Approved epoxy materials. Many epoxyresins for repairing rigid pavement are availableunder a variety of trade names. Selection of theproper epoxy resin is required to obtain satisfactoryresults for the work described in this manual.Epoxy resins shall conform to the American Societyfor Testing and Materials (ASTM) C 881. ThisASTM specification designates three types, grades,and classes of epoxy resins. Type I is used to bondhardened concrete and other materials to hardenedconcrete; Type II is used to bond freshly mixedconcrete to hardened concrete; Type III is used tobond skid-resistant materials to hardened concrete,and as a binder in epoxy resin mortars or epoxyresin concretes. A bond strength of 1,400 poundsper square inch (psi) shall be used for Type III inlieu of the 300 psi shown in Table 1 of ASTM C881. The three grades are defined according toviscosity: Grade 1-low viscosity, Grade 2-mediumviscosity, Grade 3-nonsagging consistency or highviscosity. Grade 3 is used primarily on verticalfaces. The three classes are defined according to therange of temperatures for which they are suitable:Class A for use below 40 degrees F, Class B for usebetween 40 and 60 degrees F, and Class C for useabove 60 degrees F.6. Applications. The general applications or in-tended uses of the materials are as follows:

a. Type I. Used for cementing dowels in drilledand preformed holes and for pressure grouting ofnonworking cracks. Grade 1 shall be used forpressure grouting.

b. Type II. Used as the adhesive for bondingfreshly mixed portland cement concrete (PCC) tohardened PCC. Grade 2 is preferred, but Grade 1can be used.

c. Type III. Used as a binder in epoxy resinmortars or epoxy resin concretes for repairingspalls and for filling nonworking joints.7. Effective temperature and conditioning.a. Pavements. Paragraph 5 presents the threeclasses of epoxy resins defined according to tem-perature. If pavement and atmospheric tempera-tures are less than 70 degrees F but not below 50degrees F, satisfactory repairs can be obtainedwithout creating an artificial environment, providedthe slightly increased cure time can be tolerated.The artificial environment can be a suitabletemporary structure designed to provide theminimum specified temperature for repairs. If

seasonal air temperatures are above 90 degrees F,repairs should be scheduled in early morning or theareas should be protected from direct sunlight priorto initiating repair operations. High air temperature(90 degrees F and above) will decrease the workingtime for placement of epoxy resin mortars andepoxy resin concretes. When pavementtemperatures are less than 50 degrees F, infraredheat lamps or other suitable heat sources should beplaced over the area to be repaired forapproximately 3 hours prior to placementoperations. Gentle winds can make the heat lampsineffective; therefore, temporary windbreaks shouldbe used as necessary. The raising of the pavementtemperature by the use of heat lamps reduces theheat loss into the pavement and permits a desirablemoderate heat buildup from the exothermic reactionwhich occurs when the two components of theepoxy system are combined. Although asatisfactory repair can be obtained if this moderateheat buildup does not occur, the lack of moderateheat buildup may prolong a satisfactory cure-out orhardening and thereby delay reopening to traffic.Similarly, the cure-out or hardening period forepoxy resin concretes and mortars can beaccelerated during cool weather by the use ofheated enclosures over the repaired area. Themethod of attaining the desired air temperature inthe enclosure must avoid creating localized hotspots which may cause bubbling of the liquidepoxies and also induce cracking. The best methodfor heating an enclosed area is to circulate heatedair with added precautions to ensure surfacetemperatures in the repaired areas do not exceed100 degrees F during the hardening stage.

b. Conditioning of aggregates. In the prepara-tion of epoxy resin concretes and mortars, aggre-gates should be dry and conditioned to a tempera-ture of 70 to 85 degrees F. The moisture content ofthe aggregates should not exceed 1.0 percent byweight of the aggregates. The addition of epoxymaterial to cold aggregates will result in increasedviscosity and decreased stability of the mixture.Low temperatures of the final mixture will beconducive to a reduced hardening rate. If theaggregates are too hot, the epoxy-curing agentreaction will be accelerated, making placement andfinishing difficult and possibly resulting in cracking.

c. Conditioning of epoxy resin components. Theviscosity of the two components of an epoxy resinincreases as temperatures decrease. In order toreadily obtain a homogeneous mixture of the twocomponents, the materials should be conditioned to

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60 to 100 degrees F prior to mixing with amechanical stirring device. Although adequateuniformity of the mixture might be obtained atlower temperatures by a prolonged mixing timewhen epoxy resin concretes or mortars are beingprepared, an overly “rich” mixture (a mixturecontaining excess epoxy resin) could occur due tothe reduced wetting capability.

d. “Triggering” curing chemical reaction. Toexpedite resumption of traffic over a repair area forlow pavement and atmospheric temperatureconditions, the early hardening rate of the epoxybinders can be appreciably accelerated. This may beaccomplished by warming the aggregates before theaggregates are added to the epoxy resin.Aggregates may be warmed by storing in a heatedbuilding, by burners, or by radiation. Care must betaken not to heat aggregates excessively becausesuch heating can limit the working life of the epoxymortars and epoxy concretes. Aggregatetemperatures above 120 degrees F shall be avoided.8. Aggregates for epoxy resin concretesand mortars. a. Concretes. The aggregates usedfor epoxy resin concretes should be clean, dry,washed gravel or crushed stone, 3/8-inch or ½-inchmaximum size, well graded from coarse to fine, andof the same quality as those used for PCC andbituminous mixtures. Fine aggregate and coarseaggregate of indicated sizes meeting the require-ments of ASTM C 33 should be specified for epoxyresin concrete mixtures.

b. Mortars. The fine aggregate used for epoxyresin mortars is required to conform to eitherASTM C 144 or ASTM C 33. The aggregateshould be well graded from coarse to fine with aminimum amount of material passing the No. 100sieve. The maximum size required will depend onthe intended use of the mortar. For example, in thefilling of saw kerfs, the normal width of the cutrequires the use of an aggregate with 100 percentpassing the No. 8 sieve. In general, for both epoxyresin concrete and mortar, the maximum sizeaggregate should not exceed one-third of thethickness of the layer being placed nor one-third ofthe width of the opening being filled.9. Sampling and testing epoxy resins. Allepoxy resins proposed for use should be tested forcompliance with the requirements of the applicablespecification. The manufacturer*s certificates ofcompliance with the requirements will not beaccepted in lieu of tests for large jobs. The USArmy Engineer Waterways Experiment Station andthe South Pacific Division Laboratories, US ArmyCorps of Engineers, have been designated toconduct the required tests for acceptance of epoxyresins. The method of sampling, amount of sample

required, and the test procedures are given inappendix B. If epoxy resin concretes are to be used,samples of fine aggregate and coarse aggregateshould be submitted for testing. The contractor isrequired to supply the testing laboratory theproportions of aggregate used by weight or vol-ume.10. Trial batches. a. Epoxy resin mortars andepoxy resin concretes. Variations in aggregategrading and particle shape may affect the propor-tions required to obtain an economical mixture thathas satisfactory placing and finishing characteristics.Small laboratory trial batches shall be prepared andtested prior to the start of field placementoperations. The quantity of epoxy resin systemprepared for use in these trial batches should be atleast 300 grams. The labels on the shippingcontainers will specify the manufacturer*srecommended mixing proportions. A polyethylenecontainer having a hemispherical (convex) bottomshould be used as the mixing vessel. Therecommended proportions of the two componentsare added to the mixing vessel and mixed until auniform mixture is obtained. The rate of stirringshould be such that the amount of entrapped air isminimized. Hand-mixing is usually unsatisfactoryand a powerdriven (air or spark-proof), propeller-type blade should be used. The mixed epoxy resinsystem must be uniform and homogeneous. Mixingmay require 2 to 5 minutes depending on theviscosity and density of the epoxy resin. Epoxyresin concrete proportions by weight may vary from6 to 10 parts aggregate to 1 part epoxy resinbinder, which is equivalent to a ratio of approxi-mately 4 to 7 parts aggregate to 1 part epoxy resinbinder by volume. The aggregate mixture (fine andcoarse aggregate) should contain 55 ± 5 percentfine aggregate by weight. The epoxy resin mortarsmay vary from 4 to 7 parts aggregate by weight to1 part epoxy resin binder, which is equivalent to aratio of approximately 3 to 5 parts aggregate to 1part epoxy resin binder by volume. The proportionssuggested are applicable only to aggregates in the2.60 to 2.80 specific gravity range. Aggregateshaving specific gravities above or below thesevalues will probably require adjustment of thesuggested proportions. The trial batch procedurewill assist field personnel in obtaining the properproportions of aggregate and binder in preparingthe larger field batches.

b. Epoxy resin system and epoxy resin grout.Trial batches are not required when using an epoxyresin system as a bonding medium between plasticand hardened PCC or when using epoxy resin groutfor filling cracks and/or placing dowels. The twocomponents of a grout will usually be mixed in the

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proportions specified by the producer withoutadditional fillers and/or aggregate.11. Field mixing and batch size. Smallmechanical mixers of the drum type and mortarmixers have been used successfully for mixingepoxy resin concrete and mortars. Small batches ofapproximately 0.1 cubic foot (1 gallon) can behand-mixed using a spatula or trowel. Themaximum batch size will be limited by the ability tothoroughly mix the epoxy resin system andaggregate. Experience has demonstrated that themaximum batch size will range from 200 to 300pounds (1.5 to 2.0 cubic feet). Prior to startingoperations, the immediate on-site availability of allmaterials and the suitability and adequacy of themixing and placing tools shall be carefully checked.Several 2- to 5-gallon plastic graduated bucketshave been found to be satisfactory forproportioning by volume. The mixing procedure ofan epoxy resin system must produce a uniform andhomogeneous mix. The components of the epoxyresin system are mixed by stirring or agitation toeffectively put them into solution. For mixing epoxyresin systems in small containers (1 quart), aspatula, palette knife, or similar device can be used.For larger volumes, the epoxy resin system shall bemechanically mixed in plastic buckets. A paintmixing paddle driven by a low-speed electric drillmay be used for the mixing. After mixing the epoxycomponents, the mixture should be immediatelytransferred to the mixing pan (small mixes) or themechanical mixer (large mixes) and the aggregatesimmediately added. Delays in adding the aggregateto the mixed epoxy resin system can result in a lossof the binder due to the accelerated chemicalreaction. In mixing epoxy resin concrete, the largeaggregate should be added to the mixed epoxy resinbinder first, followed by the fine aggregate. Thisorder of addition will help prevent the tendency ofthe mix to “ball.” The mechanical mixers should becleaned immediately after usage to prevent theepoxy compounds from curing in the mixers. High-pressure water can be used to remove the uncuredepoxy if used shortly after the application. Themost widely used cleaning method is to immersethe tools and wash the mixers with solvents such asmethyl-ethyl-ketone or methylene chloride. Mineralspirits or toluene may also be used with greatersafety although they are not as efficient as thepreviously mentioned solvents. If the epoxy resinshave hardened on the tools or mixers, strippers,mechanical abrasion, or burning will be necessary toremove the cured epoxies.12. Procedures for conditions 1 and 2.Conditions of pavements, as described in thismanual, are shown in figure 1. Conditions 1 and 2

require that the random crack be widened with arotary-type grooving tool and sealed with a jointsealer so as to function as the working joint, andthe existing nonworking joint be filled with anepoxy resin mortar. The vertical faces of the jointgroove should be free of oils, greases, residual finesfrom sawing operation, or other coatings. All fillersand joint sealant material should be removed fromthe joint. Oils and greases will rarely be present, butif inspection indicates areas of even minor traces ofoil and grease, these areas shall be cleaned bysandblasting. Inspection of joints or other smallopenings can be facilitated by using a small mirrorto reflect light into the opening. Residual fines fromsawing operations or sandblasting should beremoved by the use of high-pressure water jetfollowed by an air jet to dry the concrete beforeapplying the epoxy resin system. A moderately richepoxy resin mortar should be used for filling jointgrooves and other small openings where it may bedifficult to hand-fill and compact a lean mix.However, care should be exercised to ensure thatthe epoxy resin mortar is not so rich that thematerial flows. The epoxy resin mortar batch sizeshould be adjusted so that the personnel availablecan complete all placing and finishing operationsbefore the epoxy resin mortar starts to gel. Thebatching operations will follow the same sequenceas that for trial batches. The epoxy resin system isprepared first and the fine aggregate graduallyadded while continuing mixing until all particles arecoated. After the joint or crack has been filled withthe epoxy mortar, the surface should be neatlyfinished, flush with the pavement surface, usingappropriate hand tools. Excess material shall becarefully removed and not thinly spread on theadjacent concrete.13. Procedure for condition 3. Repair of thistype of condition requires that the area within thebroken corner (fig. 1) be removed and replacedwith new PCC. The new concrete will be bonded tothe old concrete with an epoxy resin system at theprepared vertical faces of the patch area. Thevertical face of the joint must be maintained toprevent the new PCC from bonding to the adjacentslab. If the joint is not properly maintained, theconcrete patch will break loose due to slab move-ment caused by variations in temperature.

a. Preparation of repair area. The area to berepaired should be outlined using a concrete saw.The saw cut lines should be located at least 2 inchesoutside the crack in sound concrete, and notextend past the joint into the adjacent slab. Thedepth of the saw cut should be at least 2 inches.Remove the broken corner and the remainingconcrete inside the saw cut to the full depth of the

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slab using air hammers. All joint sealant materialinside the repair area should also be removed. Allexposed vertical faces within the repair area shouldbe cleaned. Prior to the placement of the newconcrete, the exposed subgrade should bereconditioned to comply with the specified require-ments.

b. Maintaining the joint. To prevent bonding thenew concrete to adjacent slabs at the joints, thevertical faces should be protected with a bond-breaking medium. The existing contraction jointmay be maintained by the use of temporary insertsof appropriate dimensions or by sawing therequired kerf. Sawing must be done early enough toprevent development of a random crack at the joint.

c. Placement of new concrete. After removingthe concrete and preparing the subgrade, thecleaned vertical surfaces should be coated with atleast a 20-mu film of the epoxy resin system, usinga stiff bristle brush or roller to ensure thoroughwetting of the concrete. Placement of the newconcrete should be delayed until some degree oftack has developed (30 minutes to 1 hour). Whenvibrators are used, it is essential to allow the epoxybond coat to reach a tacky state since vibration candisplace the epoxy from the existing concrete byemulsifying the fluid epoxy bond coat. Vibratorsshould not come in contact with the epoxy coating.If the concrete placement is delayed until the epoxycoating reaches a soft rubberlike stage, a secondapplication of epoxy bond coat equal to the amountof the first coat should be applied to the existingbond coat. If the concrete placement is delayeduntil the epoxy coating is no longer tacky, theepoxy coating will have to be removed or abradedby sandblasting and a fresh coat applied. Forms, ifneeded, should be placed after the concretepavement has been properly prepared. The formsshould be lined with polyethylene sheets or waxedpaper to prevent any adhesion to the form that mayresult from the override of epoxy onto the form.The use of form oil will not be permitted. Theconcrete mixture should be relatively dry and theslump of the concrete should not exceed 2 inches.Placement, consolidation, finishing, and curing ofthe concrete are accomplished by normalprocedures, as specified in TM 5-822-7. The repairis to be finished so as to match the texture of thesurrounding concrete. After the concrete has cured,the reconstructed joints should be sealed in theconventional manner.14. Procedure for condition 4. The repairsrequired under condition 4 do not use epoxy resingrouts, mortars, or concrete.

15. Procedure for condition 5. The repairsrequired under condition 5 (fig. 1) include all spallswhich occur along joints and along working cracks.The same general procedures as mentioned forcondition 3 are used for the repair of isolated smallsurface spalls or popouts. The repair of all spallsconsists of removing unsound or damagedconcrete, modifying the spall cavity dimensions asnecessary to prevent further breakout, taking pre-cautions in the repair procedure to ensure freedomof movement at working joints, and taking appro-priate measures to properly seal the joint. Largespall areas should be repaired using PCC bondedwith the proper epoxy resin system. “Popouts” arenot normally repaired unless hazardous to tires. Ifthey are determined to be hazardous to tires, repairwith epoxy resin systems.

a. Removing unsound or damaged concrete. Allunsound or damaged concrete must be removedprior to repairs. The defective areas to be removedcan be determined by tapping with a hammer orsteel rod throughout the area and listening for dullor hollow sounds. The Schmidt hammer can beused by those experienced with this test. A tensiletest that can be used in the field to check thesoundness of the substrate concrete has beensuggested in the American Concrete Institute (ACI)Committee Report 503; the test is designated as a“Field Test for Surface Soundness and Adhesions.”The periphery of the area required to be removedshould be sawed to a depth consistent with the typeof repair. Saw cutting delineates the repair area andserves to essentially eliminate edge spalling andweakness that might be introduced by outlining therepair area with other types of equipment. The sawcut lines should be located outside the defectivearea and in sound concrete. The saw cut should notbe extended across the joint into the adjacent slabunless that area is also spalled. The depth of thesaw cut should be at least ½ inch for epoxy resinmortar repairs and 2 inches for epoxy resinconcretes and epoxy resin bonded PCC. Inpreparing cutouts for popouts or small spallswholly within a structural component and notinvolving joints; edges, or corners, featheredging ispermissible. The feather-edge should be at least 1/4inch deep to provide a shoulder of sufficient depthto obtain a smooth finish. High-frequency chippinghammers can be used to make cutouts for this typeof repair in lieu of saw cuts. Concrete removalinside the saw cut should be accomplished usingmedium to lightweight air hammers. The bottom ofthe cutout should be smooth in order to reduce thesurface area and therefore reduce the quantity ofepoxy resin concrete needed for the patch. Also, in

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edge or joint replacement areas, concrete removal working cracks, the cracks must be maintained likeshould have a bottom slope not exceeding 30 de- a working joint. A different approach is requiredgrees. The minimum depth of the concrete removal because rigid temporary inserts cannot be used. Inwill depend on the maximum depth of the spalled or this case a bond-breaking medium must be used todamaged area. The concrete should be removed to prevent bonding the epoxy concrete to the concretea sufficient depth to expose sound concrete in the adjacent to the spall area which could possiblyentire patching area. The removal depth should be result in further spalling. One bond-breakingat least 2 inches, except where interior slab spalls, medium uses polyethylene foam strips cut to fit thesuch as popouts, are to be repaired. In this case, the entire working face adjacent to the spall and anminimum depth should be 1 inch. appropriately sized flexible polyethylene backing

b. Surface preparation. All newly exposed sur- rod which is temporarily embedded to provide afaces are to be cleaned by sandblasting. Dust and groove for the joint-sealing material. Another bond-other debris resulting from the removal of deterio- breaking medium involves coating the working facerated surfaces or contaminants must be removed. adjacent to the spall area with a bond-breakingCleaning may be accomplished by jetting the sur- medium, such as grease, and temporarilyface with compressed air, thorough washing with embedding a backing rod for groove-forming as inhigh-pressure water jets, or by use of a high-suction the previous case. With either of the suggestedvacuum. The vacuum method should only be used methods, the backing rod must be removed afterwhen other procedures cannot be employed. All the epoxy concrete hardens.equipment for providing compressed air must have e. Repair of spalls within working cracks.oil and water traps in the air supply lines. Where working cracks continue through areas to be

c. Maintaining the working joint. The regular patched, the crack should be maintained as a jointworking joint may be maintained by the use of a through the freshly placed epoxy resin concrete.fiberboard coated with a polyethylene film, poly- After removal of the unsound concrete and cleaningethylene foam strips, or other suitable material. The of the prepared spall area, a polyethylene foamseparating medium should be approximately ½ inch sheet should be cut to fit along the alignment of thethick cut to closely fit the pattern of the cavity crack within the prepared cavity. The concretealong the adjacent slab (see fig. 2). If fiberboard is surface along the alignment of the crack should notused, it should be coated with a polyvinyl film or be excessively irregular which would produce voidsvinyl duct tape to prevent epoxy from binding to greater than 1/4 inch deep below the sheet whenthe board. If necessary, the irregular surface treated placed over the crack. A small chipping hammerat the crack of the pavement joint should be coated equipped with a ½- to 1-inch-wide blade may bewith a suitable bond-breaking medium. A flexible used to remove high spots along the crack to formlatex caulking compound may be used to fill any a regular surface. When placing the epoxy resinvoids underneath the sheet material. The insert concrete, placements need to be carefully madeshould be removed after the epoxy resin concrete around the joint filler sheet to prevent tilting orhardens, or it may be cut out with a concrete saw to misalignment of the sheet. Maintaining an activeform the joint sealant reservoir. The formed joint is crack through an area being repaired is shown inlater sealed with an acceptable joint-sealant figures 3 and 4.material. Oils, waxes, greases, or silicones should f. Placement of epoxy resin concretes and mor-not be used on the insert since these substances tars. In scheduling the placement of epoxy resinprevent bonding of the joint-sealant materials. concretes and/or mortars, the correct type and

d. Spalls along working cracks. For spalls along classification of epoxy resin system should beprocured, pavement and materials temperaturesshould be carefully considered, and appropriateoperational conditions and procedures established.

(1) Prior to the placement of epoxy resinconcrete or mortars, the surface of the cavity(except for the face of the working joint) shall beprimed with the binder. The primer should beapplied in a relatively thin coat (15 to 20 mils) andbriskly scrubbed into the concrete surface with astiff bristle brush or roller. Placement of the epoxyresin concrete or mortar should begin immediatelyafter application of the prime coat.

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Figure 3. Placement of joint filler sheet to maintain active crack

through area to be patched.

Figure 4. Finishing a patch containing an active crack.

(2) The general procedure for batching theepoxy resin concrete or mortar is outlined inparagraphs 10 and 11. The size of the batch to beprepared at one time will vary with the area to berepaired. In cases where the depth of the area beingrepaired is greater than 2 inches, a multiple-courseprocedure will be followed. It has been found thatthe heat buildup in courses thicker than 2 inchessometimes is sufficient to cause cracking. Theplacement of an additional course or courses, ifrequired, should be delayed until the peaktemperature has been reached and the temperatureof the previously placed material is decreasing. Inmost instances, large patches (typically thoserequiring more than 5 gallons of an epoxy resinsystem) should be made with PCC unless therepaired area has to be opened to traffic within 48hours.

(3) The methods for epoxy resin concrete ormortar placement including consolidation, screed-ing, and finishing will generally follow normal smallarea PCC operations, except that delays cannot be

tolerated. Because of the relatively thin layers ofcourses necessary, the use of internal spud-typevibrators to properly consolidate the mixtures isdifficult. The use of a mechanical plate, screed, andfloat or float vibrators has proven satisfactory. Inmany instances, because of dimensional and shaperestrictions, consolidation by hand tampers will benecessary.

(4) In the final finishing operations, the surfaceshall not be left slick due to excess epoxy resinbleeding to the top. Fine aggregate can bebroadcast on top of slick areas before the epoxyresin hardens to improve the surface texture. Thefinal surface should be left even with the sur-rounding pavement. Excess mortar or binder shouldbe removed since featheredge finishing usually willform a weak bond resulting in chipping undertraffic.

(5) The formed joint should be sealed in theconventional manner as specified in Joint Depart-ments of the Army and Air Force TM 5-822-7/AFM 88-6, Chapter 8, and Air Force AFM 88-6,Chapter 7. This work can usually be initiated about24 hours after epoxy resin concrete or mortarplacement unless low temperatures haveappreciably retarded the hardening of the epoxyresin binder.16. Procedure for condition 6. Repair of thetype of failure in condition 6 (fig 1) involvesremedial measures to stop progression of the longi-tudinal crack in both directions. The procedure forthis is similar to the repair of spalled areas. The fulllength of the crack should be routed with a rotary-grooving tool after the pavement surface iscarefully examined to locate the ends of the crack.Since the crack termination points may be almostindiscernible, sandblasting and high-pressure air jetsshould be used near the apparent ends to removefines embedded in the crevices. Also, laitancebeyond the apparent ends should be removed bysandblasting to make identification of the actualends of the crack more accurate. Core holes, 4 to 6inches in diameter should be drilled at each end ofthe crack. These core holes should be centered onthe ends of the crack to assure complete crackremoval. After removal of the core, all residualfines on the core hole wall should be removed byscrubbing the walls with a stiff bristle brush,followed by washing and removal of excess waterfrom the core hole. The removal of the residualfines is necessary to ensure that the required bondof the epoxy resin concrete to the PCC is obtained.The application of primer to the core hole wall andplacement of the epoxy resin concrete to fill thecore hole should be similar to the procedures for

TM 5-822-9/AFM 88-6, Chap.10

9

the repair of spalls as described in paragraph 13.Because the FCC mass is much greater than that ofthe epoxy resin concrete, the heat generated by theepoxy binder will be diffused rapidly; the thicknessof the courses placed may be increased to 6 inches.In some climatic areas or under certain weatherconditions where pavement temperatures may berelatively high, it may be advisable to place thinnercourses to avoid cracking. The thickness of coursesand time interval between courses should be suchthat the temperature of the epoxy resin concretenever exceeds 140 degrees F during hardening. Thepeak temperature of the epoxy resin concrete canbe determined by placing the epoxy resin concreteinto a container, such as a can or pail approximatelythe same diameter as the core hole, and measuringthe temperature with a thermometer. The grooveformed in the routing operation will be sealed withan appropriate type of joint sealant in accordancewith accepted methods for sealing pavements.17. Procedure for condition 7. The repairsrequired under condition 7 do not use epoxy resingrouts, mortars, or concretes.18. Protection of repaired areas fromweather and traffic. Repaired areas should beprotected as follows:

a. Temperature. Pavement repairs made whenambient temperatures during the following 24 hoursmay be 60 degrees F or lower require limitedprotection to maintain the epoxy concrete or mortarat temperatures which will provide a normalhardening rate. The use of tarpaulins supportedseveral inches above the surface of the repairedarea will help to maintain the desired conditions,provided the temperature difference or drop is nottoo great. Heated enclosures may also be used toprovide effective temperature conditions (para 7).

b. Water. The epoxy resin grout and binder willbond to a damp concrete surface, but greater bondstrengths are obtained when the surface is dry. Theepoxy resin systems should not be applied to aconcrete surface containing excessive moisture.Excessive moisture may be detected by tightlycovering the surface with a transparent plastic film.If no moisture has accumulated under the film after24 hours, capillary moisture may be consideredinsufficient to adversely affect the bond. During theearly hardening stages, which may vary from 2 to12 hours depending upon weather conditions, theepoxy resin mortars and concretes should beprotected from rain.

c. Traffic. The repaired areas should be barri-caded to prohibit traffic of all types until the epoxyresin concrete or mortar has hardened. The time

interval over which protection against traffic is tobe maintained will vary with weather conditions,but will usually be less than 24 hours.19. Cleaning of equipment and tools.Because of the nature of the hardened epoxy resinsystems, all tools and equipment must bethoroughly cleaned before the epoxy materials set.Toluene, xylene, or other aromatic petroleumsolvents must be used with proper precautionsconcerning the fire and/or explosion hazard. In thecleaning operations the workmen must wearsolvent-resistant gloves and aprons, and the use ofprotective creams is desirable. Cleaning should bedone in a well ventilated area or respirators shouldbe used in a closed area.20. Safety and health precautions. a.General precautions. The materials used in the twoepoxy systems and the solvents used for cleanup donot ordinarily present a serious health hazardexcept to hypersensitive individuals. Materials maybe handled with complete safety if adequate precau-tionary measures, such as the following, are ob-served:

(1) Handle only in well ventilated areas.(2) Prevent skin contact.(3) Wear neoprene or other suitable impervious

gloves whenever the possibility of skin contactoccurs. When gloves become contaminated, theyshould be discarded or reconditioned by washingwith soap and water, preferably while they are stillon the hands of the operator. Gloves should bedried and kept in a clean place. Powdering theinside of the gloves with talcum is recommended.Contaminated gloves, aprons and sleeves, clothing,and working tools shall not be removed from thework area, except for discarding or cleaning.

(4) Protective ointments or proprietary creamsshould be applied to exposed skin surfaces beforebeginning work and should be removed by washingafter the work is completed.

(5) Wear full face shields or goggles during theblending and mixing operations. WARNING:Goggles must be worn to protect eyes from theepoxy resin system. Goggles are mandatory forpersons doing the blending and mixing operations,but the hazard is reduced for persons engaged inthe placing operations.

(6) Restrict blending and mixing operations tothe open areas or, if in a building, near an operatinghood ventilating system. Use disposable papercoverings in the work area where drips orcontamination may be expected.

(7) Maintain good housekeeping and personalhygiene standards. DANGER: SOLVENTS AREFIRE HAZARDS.

TM 5-822-9/AFM 88-6, Chap.10

10

(8) Thorough instruction to the inspectors and e. Moving sensitized persons. Remove fromforemen concerning the danger of working with exposure individuals who develop sensitivity to anyresins and hardeners, the nature of skin irritation, of the epoxy system constituents. The limiting orand measures to be taken to avoid skin irritation is complete removal of subsequent contact with mate-recommended. rials will be made by a competent physician or

(9) Work rooms should be provided with new, dermatologist.unused cleaning rags. f Obtaining further information on health fac-

b. Personal sensitivity. A few individuals have tors. HQDA (CEEC-S), WASH, DC 20314-1000,developed dermatitis from skin contact of epoxy will be available to provide technical occupationalresin components and cleaning solvents (toluene, health consulting service and guidance to fieldxylene, and other aromatic petroleum solvents); activities. In accordance with Federal Standard No.therefore, adequate precautionary measures should 313, hazardous material identification data sheetsbe exercised. Epoxy resin systems containing poly- are required for all materials which, because of theirsulfide curing agents have an obnoxious odor from potentially dangerous nature, require control tothe polysulfide constituent which may nauseate assure adequate safety to life and property.some individuals. Inhalation of the vapors should be Materials safety data sheets are available at theavoided or kept to an absolute minimum. The following addresses:amine-type curing agents incorporated in the epoxyresin system are caustic and may cause tissue Commanding Generaldamage upon direct contact with the skin. Con- Army Materiel Command (DRCSF-S)tamination of the eye by the curing agent compo- 5001 Eisenhower Avenuenent can cause severe damage, and exposure to Alexandria, VA 22304high vapor concentrations may also irritate the eyesand mucous membranes. Commanding Officer

c. First aid. Provide necessities for prompt Navy Fleet Material Support Officetreatment of accidental skin or eye contact. Mechanicsburg, PA 17055

(1) Eyes. In cases of accidental skin contami-nation, immediately and thoroughly flush the af- Commanding Generalfected eye for at least 15 minutes with running Air Force Logistics Command (DSPX)water, bathe the eye with a normal saline solution, Wright-Patterson AFB, OH 45433and see a physician if there is any possibility ofpotential eye damage. Director

(2) Skin. Cleanse all areas thoroughly with soap Defense Supply Agency (DSAH-OW)and water following accidental skin contact. If Cameron Stationnecessary, fresh alcohol, acetone, toluene, or Alexandria, VA 22314methyl-ethyl-ketone may be used as a solvent, butthe use of such solvents should be kept to a General Services Administration Federal Supplyminimum. In cases of spills, clothing which may be Service (FMH)involved should be immediately removed and Washington, DC 20406decontaminated in the manner described herein for 21. Information. HQDA (CEEC-EG), WASH,gloves. DC 20314-1000, will be advised by the divisions

d. Removing source of contact. If a worker concerning all contemplated pavement repairs ofdevelops dermatitis, the source of contact should be the type described herein. This maybe accomplisheddetermined and eliminated. Treatment of such a by copies of correspondence, teletypes, orcondition should be handled by a competent physi- memoranda of telephone communications. In casescian or dermatologist, with full information being of contemplated application other than describedfurnished as to the probable cause of the herein, full information will be furnished to HQDAproblem. (CEEC-EG) for approval prior to the initiation of

the work.

TM 5-822-9/AFM 88-6, Chap.10

The proponent agency of this publication is the Office of the

Chief of Engineers, United States Army. Users are invited to

send comments and suggested improvements on DA Form 2028

(Recommended Changes to Publications and Blank Forms)

direct to HQUSACE,(CEEC-EG, WASH DC 20314-1000

By Order of the Secretaries of the Army and the Air Force:

CARL E. VUONO

General, United States Army

Official: Chief of Staff

WILLIAM J. MEEHAN II

Brigadier General, United States Army

The Adjutant General

LARRY D. WELCH, General, USAF

Official: Chief of Staff

WILLIAM 0. NATIONS, Colonel, USAF

Director of Information

Management and Administration

Distribution:

Army:

Air Force: F

jU.S. GOVERNMENT PRINTING OFFICE:1989-242-447:80088

PIN: 025948-000

Repair'of'Rigid'Pavements'Using'Epoxy'Resin'Grouts,'Mortars'and'Concretes'Updated'on:'8/15/2012'

'1. __________'is'the'cementitious'part'of'a'grout,'mortar,'or'concrete'that'binds'the'

aggregate'or'filler'into'a'cohesive'mass.'''

a) Binder'b) Resin'c) Filler'd) none'of'the'above'

'2. The'product'obtained'by'combining'both'fine'and'course'aggregate'with'the'epoxy'

resin'system'is'called'__________.''

a) binder'b) epoxy'resin'grout'c) epoxy'resin'concrete'd) epoxy'resin'mortar'

'3. In'the'preparation'of'epoxy'resin'concretes'and'mortars,'__________'should'be'dry'and'

conditioned'to'a'temperature'of'70'to'85'degrees'F.''

a) aggregates'b) resins'c) epoxies'd) binders'

'4. Variations'in'aggregate'grading'and'__________'may'affect'the'proportions'required'to'

obtain'an'economical'mixture'that'has'satisfactory'placing'and'finishing'characteristics.'

'a) particle'strength'b) particle'shape'c) epoxy'strength'd) binder'workability'

'5. Trial'batches'are'not'required'when'using'epoxy'resin'system'as'a'bonding'medium'

between'plastic'and'hardened'PCC'or'when'using'epoxy'resin'grout'for'filling'cracks'and/or'placing'dowels.'

'a) True'b) False'

'6. To'prevent'bonding'the'new'concrete'to'adjacent'slabs'at'the'joints,'the'vertical'

faces'should'be'protected'with'a'__________.''

a) bondVbreaking'medium'b) slipVjoint'medium'c) bondVadhesive'medium'd) keyed'joint'

'

7. All'unsound'or'damaged'concrete'must'be'removed'prior'to'repairs.''

a) True'b) False'

'8. Pavement'repairs'made,'when'ambient'temperatures'during'the'following'__________'

may'be'60'degrees'F'or'lower,'require'limited'protection'to'maintain'the'epoxy'concrete'or'mortar'at'temperatures'which'will'provide'a'normal'hardening'rate.'

'a) 2'hours'b) 3'days'c) 24'hours'd) 1'week'

'9. If'a'worker'develops'dermatitis,'the'source'of'contact'should'be'determined'and'

eliminated.''

a) True'b) False'

'10. Materials'may'be'handled'with'complete'safety'if'__________.'

'a) handled'only'in'wellVventilated'areas'b) one'prevents'skin'contact'c) one'wears'neoprene'or'other'suitable'impervious'gloves'd) all'of'the'above'

'