Master of Science / Department of Civil Engineering / Robert J. Peterman / Epoxy polymer overlays have been used for decades on existing bridge decks to protect the deck and extend its service life. The polymer overlay’s ability to seal a bridge deck is now being specified for new construction. Questions exist about the amount of drying time needed to achieve an acceptable concrete moisture content to ensure an adequate bond to the polymer overlay. Current Kansas Department of Transportation (KDOT) specifications for new bridge decks call a 14 day wet curing period followed by 21 days of drying (Kansas DOT, 2007) If not enough drying is provided, the moisture within the concrete can form water vapor pressure at the overlay interface and induce delamination. If too much drying time is provided projects are delayed, which can increase the total project cost or even delay overlay placement until the next spring. A testing procedure was developed to simulate a bridge deck in order to test the concrete moisture content and bonding strength of the overlay. Concrete slabs were cast to test typical concrete and curing conditions for a new bridge deck. Three concrete mixtures were tested to see what effect the water –cement ratio and the addition of fly ash might have on the overlay bond strength. Wet curing occurred at 3 different temperatures (40°F, 73°F, and 100°F) to see if temperature played a part in the bond strength as well. The concrete was then allowed to dry for 3, 7, 14, or 21 days. Five epoxy-polymer overlay systems that had been preapproved by KDOT were each used in conjunction with the previously mentioned concrete and curing conditions. After, the slabs were setup to perform pull-off tests to test the tensile rupture strength. The concrete slabs with the different epoxy overlays were heated to 122-125°F to replicate summer bridge deck temperatures. Half of the pull-off tests were performed when the slabs were heated and half were performed once the slabs had cooled back down to 73°±5°F. Results from the pull-off tests as well as results from a moisture meter taken on the concrete prior to the overlay placement were compared and analyzed. Testing conditions were compared with each other to see which had a larger effect on the epoxy polymer overlay’s bond strength.

The purpose of this research was to identify the types of surface treatments available for use on concrete bridge decks and to determine which materials are most capable of providing long-term protection from contamination by chloride ions. The products addressed in this report primarily include urethanes, silicon-based sealers, and epoxies. An extensive literature review was conducted to document common overlay distresses, performance histories, and properties of specific surface treatment products currently available in the industry. In addition, three reports summarizing in-house experiments performed by the Utah Department of Transportation between 1995 and 2003 regarding various types of surface treatments were reviewed as part of this research. Finally, a nationwide questionnaire survey was conducted to investigate the state-of-the-practice with regard to surface treatment applications on bridge decks by state departments of transportation throughout the United States. Of the three types of materials addressed in this research, epoxy-based products have the greatest ability to protect concrete and remain uncracked with an acceptable level of skid resistance. Silicon-based products do not crack because they seep into the pores of the concrete, but they do not protect the concrete from the wearing effects of traffic or improve skid resistance. Published field studies indicate that urethane surface treatments do not resist the effects of traffic as well as epoxy-based materials, nor do they offer a substantial decrease in expense or health risk when compared to epoxy-based products. The results of the nationwide questionnaire clearly indicate that bridge deck surface treatments are valuable as both chloride barriers and skid-resistant wearing courses. No standard practice appears to exist with regard to timing of surface treatments, however. Some states arbitrarily apply surface treatments at 10 to 12 years after construction, other states wait until cracking has become fairly considerable before action is taken, and still other states apply surface treatments when the chloride content of the concrete reaches a certain level. Because concrete decks with significant cracking are not ideal substrates for polymer applications, surface treatments should be applied as preventive measures early in the service lives of bridge decks to effectively prevent chloride concentrations from reaching critical levels. This research suggests that epoxy-based surface treatments should be specified for concrete bridge decks when both a chloride barrier and improved skid resistance are desired. If a chloride barrier is all that is needed or desired, a silane surface treatment should be considered; silane treatments are less expensive and easier to apply than epoxy treatments. When a large amount of epoxy is to be mixed, automatic proportioning equipment that can precisely monitor and control the ratios of components should be employed.

Chloride-induced deterioration of concrete bridge decks can be described in terms of three phases: 1) initiation of rebar corrosion, 2) rust formation and development of deck damage, and 3) accelerated deck damage towards structural failure. The first objective of this research was to investigate relationships among chloride concentration at the top mat of reinforcing steel, deck age, cover depth, and occurrence of delamination for concrete bridge decks with selected surface treatments and rebar types. Relating these factors can help establish greater understanding about the duration of each phase of the deterioration process. A second objective of this research was to investigate the relationship between chloride concentrations that develop between the bars and those that develop directly above the bars in the top mat of reinforcing steel to better understand the effects of the presence of reinforcing steel on diffusion of chloride ions through the concrete matrix.Data collected from 48 concrete bridge decks in Utah were used to address both of the objectives stated for this research. Surface treatment types included bare concrete, thin-bonded polymer overlays, and asphalt overlays, and rebar types included uncoated and epoxy-coated rebar. Regarding the first objective, baseline relationships between chloride concentration, deck age, and cover depth were developed for all three deck types. The results show that, as deck age increases, chloride concentration also increases and that chloride concentrations are much higher for shallower concrete depths than for deeper concrete depths. Based on these relationships, the duration of the first phase of the deterioration process was estimated using the critical chloride threshold of 2.0 lb Cl-/yd3 of concrete. For decks with asphalt or polymer overlays, development of clear relationships between chloride concentration, deck age, and cover depth required consideration of treatment time. The data show that chloride concentrations for decks that had an overlay applied 10 or more years after construction are higher than those for decks that had an asphalt overlay applied immediately after construction. Relevant to determining the duration of the second phase of the deterioration process, the relationship between delamination occurrence and chloride concentration for bare concrete bridge decks was developed. In general, the results show that the occurrence of delamination increases with increasing chloride concentration. Estimated durations of the second phase of the deterioration process were then determined using a chloride concentration threshold of 4.0 lb Cl-/yd3 of concrete for each of the same combinations of surface treatment and cover depth used for determining durations of the first phase of the deterioration process. Regarding the performance of epoxy-coated bar, the data clearly demonstrate the benefit of epoxy coatings on reinforcing steel for the purpose of significantly delaying the onset of chloride-induced delamination in concrete bridge decks. The relationship between the ratio of chloride concentrations directly above and between steel reinforcing bars and deck age was then developed. The results show that, as deck age increases, the average ratio of chloride concentrations directly above and between the bars asymptotically decreases from above 1.5 toward 1.0, which is reached at a deck age of approximately 30 years. Given that increasing deck age generally corresponds to increasing chloride concentration, which would in turn eventually lead to similar chloride concentrations directly above and between bars as the concrete pore water within the cover depth approached chloride saturation, this observed relationship is consistent with theory.