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Statewide Conference on Local Bridges

BRIDGE DECK OVERLAY OPTIONS

By. Harry L. White 2nd, PE

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What is a Bridge Deck Overlay? Provide Waterproofing Establishes Smooth Riding Surface Restore Friction Rehabilitate Roadway Rutting

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Overlay vs. Replacement Overlays are: Cheaper Faster Less Intrusive

Replacements are: Long Lasting Reliable Predictable

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When to Overlay Small Percentage of Deck Distressed Definition of ‘Small’ is Conditional Percentage of Deck Area Isolated Area

Definition of ‘Distress’ is Conditional Delaminations are Identified and Repaired Concrete has Freeze/Thaw Resistance

Compatible with Project Parameters No Geometric Deficiencies Not Programmed for Replacement

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Latex Modified Concrete Suspension of tiny styrene-butadiene

polymer particles in concrete mix water

http://www.dot.state.oh.us/engineering/OTEC/2015_OTEC_Presentations/Wednesday_Oct.28/51/Martens_51%20(Ohio)_Version_2.pdf

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Latex Modified Concrete Latex particles form waterproof layer Placed between 1 ½ in. to 5 in. thick 18 Year Lifespan Assumed for Thin

Applications 50 Year Service Possible for Monodeck

Applications over Hydro-Demolition Approx. $19/SF (Upstate) Assuming a 3” Thickness

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Latex Modified Concrete Proper Surface Preparation is Critical Shot Blast 4,000-7,000 PSI Water Blast

Thin Application over Large Area Prone to Shrinkage Problems Evaporation Retardant Application Covering Wetting

Traffic Vibrations Affect Bond

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Micro-Silica Overlay Very similar to Latex Modified Concrete Placed between 1 ½ in. to 5 in. thick 20 Year Lifespan Assumed for Thin

Applications 50 Year Service Possible for Monodeck

Applications over Hydro-Demolition Approx. $5/SF (Upstate)

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Micro-Silica Overlay Proper Surface Preparation is Critical Shot Blast 4,000-7,000 PSI Water Blast

Thin Application over Large Area Prone to Shrinkage Problems Evaporation Retardant Application Covering Wetting

Traffic Vibrations Affect Bond

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Concrete Overlay, Class DP Smaller Aggregate Microsilica Fly Ash and/or GGBFS High Cement Content Approx. $8-20/SF

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Concrete Overlay, Class DP Proper Surface Preparation is Critical Shot Blast 4,000-7,000 PSI Water Blast

Thin Application over Large Area Prone to Shrinkage Problems Evaporation Retardant Application Covering Wetting

Traffic Vibrations Affect Bond

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Thin Polymer Overlay (TPO) Epoxy Type Base Layer Broadcast Aggregate Cure Sweep Additional Epoxy Type Layer Cure Final Sweep

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Thin Polymer Overlay (TPO) Epoxy Type Base Layer Broadcast Aggregate Cure Sweep Additional Epoxy Type Layer Cure Final Sweep

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Thin Polymer Overlay (TPO) Thickness of 3/8 in. (min.) 15 Year Lifespan Approx. $5/SF (Upstate) Approx. $15/SF (Downstate)

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Polyester Polymer Concrete Proper Surface Preparation is Critical Steel Shot Blast

Short Working Window Full Cure in 2-4 Hours Traffic Vibrations Do Not Affect Bond

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Polyester Polymer Concrete (PPC) Thickness of ¾ in. (min.) 30 Year anticipated Lifespan Approx. $15/SF (Upstate) Approx. $18/SF (Downstate)

Epoxy Polymer Concrete (EPC) Similar Properties Similar Lifespan Similar Pricing

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Scarify Deck and Block Scupper

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Prepared Deck Surface

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PPC Headers at Same Time

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HMWMM Primer Coat

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Self-Feeding Mixer

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PPC Paving Maching

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PPC Placement

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Tining Operations

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Broadcast Top Sand

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Finished Lane Overlay

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Placing Shoulders by Hand

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SawcutDiamond Grind

and Sawcut

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Prep for PPC Deck Repair

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Repaired and Ready for Overlay

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Sheet Membrane Under Asphalt Sensitive to Installation Environmental

Conditions Must use Full Thickness Asphalt Lack of Bond Shoving Raveling

15 Year Anticipated Lifespan Approx. $3/SF (Cold-Applied) Approx. $11/SF (Hot Applied)

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Spray Membrane Under Asphalt Sensitive to Installation Environmental

Conditions Must use Full Thickness Asphalt Lack of Bond Shoving Raveling

20 Year Anticipated Lifespan Approx. $12/SF (Upstate)

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Spray Membrane Under Asphalt

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Waterproofing Hot-Mix Asphalt Sensitive to Installation Environmental

Conditions Approximately 1 ½ in. Thick 20 Year Anticipated Lifespan Approx. $4/SF ($450/TON)

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UHPC Bridge Deck Overlay Proper Surface Preparation is Critical Hydro-Demolition Saturated Surface Dry Condition

Preventing Shrinkage Evaporation Retardant Application Covering

Traffic Vibrations Do Not Affect Bond 20 Year Anticipated Lifespan Approx. $45/SF $350/CF @ Approximately 1½ in. Thick

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Conclusions Different types of Overlays Budget Time Traffic Work Plan Functional Need Future Work

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QUESTION 1 Overlays are typically more _____ than a

deck replacement:a. Durableb. Predictablec. Economical

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QUESTION 1 Overlays are typically more _____ than a

deck replacement:a. Durableb. Predictablec. Economical

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QUESTION 2 Overlay performance is almost always

dependent on the:a. Soundness of the substrateb. Cleanliness of the surfacec. Quality of the Installationd. All of the above

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QUESTION 2 Overlay performance is almost always

dependent on the:a. Soundness of the substrateb. Cleanliness of the surfacec. Quality of the Installationd. All of the above

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QUESTION 3 Overlays are a good way to solve the

following deck problems, except:a. Provide Waterproofingb. Establishes Smooth Riding Surfacec. Restore Frictiond. Repair Working Crackse. Rehabilitate Roadway Rutting

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QUESTION 3 Overlays are a good way to solve the

following deck problems, except:a. Provide Waterproofingb. Establishes Smooth Riding Surfacec. Restore Frictiond. Repair Working Crackse. Rehabilitate Roadway Rutting