1 Introduction
Analysis approach | Percentage of deficient bridges by year | ||||
---|---|---|---|---|---|
2001 | 2003 | 2005 | 2007 | 2009 | |
Weighted by deck area | |||||
Structurally deficient (%) | 8.4 | 8.8 | 8.5 | 8.4 | 8.2 |
Functionally obsolete (%) | 22.0 | 20.9 | 21.3 | 21.3 | 21.0 |
Total deficient (%) | 30.4 | 29.7 | 29.8 | 29.7 | 29.2 |
Weighted by ave. daily traffic | |||||
Structurally deficient (%) | 7.2 | 7.1 | 6.6 | 6.5 | 6.2 |
Functionally obsolete (%) | 20.5 | 20.0 | 20.2 | 20.2 | 20.0 |
Total deficient (%) | 27.7 | 27.1 | 26.8 | 26.7 | 26.2 |
Weighted by bridge count | |||||
Structurally deficient (%) | 6.0 | 5.9 | 5.7 | 5.5 | 5.2 |
Functionally obsolete (%) | 17.4 | 17.0 | 16.9 | 16.7 | 16.6 |
Total deficient (%) | 23.3 | 22.9 | 22.6 | 22.2 | 21.9 |
2 Literature Review of Products and Systems to Protect Concrete Bridge Elements
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Surface sealers are products of 10 mils (0.25 mm) or less in thickness that are applied to the surface of the concrete.
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High-build coatings consist of materials with a dry thickness greater than 10 mils (0.25 mm) and less than 30 mils (0.75 mm) and are applied to the surface of the concrete.
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Membranes are classified as surface treatments with a thickness greater than 30 mils (0.7 mm) and less than 250 mils (6 mm) and are applied to the surface of the concrete.
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Overlays are products of 250 mils (6 mm) or greater in thickness and are generally bonded to the surface of the concrete (Needham and Douglas 2000).
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Carbon fiber-reinforced polymer wrap: that consisted of the carbon fiber fabric, primer, putty, and resin. Two fabric/resin layers (resin-sheet-resin-sheet) were installed on the beam with fiber orientation in the two layers at 90° with respect to each other.
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Polymer resin coating: Two coats of the resin component of the REPLARK 30 system (no fiber) were applied with a paint roller after application of the primer and putty.
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Epoxy coating: Two coats of MASTERSEAL GP Epoxy Sealer (could be applied with a squeegee, roller, or spray equipment to a clean, dry surface).
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Sealer: Two coats of MASTERSEAL SL 40 VOC (solvent based silane penetrating sealer) applied using a roller and paint brush.
Low severity distress | Moderate severity distress | High severity distress |
---|---|---|
Sealers | Partial depth repair | Partial depth repair |
Coatings | Cathodic protection | Replacement |
Do nothing | Combined sealers and coatings | – |
3 Information on Beam End Treatments Obtained from Surveys and Interviews
3.1 Survey Results for Concrete Coatings and Treatments
Type of coating | Number of products reported | Product names or description | Manufacturers |
---|---|---|---|
Coatings | 8 | TEXCOTE XL 70 BRIDGE COTE | Textured Coatings of America, Inc. |
TEXCOTE XL 70 BRIDGECOTE W/SILANE | Textured Coatings of America, Inc. | ||
Multi laminate epoxy/urethane coating system pecoraDeck P-808 primer Pecoradeck P-806 Top Coat | Pecora Corporation | ||
Safe-Cure & Seal EPX Duraguard 310CRU | ChemMasters | ||
Epoxykote 100WB | ChemMasters | ||
Waterbased Epoxy | Pruett-Schaffer Chemical Co. | ||
FX-498 Hydro Ester High Build Coating | Fox Industries Inc. | ||
Epoxy: Plymastic 650 | Sherwin-Williams | ||
Membranes | 6 | Soprema Alsan RS (PMMA waterproofing system) | Soprema Inc. |
Soprema Alsan Flashing (Asphalt-modified urethane) | Soprema Inc. | ||
Multi laminate epoxy/urethane coating system pecoraDeck P-808 primer Pecoradeck P-806 Top Coat | Pecora Corporation | ||
Safe-Cure & Seal EPX Duraguard 310CRU | ChemMasters | ||
Epoxykote 100WB | ChemMasters | ||
Waterbased Asphalt Emulsion | Pruett-Schaffer Chemical Co. | ||
Penetrating sealers | 4 | Evercrete Deep Penetrating Sealer (DPS) | Evercrete Corp. |
TEXCOTE XL 70 BRIDGECOTE W/SILANE | Textured Coatings of America, Inc. | ||
Sil-Act ATS-100LV | Advanced Chemical Technologies Inc. | ||
Penetrating Concrete Sealer: SW DOT Concrete Sealer 100 | Sherwin-Williams | ||
Surface sealers | 4 | Dynapoxy Low Mod Epoxy - Low Mod 2 component fast curing epoxy based coating | Pecora Corporation |
Safe-Cure & Seal EPX Duraguard 310CRU | ChemMasters | ||
Epoxykote 100WB | ChemMasters | ||
Sil-Act EP 700D | Advanced Chemical Technologies Inc. | ||
Combination systems | 3 | Evercrete Top Seal (TS) | Evercrete Corp. |
Si-Rex03 Silicone Resin Emulsion Paint (SREP) | Klaas Coatings (North America) LLC | ||
FX-460 Breathable Masonry Coating System (1 Coat Primer, 1 Coat Top Coat) | Fox Industries Inc. | ||
Electochemical methods | 0 | ||
Corrosion inhibitors | 0 | ||
Admixtures | 0 | ||
Patching | 0 | ||
Reinforcing steel protection | 0 | ||
Overlays | 0 |
Type of Coating | Expected Service Life (years) | |||||||
---|---|---|---|---|---|---|---|---|
0-5 | 6-10 | 11-15 | 16-20 | 21-30 | 31-40 | 41-50 | 50+ | |
Penetrating Sealers | 0 | 2 products: | 1 product: | 0 | 0 | 0 | 1 product: | 0 |
• TEXCOTE XL 70 BRIDGECOTE W/SILANE | • Evercrete Deep Penetrating Sealer (DPS) | |||||||
• Sil-Act ATS-100LV | ||||||||
• SW DOT Concrete Sealer 100 | ||||||||
Surface Sealer | 0 | 0 | 2 products: | 2 products: | 0 | 0 | 0 | 0 |
• Epoxykote 100WB | • Sil-Act EP 700D | |||||||
• Dynapoxy Low Mod Epoxy | • Safe-Cure & Seal EPX Duraguard 310CRU | |||||||
Membranes | 0 | 0 | 2 products: | 4 products: | 0 | 0 | 0 | 0 |
• PecoraDeck P-808 primer Pecoradeck P-806 Top Coat | • Soprema Alsan RS | |||||||
• Soprema Alsan Flashing | ||||||||
• Epoxykote 100WB | • Safe-Cure & Seal EPX Duraguard 310CRU | |||||||
• Waterbased Asphalt Emulsion | ||||||||
Coatings | 0 | 0 | 5 products: | 3 products: | 0 | 0 | 0 | 0 |
• FX-498 HYDRO ESTER HIGH BUILD COATING | • Epoxy Plymastic 650 | |||||||
• Waterbased Epoxy | ||||||||
• Safe-Cure & Seal EPX Duraguard 310CRU | ||||||||
• Epoxykote 100WB | ||||||||
• PecoraDeck P-808 primer Pecoradeck P-806 Top Coat | ||||||||
• TEXCOTE XL 70 BRIDGE COTE | ||||||||
• TEXCOTE XL 70 BRIDGECOTE W/SILANE | ||||||||
Combination Systems | 1 product: | 0 | 0 | 2 products: | 0 | 0 | 0 | 0 |
• Si-Rex03 Silicone Resin Emulsion Paint (SREP) | ||||||||
• FX-460 BREATHABLE MASONRY | ||||||||
• Evercrete Top Seal (TS) | ||||||||
COATING SYSTEM |
3.2 Ranking of Concrete Products Based on Concrete Manufacturer Data
Product name | Manufacturer | Performance measures | History | Time to first application | Frequency of inspection | Ease of application | Cost | Service life |
---|---|---|---|---|---|---|---|---|
Weighted Importance | 1 | 2 | 2 | 2 | 3 | 2 | ||
Ranking | 1 = 0 DOTs 2 = 1–5 DOTs 3 = 6–10 DOTs 4 = >10 DOTs | 1 = >21 days 2 = 15 - 21 days 3 = 8–14 days 4 = 2–7 days 5 = 0–1 day | 1 = 2–5 years 2 = 6–10 years 3 = 10–15 years 4 = 15–20 years 5 = None | 1 = Professional 2 = Moderate 3 = Novice | 1 = > $60/gal. 2 = $46–$60 3 = $31–$45 4 = $16–$30 5 = $0–$15 | 1 = 0–5 years 2 = 6–10 years 3 = 11–15 years 4 = 16–20 years 5 = >20 years | ||
Evercrete Deep Penetrating Sealer (DPS) | Evercrete Corporation | 2 | 4 | 5 | 3 | 4 | 5 | |
Waterbased Asphalt Emulsion | Pruett-Schaffer Chemical Co. | 1 | 5 | 5 | 3 | 5 | 4 | |
TEXCOTE XL 70 BRIDGE COTE | Textured Coatings of America, Inc. | 4 | 5 | 3 | 2 | 4 | 3 | |
TEXCOTE XL 70 BRIDGECOTE W/SILANE | Textured Coatings of America, Inc. | 4 | 5 | 3 | 2 | 4 | 3 | |
Waterbased Epoxy | Pruett-Schaffer Chemical Co. | 1 | 5 | 5 | 3 | 3 | 4 | |
Evercrete Top Seal (TS) | Evercrete Corporation | 2 | 4 | 1 | 3 | 4 | 1 | |
Penetrating Concrete Sealer: SW DOT Concrete Sealer 100 | Sherwin-Williams | 3 | 5 | 2 | 3 | 3 | 2 | |
Dynapoxy Low Mod Epoxy | Pecora Corporation | 3 | 3 | 2 | 1 | 4 | 3 | |
Soprema Alsan Flashing | Soprema Inc. | 1 | 5 | 1 | 3 | 2 | 4 | |
Si-Rex03 Silicone Resin Emulsion Paint (SREP) | Klaas Coatings (North America) LLC | 2 | 3 | 4 | 2 | 3 | 4 | |
Soprema Alsan RS | Soprema Inc. | 1 | 5 | 1 | 2 | 1 | 4 | |
PecoraDeck P-808 primer Pecoradeck P-806 Top Coat | Pecora Corporation | 3 | 3 | 2 | 1 | 3 | 3 | |
Sil-Act ATS-100LV | Advanced Chemical Technologies Inc. | 4 | 4 | 2 | 3 | 3 | 2 | |
Epoxy : Plymastic 650 | Sherwin-Williams | 3 | 4 | 2 | 2 | 2 | 4 | |
FX-460 BREATHABLE MASONRY COATING SYSTEM | Fox Industries Inc. | 3 | 2 | 3 | 2 | 1 | 4 | |
Safe-Cure & Seal EPX Duraguard 310CRU | ChemMasters | 2 | 2 | 2 | 2 | 3 | 4 | |
Sil-Act EP 700D | Advanced Chemical Technologies Inc. | 4 | 1 | 2 | 2 | 2 | 4 | |
FX-498 HYDRO ESTER HIGH BUILD COATING | Fox Industries Inc. | 3 | 1 | 2 | 1 | 3 | 3 | |
Epoxykote 100WB | ChemMasters | 2 | 2 | 2 | 2 | 2 | 3 |
Product name | Cure time | Durability to Variable temperature exposure | Freeze/thaw durability | UV exposure | Loss of color durability | Loss of bond durability | Resistance to cracking/chipping | Total Score max score: 62 |
---|---|---|---|---|---|---|---|---|
2 | 1 | 1 | 1 | 1 | 1 | 1 | ||
1 = 1 week 2 = days 3 = 9– 24 h 4 = 5–8 h 5 = 0–4 h | 1 = very poor 2 = poor 3 = fair 4 = good 5 = very good | 1 = very poor 2 = poor 3 = fair 4 = good 5 = very good | 1 = very poor 2 = poor 3 = fair 4 = good 5 = very good | 1 = very poor 2 = poor 3 = fair 4 = good 5 = very good | 1 = very poor 2 = poor 3 = fair 4 = good 5 = very good | 1 = very poor 2 = poor 3 = fair 4 = good 5 = very good | ||
Evercrete Deep Penetrating Sealer (DPS) | 5 | 5 | 5 | 5 | 5 | 5 | 5 |
88
|
Waterbased Asphalt Emulsion | 4 | 5 | 5 | 3 | 4 | 3 | 4 |
82
|
TEXCOTE XL 70 BRIDGE COTE | 5 | 5 | 5 | 5 | 4 | 5 | 5 |
81
|
TEXCOTE XL 70 BRIDGECOTE W/SILANE | 5 | 5 | 5 | 5 | 4 | 5 | 5 |
81
|
Waterbased Epoxy | 5 | 5 | 5 | 2 | 3 | 4 | 5 |
78
|
Evercrete Top Seal (TS) | 5 | 5 | 5 | 5 | 5 | 5 | 5 |
72
|
Penetrating Concrete Sealer: SW DOT Concrete Sealer 100 | 3 | 5 | 5 | 5 | 5 | 5 | 5 |
72
|
Dynapoxy Low Mod Epoxy | 5 | 5 | 4 | 5 | 4 | 5 | 5 |
71
|
Soprema Alsan Flashing | 4 | 5 | 5 | 5 | 5 | 5 | 5 |
71
|
Si-Rex03 Silicone Resin Emulsion Paint (SREP) | 1 | 5 | 5 | 5 | 5 | 5 | 5 |
69
|
Soprema Alsan RS | 5 | 5 | 5 | 5 | 5 | 5 | 5 |
68
|
PecoraDeck P-808 primer Pecoradeck P-806 Top Coat | 4 | 5 | 5 | 5 | 4 | 5 | 5 |
67
|
Sil-Act ATS-100LV | 5 | 3 | 3 | 3 | 3 | 3 | 3 |
63
|
Epoxy : Plymastic 650 | 2 | 5 | 5 | 2 | 2 | 5 | 5 |
61
|
FX-460 BREATHABLE MASONRY COATING SYSTEM | 5 | 5 | 5 | 5 | 1 | 1 | 5 |
60
|
Safe-Cure & Seal EPX Duraguard 310CRU | 3 | 5 | 5 | 5 | 1 | 1 | 4 |
58
|
Sil-Act EP 700D | 5 | 3 | 3 | 3 | 3 | 3 | 3 |
56
|
FX-498 HYDRO ESTER HIGH BUILD COATING | 3 | 5 | 5 | 5 | 3 | 1 | 4 |
55
|
Epoxykote 100WB | 3 | 5 | 5 | 3 | 3 | 1 | 4 |
53
|
4 Products and Systems to Protect Steel Bridge Elements
4.1 Survey Results for Steel Coatings and Treatments
System recommended | Product names | Manufacturers |
---|---|---|
Organic Zinc Rich Moisture Cured Urethane | Wasser MC Zinc | Wasser |
Moisture Cured Urethane | Ferrox B | Wasser |
Moisture Cured Urethane | Ferrox A | Wasser |
Moisture Cured Urethane - Zinc Rich | Corothane I Galvapac | Sherwin Williams |
Moisture Cured Urethane | Ironox B | Sherwin Williams |
Moisture Cured Urethane | Ironox A | Sherwin Williams |
Solvent Based Inorganic Zinc | Carbozinc II HS | Carboline |
Cycloaliphatic Amine Epoxy | Carboline 893 | Carboline |
Aliphatic Acrylic-Polyester Polyurethane | Carboline 133 HB | Carboline |
Organic Zinc Rich Epoxy | Carbozinc 859 | Carboline |
Epoxy Polyamide | Carboline 888 | Carboline |
Aliphatic Acrylic-Polyester Polyurethane | Caboline 133 HB | Carboline |
Zinc & Micaceous Iron oxide Urethane | Wasser MC-Miozinc | Wasser |
Moisture Cured Urethane | Wasser MC Miomastic | Wasser |
Moisture Cured Urethane | Wasser MC Miomastic | Wasser |
Zinc & Micaceous Iron oxide Urethane | Wasser MC Miozinc | Wasser |
Moisture Cured Urethane | Wasser MC Tar | Wasser |
Moisture Cured Urethane | Wasser MC Tar | Wasser |
Organic Zinc Rich Epoxy | Carbozinc 859 | Carboline |
Aliphatic Acrylic-Polyester Polyurethane | Carbothane 133 HB | Carboline |
Organic Zinc Rich Polyamide Epoxy | Zinc Clad III HS | Sherwin Williams |
Acylic Polyurethane | Acrolon 218 HS | Sherwin Williams |
Calcium Sulfonate Alkyd | AS 8301 Series | Watson Coatings Inc. |
Zinc Rich Epoxy | Interzinc 315B | Internation Paints |
Epoxy | Intergard 475 HS | Internation Paints |
Inorganic Zinc Rich Ethyl Silicate | InterZinc 22 HS | Internation Paints |
Epoxy | Intergard 475 HS | Internation Paints |
Organic Zinc Rich Moisture Cured Urethane | MC Zinc 100 | Wasser |
Moisture Cured Urethane | MC Miomastic 100 | Wasser |
Moisture Cured Urethane | MC Ferrox A | Wasser |
Urethane | MC-Universal Primer DTM | Wasser |
Moisture Cured Urethane | Ferrox B | Wasser |
Moisture Cured Urethane | Ferrox A | Wasser |
High Build Epoxy Mastic | Corlar 2.1 ST | DuPont Industrial Coatings |
Aliphatic Poluyurethane Enamel | Imron 3.5 HG | DuPont Industrial Coatings |
High Build Epoxy Mastic | Corlar 2.1 ST | DuPont Industrial Coatings |
Polyurethane | Imron Industrial Strength | DuPont Industrial Coatings |
Organic Zinc Rich Epoxy | Zinc Clad III HS | Sherwin Williams |
Epoxy | Macropoxy 646 FC | Sherwin Williams |
Acrylic Polyurethane | Acrolon 218 HS | Sherwin Williams |
High Solids Aluminum Filled Polyamine Epoxy | Epoxy Mastic Aluminum II | Sherwin Williams |
High Solids Aluminum Filled Polyamine Epoxy | Epoxy Mastic Aluminum II | Sherwin Williams |
Acrylic Polyurethane | Acrolon 218 HS | Sherwin Williams |
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Inorganic Zinc Primer/Epoxy Mid Coat/Polyurethane Top Coat (21 %).
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Inorganic Zinc Primer/Epoxy Mid Coat/Urethane Top Coat (16 %).
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Inorganic Zinc Primer/Acrylic Mid Coat/Acrylic Top Coat (16 %).
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Organic Zinc Primer/Epoxy Mid Coat/Polyurethane Top Coat (11 %).
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Inorganic Zinc Primer/Epoxy Mid Coat/Polyurethane Top Coat - Carbonzinc 11 HS/Carboguard 893/Carbothane 133 HB. This specific set of products was reported by both, Oregon DOT and New Hampshire DOT.
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Organic Zinc Primer/Epoxy Mid Coat/Polyurethane Top Coat - Carbozinc 859/Carboline 888/Carboline 133 HB. This specific set of products was reported by New Hampshire DOT.
5 Summary and Conclusions
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Inorganic Zinc Primer/Epoxy Mid Coat/Polyurethane Top Coat
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Inorganic Zinc Primer/Epoxy Mid Coat/Urethane Top Coat
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Inorganic Zinc Primer/Acrylic Mid Coat/Acrylic Top Coat
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Organic Zinc Primer/Epoxy Mid Coat/Polyurethane Top Coat