epoxy asphalt chemco systems durable pavement for steel decks

Epoxy AsphaltEpoxy Asphalt

ChemCo Systems

Durable pavement for Steel Decks


ChemCo Systems

History

late 1950s Shell Oil develops jet fuel and hydraulic oil resistant paving for airport taxiways.

1966 Caltrans uses Epoxy Asphalt on San Mateo-Hayward Bridge (in use).

1976 Bay Bridge 18mm overlay on lightweight

concrete (in use).

1984 Golden Gate Bridge redecked (in use).

2000 2nd Nanjing (first Asia project). --5th generation product used for the first time


ChemCo Systems

Applications

Orthotropic steel decks• New construction• Replacement paving• Re-decking

Overlays Temporary chip seals

• For replacement deck panels

High (heavy weight) traffic, strategic roads with long life requirement

Fuel and chemical resistant paving

Lionsgate Br


ChemCo Systems

EA Chemistry

Epoxy cross-linked polymer: continuous phase, asphalt: discontinuous phase

2 component binder and 2 component bond coat• Part A Resin• Part B Asphalts and cross-linkers

Ambient temperature reactive cure mechanism

Cured polymer is thermoset (won’t melt)


ChemCo Systems

Properties Extremely high fatigue

resistance High strength bond coat

• Protects against delamination

• Ensures composite action with steel

• Resists high summer deck temperatures

Thermoset• Will not melt

Higher modulus than other flexible pavements• Reduces deck deflection

Element meshing

“Epoxy Asphalt has a fatigue life of 2 to 3 orders

of magnitude greater than the PG76-22 I-5 mix…”.

--Rutgers University study


ChemCo Systems

Properties

Does not oxidize (like all other asphalts)

• No embrittlement upon aging

Low voids (typically ~2 %)• Water impermeable• No chloride ion

penetration• No corrosion--no

membrane required High Temperature bond performance

FHWA OECD Long Lived Pavement Study

Turner Fairbanks Highway Research Center


ChemCo Systems

Fundamental difference

HMA Asphalt, SMA, Gussasphalt, PMA are thermoplastics: will melt

Epoxy Asphalt is thermoset: will not melt

“Epoxy Asphalt concrete has shown excellent performance including anti-cracking feature

under low temperature, stability under high temperatures and oil-corrosion resistance.…”

--W. Wang, Chang’an University


ChemCo Systems

Advantages

Low permeability prevents deck corrosion

Fatigue resistance minimizes cracks

4+ times more stability than standard AC

Handles truck wheel overloads (common in Asia)

--Rutgers Univ.


ChemCo Systems

Advantages

No rutting or shoving Use standard AC

paving equipment• Very high bond

strength• Paving placement

is fast Won’t delaminate

“The superior oxidation resistance of the epoxy asphalt

material was even more obvious in the Cantabro tests…”

--Transit New Zealand—OECD report


ChemCo Systems

Typical new construction detail


ChemCo Systems

EA Specifications

Dense graded mix, ½” (12mm) minus• Basalt rock for skid

resistance and long wear Low temperature paving (110-

121ºC)• Time/temp monitoring is

critical QC element • Similar temps to warm mix

Lab simulation (fatigue testing) advised for unique decks


ChemCo Systems

O-T Deck Pavement Stressfrom wheel load deflection

Longitudinal stiffener

TENSION


ChemCo Systems

Fatigue testingevaluate pavement design

on project specific deck

Keys• Realistic paving

composite specimens

• Good tests take time

• Research performance of local materials (aggregates)

• Use environmental chamber to control extreme temps


ChemCo Systems

Comparison: EA vs. polymer modified AC or SMA

Properties

Condition Epoxy Asphalt Polymer AC

High temperatures Will not melt Melts

Permeability None measurable

Changes with age a. Will not oxidizeb. Flexibility constant

No age related performance losses

a. Oxidizesb. Flexibility

declines

Delamination potential Very lowConsistent composite

behavior

High

Fuel resistance High Low—will soften and dissolve binder

Rutting, shoving Stable Unstable under high temps and loads


ChemCo Systems

Chinese standard deck detail

Fatigue test specimen

with 3 pt. dynamic load

on 300 mm center

300 mm stiffener spacing12 mm deck plate (prior to 1999)14 mm deck plate (after 1999)

50-55 mm EA pavingLocus of highest stress is over stiffeners, particularly in truck lanesDynamic fatigue test is good predictor


ChemCo Systems

Asian conditions High deck temps

• To 90 °C Extreme temperature cycle

between winter and summer Construction QC varies

widely Standardized deck design in

mainland


ChemCo Systems

Asian conditions

Consistent very high truck wheel overloads• To 120 MT on 18

wheelers

• SMA and gussasphalt sometimes fail as quickly as 2-3 yrs.

SuTong Br.


ChemCo Systems

EA: Disadvantages

Time and temperature controls critical• Controls can lead to higher quality and uniformity• Paving plant needs to be within 45-50 minute drive

Too complicated• Over 35 bridges in Asia in past 10 yrs successfully

completed– including 1st suspension bridge in Viet Nam

• ChemCo provides advisors• Use test section in convenient location to train local paving

crews before deck placement

Costs more• Cost difference dwarfed by frequent closures and repaving

Thuan Phuoc Bridge

DaNang, Viet Nam


ChemCo Systems

Next in N. America

Fremont, Portland 2011• Repave in July

MacDonald, Nova Scotia ~2015

• Redeck similar to Lionsgate

San Francisco-Oakland Bay ~2012• Single anchored suspension

(new East Span)


ChemCo Systems

Future

Reduce pavement weight

Local manufacturing OECD-ECMT Joint

Transport Research on long life pavements• (U.S., U.K., France,

Germany, Denmark, New Zealand, Australia)

• Open graded performance benefits demonstrated

Improve fatigue performance in most challenging applications• Decks with

extremely high wheel overloads

• Decks with thin plates (12 mm)

• Hottest tropical environments


ChemCo Systems

Conclusions

Design, test and confirm for wear course successEpoxy Asphalt, a thermoset material, performs on challenging decksEpoxy Asphalt offers life cycle cost benefits

Asian lessons learned• Over design

surfacing when realistic data not available

• Be flexible to adopt local improvements


ChemCo Systems

Thanks for your interest!

epoxy asphalt chemco systems durable pavement for steel decks

Documents

epoxy asphalt concrete

epoxy asphalt material

time slide

changan university slide

high temperatures

rutgers university study

oilcorrosion resistance

deck deflection element