1. POLYESTER POLYMER CONCRETE
Indian Roads Congress Accredited (March 2012)
Rajesh Oberoi, P.E. (California, USA)
DDR Global Infrastructure Pvt. Ltd.
WALIA INTERNATIONAL MACHINES CORPORATION
408, Vishwadeep, District Centre, Janak Puri, New Delhi –
Ph # , ,
Website :

2. Introduction DDR Global Infrastructure Pvt. Ltd. RAJESH OBEROI
P.E. (Civil) State of California, USA
B.Tech. (Civil), 1981, IIT, Kanpur, India
M.S. (Civil), 1985, Univ. of Massachussetts, Amherst, MA, USA

3. Why Polyester Concrete for Overlays in India?
Proven technology with a track record of 30+ years
ELIMINATES Maintenance Cost
Provides almost 100% protection against chloride intrusion
Provides high skid resistance
Quick return to service in less than 2 hrs
Can be placed in one lift from 25mm – 300 mm
Exceptional Bond Strength
Used in EXTREME CLIMATIC CONDITIONS with Altitude, Marine/Coastal, Humid, Freeze-Thaw and Desert Environments
Polyester
Bond line
Concrete
Break line

4. What is Polyester Concrete?
A very durable composite material made of hardened polyester resin, coarse aggregate and sand.
The polyester resin serves as the binding agent - similar to hydrated Portland Cement in PCC.
Engineered Material with Consistent Properties.
Polyester
Bond line
Concrete
Break line

5. Polyester Concrete background
First use of current system 1983 – Thomson Creek & Beaver Creek Bridges, Yreka, California, USA
1985/86 Highway overlay I-80 (10 lane miles), California, USA
5 million m2 (55 million ft2) surface in place on BRIDGES ALONE in 20 States in the USA equates to approximately 1,500 km of single lane
TODAY – An average of 2 tenders/month are advertised in just one State (California)
Neal Estrata, several small overlays, Oakland Bay br.
18 years service – low traffic but severe thermal exposure
Whitmore – 5,000 foot elevation
Composite system 5

6. What is Polyester Concrete?
POLYSTER POLYMER
CONCRETE (PPC 1121)
PORTLAND CEMENT CONCRETE
WATER
POLYESTER POLYMER RESIN
(Unsaturated Isophthalic
Poly-Styrene Co-Polymer)
CEMENT
SAND
IS383
AGGREGATE
Natural,10mm Down, River Borne
Crushed, 26.5mm Down
A very durable composite material made of hardened polyester resin, coarse aggregate and sand.
The polyester resin serves as the binding agent - similar to hydrated Portland Cement in PCC.
Engineered Material with Consistent Properties.
First use of current system 1981 – Thomson Creek & Beaver Creek Bridges, Yreka, California, USA

7. Approved by FHWA in year 1988

8. AASHTO Guide Specifications - 1995

9. Indian Roads Congress Accredited - 2012

11. Polyester Concrete use in USA
PERFORMANCE CERTIFICATE – 22 STATES HAVE IT IN THEIR STANDARD SPECIFICATIONS

12. 30+ Years of Proven Performance
Polyester Polymer Concrete Overlay Placed in 1983
These Pictures were taken in July 2011

13. Polyester Concrete Properties
Thermal coefficient of expansion – 14.6 x 10-6 deg C
Lower modulus equals less stress
Higher tensile and flexural strength
High abrasion resistance
Excellent bond strength (composite)
Very low permeability to water and chlorides
Fast setting – traffic in about 2 hours 13

14. Key Engineering Properties
Polyester Polymer Concrete (PPC 1121)
Portland Cement (8-Bags)
Chloride Permeability, Coulombs
0 – 200
1, ,000
Compressive Strength
565 Kg/cm2
490 Kg/cm2
24-hr Early Strength
280 Kg/cm2
105 Kg/cm2
Flexural Strength
155 Kg/cm2
55 Kg/cm2
Modulus of Elasticity (E)
Mpa
Mpa
Abrasion
0.25mm/year
4.0 mm/year
Open to Traffic
2 - 4 Hours
3 - 7 Days
ABRASION = 0.38 MM/YEAR THAT IS 1 MM IN 2.75 YEARS 14

15. PERMEABILITY

16. Signature Projects Polyester Polymer Concrete Overlays
San Francisco-Oakland Bay Bridge, CA- 300,000 ADT
Richmond San Rafael Bridge, CA- 80,000 ADT
Benicia Martinez Bridge, CA – 100,000 ADT
Vincent Thomas Bridge, Long Beach, CA- 35,000 ADT
South Grand Island Bridge Buffalo, NY- 40,000 ADT
McCullough Memorial Bridge, Oregon- 20,000 ADT 16

17. Richmond-San Rafael Bridge Extreme Coastal/Marine Environment Built in 1956, 8.85 KM, Upper & Lower Decks – 3 Lanes on Each Deck
Left Lane - Grinded
Right Lane - Overlain by PPC
Middle Lane - Original, Damaged, Potholed, patched

18. South Grand Island Bridge, NY Extreme Winter Conditions
1 KM long critical link, Niagara Falls and Buffalo, NY was overlaid with Polyester Concrete.
Completed: night and full weekend closures
Largest polyester project to date on East Coast
Tough winter weather conditions
Overlay applied to newly replaced precast deck system to protect thin 100 mm concrete deck section

19. San Francisco - Oakland Bay Bridge Extreme Coastal/Marine Environment
Built in 1936
Total Length = 7.18 km
Deck Surface overlaid with 25 mm Thick PPC
Total of 110,000 Square Meters
One of the busiest bridges in the US
300,000+ vehicles per day
5 lanes on the upper and lower deck

20. Polyester Concrete at Airports
Polyester Concrete has been used at airports across the country for spall and concrete repairs:
—San Diego International Airport
—Southern CA Logistics Airport
—Marine Corps Air Station Pendleton
—Sacramento International Airport
—Niagara Falls Guard Station Airport
—Denver International Airport
—Dallas Fort Worth International Airport
—Los Angeles International Airport
—PPC High Resistance to Jet Fuel/Aviation Hydraulic Fluids

21. Skid Data Marina Viaduct Measured Skid Resistance in 1991
Friction Coefficient = 0.4
Measured Skid Resistance in 2010
Measured by Towed-Trailer Skid Test

22. Polyester Overlay Construction:
Step 1 (If Required): Remove/Grinding existing asphalt or concrete overlay/coating by micro-milling
Step 2: Find & Repair spalls or unsound concrete
Step 3: Surface Preparation/Shotblasting
Step 4: Apply HMWM Resin Prime Coat
Step 5: Mix and Pave
Step 6: Finish, Tine, sprinkle dry sand, Open to Traffic!

23. Polyester Overlay Construction:
Step 1 (If Required): Remove existing asphalt or concrete overlay/coating by micromilling
Construction Keys:
Use specialized equipment to
prevent damage to concrete deck
(Caltrans Micromill spec)
6mm tooth spacing
Hand removal near metal joints
Remove slurry seals, chip seals etc.
Potholing may be needed to
determine existing overlay thickness

24. Polyester Overlay Construction:
Step 2: Find & Repair spalls or unsound concrete
Construction Keys:
Sawcut edges square
Remove only unsound material
May be placed during overlay
Sandblast or shotblast, blow w/ air

25. Polyester Overlay Construction:
Step 3: Surface Preparation/Shotblasting
Construction Keys
The objective is a surface free of loose material, laitance, previous coatings or oils.
Utilize shotblasting machines
Reblast if too much primer applied in previous shift
Remove traffic stripe or buttons prior to shotblasting
Should be blown off with high pressure air after shotblasting

26. Polyester Overlay Construction:
Step 4: Apply HMWM Resin Prime Coat
Construction Keys:
Minimize puddling
Place overlay within 15 mins of placing primer and/or before primer gels
Can be applied with sprayer or rollers
Paving equipment may drive on prime coat
Deck surface temperature between 0 to 350C
Dry deck surface conditions

27. Polyester Overlay Construction:
Step 5: Mix and Pave
Construction Keys
Volumetric mixer ensures best product consistency
Paver should have grade control & should consolidate overlay
Polyester concrete should be thoroughly mixed and should be applied within 3-5 minutes of mixing

28. Polyester Overlay Construction:
Step 6: Finish, Tine, Apply Sand, Open to Traffic!
Construction Keys:
Edges should be tapered, joints/ends may require hand finishing
Expansion joints must be blocked out or sawcut within 4 hours
Sand should be applied uniformly, with additional sand for wet or glossy looking areas
Tining should be applied by paving machine or shortly after
Paving may be opened to traffic after Schmidt hammer reading of 24 or greater

29. Polyester Concrete Spall Repair
Step 1: Determine limits, sawcut rectangular
Step 2: Chip and remove unsound concrete, prep and blow clean
Step 3: Apply HMWM prime coat
Step 4: Place and finish polyester concrete, apply sand

30. Summary Polymer Concrete Overlay
30+ years of Proven performance.
Used in EXTREME CLIMATIC CONDITIONS with Altitude, Marine/Coastal, Humid, Freeze-Thaw and Desert Environments
ELIMINATES almost 100% Maintenance Cost
High Strength – Flexural, Tensile, and Compressive Strength
100% Seals bridge deck surfaces against chloride intrusion, Extremely low permeability to seal the deck
Superior adhesion, Exceptional Bond Strength
Placement temperature - 00 C to 350 C
Performance Temperature: C to +500 C
Open to traffic quickly – in 2 hours
Provides high skid resistance
Thermal coefficient of expansion – compatible to PCC
Lower modulus and higher creep equals less stress
Excellent abrasion resistance – 16 Times Portland Cement Concrete
Thin composite - minimizing dead load/clearance issues
Improves ride quality and drainage
MULTIPLE USES APPLICATION – ONE MATERIAL 30

31. Polyester Polymer Concrete Conventional Overlay on Concrete
WHAT ABOUT THE COST?
OVER A LIFE OF 30 YEARS
Polyester Polymer Concrete
Overlay (25 mm)
Conventional Overlay on Concrete
(Typical mm)
Rs. 4,500/Sq. m.
Rs. 60,000/Sq. m.
Rs Cr/Km Lane Length
Rs. 21 Cr/Km Lane Length