Manual Chapter Template - the Texas Department of Transportation

Departmental Material Specifications
DMS-6100 – Epoxies and Adhesives
DMS-6100
Epoxies and Adhesives
Overview
Effective Dates: May 2006–September 2007.
This Specification details requirements for various types of epoxy and adhesive materials
suitable for highway use. These materials consist of a resin component and a hardener
component or a catalyzing agent mixed to produce the finished product.
All epoxies and adhesives must be resistant to the action of weathering, moisture, acids,
alkalis, and other environmental factors.
This Specification describes the following types of epoxies and adhesives:
♦
Type I (Classes A, B, and C): precast concrete segment adhesive
♦
Type II: traffic marker adhesives
♦
Type III (Classes A, B, and C): dowel and tie bars adhesives
♦
Type IV: bridge deck sealant and adhesive
♦
Types V and VII: concrete adhesives
♦
Type VIII (Classes A and B): binder for producing grout or concrete
♦
Type IX: epoxy for crack injection
♦
Type X: epoxy coating for concrete.
Units of Measurement
The values given in parentheses (if provided) are not standard and may not be exact
mathematical conversions. Use each system of units separately. Combining values from the
two systems may result in nonconformance with the standard.
Material Producer List (MPL)
The Materials and Pavements Section of the Construction Division (CST/M&P) maintains a
quality monitoring program (QMP) for epoxies and adhesives outlined in "DMS-6110,
Quality Monitoring Program for Epoxies and Adhesives." Prequalified materials are on the
MPL entitled "Epoxies and Adhesives." Products on this list do not need further testing
unless deemed necessary by the Engineer.
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Departmental Material Specifications
DMS-6100 – Epoxies and Adhesives
Products that are not currently on the MPL require project-specific testing and approval
before their use unless otherwise shown on the plans. Submit samples with a certified test
report from an independent laboratory with test data verifying that the material meets the
requirements stated within this Specification. Do not use this material until testing is
complete.
Sampling and Testing
The Department samples in accordance with "Tex-734-I, Sampling Epoxy." The Department
tests in accordance with "Tex-614-J, Testing Epoxy Materials," and other test procedures as
stated.
Costs of sampling and testing are normally borne by the Department. However, the costs of
sampling and testing of material failing to conform to the requirements of this Specification
are borne by the Contractor or supplier. Costs of sampling and testing failing material will
be assessed at the rate established by the Director of CST/M&P in effect at the time of
testing. Amounts due to the Department for conducting such tests will be deducted from
monthly or final estimates on Contracts or from partial or final payments on direct purchases
by the State.
Material Properties
Type I - Precast Concrete Segment Adhesive
♦
Description
Type I adhesives are used for the joining of precast bridge segments. The adhesive
functions as a lubricant during the joining of the match cast segments and as a durable,
watertight bond at the joint. There are three epoxy classes, which are:
1.
Class A - low temperature. This formulation provides a fast reacting system for
placement when the concrete temperature is between 40°F and 60°F (4°C and
16°C).
2.
Class B - medium temperature. This formulation is suitable for placement when the
concrete temperature is between 55°F and 80°F (13°C and 27°C).
3.
Class C - high temperature. This formulation is suitable for placement when the
concrete temperature is between 77°F and 105°F (25°C and 41°C).
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Departmental Material Specifications
♦
DMS-6100 – Epoxies and Adhesives
Physical Requirements
The following table describes the requirements for precast concrete segment adhesive.
Type I
Physical Property
Test Method
Workability
-
Gel Time, min.
Class A @ 60°F (16°C)
Class B @ 80°F (27°C)
Class C @ 105°F (41°C)
Contact Time, min.
Class A @ 60°F (16°C)
Class B @ 80°F (27°C)
Class C @ 105°F (41°C)
Thixotropy, in. (mm)
Class A @ 60°F (16°C)
Class B @ 80°F (27°C)
Class C @ 105°F (41°C)
Tensile Bond Strength @ 24 hr., psi (MPa)
Class A @ 40°F (4°C)
Class B @ 55°F (13°C)
Class C @ 77°F (25°C)
Compressive Strength @ 24 and 48 hr., psi (MPa)
Class A @ 40°F (4°C)
Class B @ 55°F (13°C)
Class C @ 77°F (25°C)
Hardness @ 120°F (49°C)
♦
Requirements
The mixed adhesive must be
sufficiently fluid to apply by
spatula or trowel without
any difficulty.
24 Min
60 Min
Tex-614-J
0.2 (5.0) Min
290 (2.00) Min
At 24 hr. - 2,000 (14.0) Min
At 48 hr. - 6,000 (41.5) Min
ASTM D 2240
77 Min
General Requirements
•
The adhesive has a low sensitivity to damp conditions during application.
•
After curing, the adhesive exhibits high bonding strength to cured concrete, good
water resistivity (resistance), and low creep characteristics.
Type II - Traffic Marker Adhesives
♦
Description
Type II adhesive is
•
designed for machine application and
•
suitable for bonding ceramic, plastic, or metal markers to concrete pavements.
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DMS-6100 – Epoxies and Adhesives
Include the following information with every shipment:
♦
1.
proper type of dispensing equipment to be used and
2.
weather conditions, during application, that are detrimental to material
performance.
Physical Requirements
The following table describes the requirements for traffic marker adhesive.
Type II
Physical Property
Gel Time, min.
Tensile Bond @ 2 hr., psi (MPa)
Stability, % increase
Increase in Viscosity after 14-day heat aging @ 120°F
(49°C)
Difference in Viscosity Between the 2 Components, %
Tensile Shear Strength, psi (MPa)
Impact Strength, ft.-lb. (N-m)
Wet Strength, psi (MPa)
Thixotropy @ 120°F (49°C) (sag on test panel), in. (mm)
Test Method
Requirements
7 Min
200 (1.40) Min
20 Max
Tex-614-J
15 Max
1,800 (12.40) Min
6-1/2 (9.0) Min
270 (1.85) Min
0.2 (5.0) Max
The following table indicates the approximate set time for field conditions for traffic
marker adhesive.
Approximate Set Time for Type II Epoxy
Pavement Temperature
Set Time (Hr.)
0.5
115°F (46°C)
1.0
95°F (35°C)
2.0
77°F (25°C)
4.0
60°F (16°C)
7.0
50°F (10°C)
♦
General Requirements
•
The ratio of the epoxy adhesive resin to hardener components is 1:1 by volume.
•
The producer must not use alumina or hard abrasive materials that might abrade or
damage the application equipment as fillers.
•
The producer must distinctly pigment each component of adhesive to produce a
third color similar to concrete when properly mixed.
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DMS-6100 – Epoxies and Adhesives
Type III - Dowel and Tie Bars Adhesives
♦
Description
Type III adhesives are:
•
used to anchor dowels and tie bars in concrete and
•
suitable to bond steel to hardened concrete.
There are three classes, which are:
♦
1.
Class A is a bulk material used in horizontal applications.
2.
Class B is a bulk material used only in vertical applications.
3.
Class C is either a cartridge dispensed material or a bulk material for machine
application only. Class C is used for either horizontal or vertical application.
Physical Requirements
The following table describes the requirements for dowel and tie bar adhesives.
Type III
Physical Property
Gel Time, min.
Test Method
Viscosity of mixed components,
poise (Pa-s)
Class A
25 Min
1,200 (120) Max
Tensile Bond @ 6 hr., psi (MPa)
200 (1.40) Min
Requirements
Class B
25 Min
20 (2) Min
150 (15) Max
200 (1.40) Min
Class C
6 Min
200 (1.40) Min
Tex-614-J
Tensile Bond @ 120°F (49°C),
400 (2.8) Min
400 (2.8) Min
400 (2.8) Min
psi (MPa)
Thixotropy @ 120°F (49°C),
30 (0.75) Min
30 (0.75) Min
mils (mm)
1
Wet Pullout Strength, lbf. (kN)
4,500 (20) Min
4,500 (20) Min 4,500 (20) Min
1
The wet pullout test determines the strength of the adhesive bond between a steel anchor and the surface of
a hole in concrete or masonry units.
♦
General Requirements
•
The producer must distinctly pigment each component of adhesive to produce a
third color when properly mixed.
•
The fillers present in Class A and B must not abrade or damage the dispensing
equipment.
•
Use a 1:1 extruder with fully contained proportioning and dispensing system for
two-component adhesives to handle the viscosity range defined in this
Specification for Class A (horizontal) and Class B (vertical) applications.
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DMS-6100 – Epoxies and Adhesives
Type IV - Bridge Deck Sealant and Adhesive
♦
Description
Type IV adhesive is a low viscosity epoxy intended for use in sealing cracks in concrete
and restoring its structural integrity.
♦
Physical Requirements
The following table describes the requirements for bridge deck epoxy.
Type IV
Physical Property
Viscosity of Mixed Components, centipoise (Pa-s)
Gel Time, min.
Compressive Stress, @ 5% strain after 48-hr. cure @ 77°F
(25ºC), psi (MPa)
Wet Strength, psi (MPa)
Tex-614-J
ASTM C 679
40 mil thickness
Track-Free Time, @ 77°F (25ºC), hr.
♦
Test Method
Requirements
125 (0.125) Max
25 Min
5,000 (34.5) Min
350 (2.4) Min
5 Min
8 Max
General Requirements
•
The consistency of epoxy allows for the filling of voids in concrete by gravity flow.
•
The epoxy has the capability of bonding to damp surfaces without shrinking,
swelling, or cracking during or after its curing process.
Type V and Type VII - Concrete Adhesives
♦
Description
Type V and Type VII adhesives are used to bond fresh concrete to existing concrete and
to bond hardened concrete to hardened concrete.
Type V is suitable for sealing the surface of fine cracks in concrete or for waterproofing
applications and designed for applying to horizontal and vertical surfaces.
Type VII is a high-viscosity epoxy for vertical wall and overhead application where a
high build-up is required. Type VII is also suitable for sealing the surface of cracks in
concrete.
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♦
DMS-6100 – Epoxies and Adhesives
Physical Requirements
The following table describes the requirements for concrete adhesives.
Type V and Type VII
Requirements
Test
Method
Physical Property
Gel Time, min.
Tensile Bond @ 6 hr., psi (MPa)
Viscosity of Mixed Components, poise (Pa-s)
Stability, % increase
Increase in Viscosity after 14-day heat aging @
120°F (49°C)
Bond Strength of fresh concrete to cured
concrete, psi (MPa)
♦
Type V
Type VII
30 Min
200 (1.40) Min
400 (40) Max
30 Min
200 (1.40) Min
1,200 (120) Min
20 Max
20 Max
350 (2.4) Min
300 (2.10) Min
Tex-614-J
General Requirements
•
The ratio of resin and hardener components is either 1:1 or 2:1 by volume.
•
The concrete adhesive must not contain volatile solvents.
Type VIII - Binder for Producing Grout or Concrete
♦
Description
Type VIII epoxies are binder materials mixed with select aggregates to form a quicksetting epoxy for use in concrete repair. There are two classes, which are:
1.
Class A. This material is a low-modulus epoxy grout used to repair spalls, chipped
areas, and other defects in precast concrete.
2.
Class B. This material is a high strength epoxy grout used to repair potholes, cracks
or spalls, and other defects in concrete.
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♦
DMS-6100 – Epoxies and Adhesives
Physical Requirements
The following table describes the requirements for binder components of the epoxy
grout without aggregate.
Type VIII (Binder)
Physical Property
Gel Time, min.
Stability, % increase
Increase in Viscosity after 14-day heat
aging @ 120°F (49°C)
Tensile Bond @ 24 hr. for Class A and 6
hr. for Class B, psi (MPa)
Water Gain, %
Elongation, %
Test Method
Requirements
Class A
Class B
30 Min
30 Min
20 Max
20 Max
200 (1.40) Min
200 (1.40) Min
0.5 Max
-
40 Min
-
Tex-614-J
“Tex-618-J, Testing
Elastomeric Concrete”
The following table describes requirements for the complete epoxy grout (binder and
aggregate).
Type VIII (Grout)
Physical Property
Compressive Strength, psi (MPa)
Resilience, %
Old concrete to new grout mix, psi (MPa)
Thixotropy (sag on test panel), in. (mm)
♦
Test Method
Tex-618-J
Tex-614-J
Requirements
Class A
Class B
500 (3.4) Min
5,000 (34.5) Min
70 Min
200 (1.4) Min
290 (2.0) Min
0.2 (5.0) Max
0.2 (5.0) Max
General Requirements
•
The manufacturer must include the suitable mixing ratio on the label of every
container for the resin, hardener, and the aggregate mix by volume.
•
The manufacturer must specify the type and gradation of aggregate in the
binder/aggregate mixture.
Type IX - Epoxy for Crack Injection
♦
Description
Type IX epoxy is a low viscosity epoxy adhesive to be pressure-injected into cracks in
concrete to restore its structural integrity.
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♦
DMS-6100 – Epoxies and Adhesives
Physical Requirements
The following table describes the requirements for epoxy for crack injection.
Type IX
Physical Property
Gel Time, min.
Viscosity of Mixed Components, centipoise (Pa-s)
Wet Strength, psi (MPa)
♦
Test Method
Requirements
20 Min
1,000 (1.0) Max
250 (1.7) Min
Tex-614-J
General Requirements
•
Type IX epoxy is capable of bonding to damp surfaces.
•
The pigment of the mixed adhesive is gray in color with no streaks.
Type X - Epoxy Coating for Concrete
♦
Description
Type X epoxy is a high-solids epoxy coating designed mainly as a coating for pier caps
and the interior walls of rest areas.
♦
Physical Requirements
The following table describes the requirements for the resin component of epoxy
coating for concrete.
Type X (Resin Component)
Physical Property
Test Method
Grind (Fineness of Dispersion), Hegman
Tex-614-J
Requirements
4 Min
The following table describes the requirements for the mixed resin and hardener
components of epoxy coating for concrete.
Type X (Mixed Resin and Hardener Components)
Physical Property
Test Method
Gel Time, min.
Thixotropy, mil (mm)
Thickness retained from a coating of 10 mil (0.25
mm)
Hiding Power (contrast ratio)
Tex-614-J
FTM-4122
Requirements
80 Min, 160 Max
8 (0.20) Min
0.80 Min
Packaging and Labeling
Package components in airtight containers and protect from light and moisture. Include
detailed instructions for the application of the material and all safety information and
warnings regarding contact with the components.
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DMS-6100 – Epoxies and Adhesives
The label must include the following:
♦
resin or hardener components
♦
brand name
♦
name of manufacturer
♦
lot or batch number
♦
temperature range for storage
♦
date of manufacture
♦
expiration date and
♦
the quantity contained therein.
Storage
Store the epoxy and adhesive components at temperatures recommended by the
manufacturer.
Do not use:
♦
damaged or previously opened containers and
♦
any material that shows evidence of crystallization, lumps, skinning, extreme
thickening, or settling of pigments that cannot be readily dispersed with normal
agitation.
Environmental Requirements
Follow sound environmental practices when disposing of epoxy and adhesive wastes.
Dispose of all empty containers separately.
♦
Dispose of individual components by mixing according to manufacturers' instruction
and allowing the mixed adhesive to cure before disposal.
♦
Dispose of epoxy adhesive provided in prepackaged containers by completely emptying
and mixing the epoxy before disposal.
Archived Versions
The following archived versions of “DMS-6100, Epoxies and Adhesives,” are available:
♦
6100-0300 for the Specification effective March 2000 through July 2003
♦
6100-0803 for the Specification effective August 2003 through July 2004
♦
6100-0804 for the Specification effective August 2004 through April 2006.
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