Bridge deck repairs to fix spalling coupled with a Polymer Overlay is becoming a common and affordable maintenance program for concrete bridge decks. To find a good candidate for this process, it’s important to utilize the bridge inspection reports that are done every two years. Be aware that any bridge under 20’ in length will not have a bridge inspection report. Particular attention should be paid to these 20’ and under bridges since they aren’t included in the reporting process.
When looking at the bridge inspection report, there is typically a recommendations section that will point out areas: placing rip rap, painting guard rails, clearing brush, sealing cracks, repairing delamination, milling the deck, and sealing the deck. When sealing your deck, one of the most cost effective methods is the application of a Polymer Overlay. It’s a quick, affordable, and long lasting process that requires minimal traffic delays. The bridge will first be “sounded” to detect any delaminated areas. Delaminated areas will be removed by saw cutting and jack hammering the area out. The area is then sand blasted, cleaned, and the rebar is checked. Once clean either a concrete bag mix is done on sight or for larger repairs a State Grade E 9 concrete bag mix is brought in by truck. If the state grade E mix is used, the bridge must cure for 28 days prior to the polymer overlay. Once delaminated areas are repaired, the bridge is then shot blasted clean and then the first epoxy application is applied and covered with specialized aggregate. After the first lift cures, the loose aggregate is swept and a second layer of epoxy and stone is applied. After curing, the loose stone is swept off and you will have a new heavy friction surface on your bridge.