DMS - 6100 EFFECTIVE DATE: JUNE 2014 6100.1. Description. 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 C, D, E, and F) dowel, tie bar, and anchoring 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 6100.2. Units of Measurements. 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. 6100.3. Material Producer List (MPL). The Materials and Pavements Section of the Construction Division (CST/M&P) maintains the Quality Monitoring Program (QMP) for epoxies and adhesives, as outlined in DMS-6110. Materials listed on the MPL, entitled Epoxies and Adhesives, do not require further testing, unless deemed necessary by the Engineer. Products not currently listed on the MPL require project-specific testing and approval before 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 of this Specification. Do not use the material until testing is complete. 6100.4. Sampling and Testing. The Department samples in accordance with Tex-734-I and tests in accordance with and other test procedures as stated. Costs of sampling and testing are normally borne by the Department; however, the costs of sampling and testing material that fails to conform to the requirements of this Specification are borne by the Contractor or supplier. The Director of CST/M&P will assess the cost of sampling and testing failing material 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. TEXAS DEPARTMENT OF TRANSPORTATION 1 9 EFFECTIVE DATE: JUNE 2014
6100.5. Material Properties. A. Type I Precast Concrete Segment Adhesive. 1. 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. a. Class A Low Temperature. This formulation provides a fast reacting system for placement when the concrete temperature is 40 60 F (4 16 C). b. Class B Medium Temperature. This formulation is suitable for placement when the concrete temperature is 55 80 F (13 27 C). c. Class C High Temperature. This formulation is suitable for placement when the concrete temperature is 77 105 F (25 41 C). 2. Physical Requirements. Table 1 describes the requirements for precast concrete segment adhesive. Table 1 Type I s Workability 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) The mixed adhesive must be sufficiently fluid to apply by spatula or trowel without any difficulty. 24 Min 60 Min 0.2 (5.0) Max 290 (2.00) Min At 24 hr. 2,000 (14.0) Min At 48 hr. 6,000 (41.5) Min Hardness @ 120 F (49 C) ASTM D 2240 77 Min TEXAS DEPARTMENT OF TRANSPORTATION 2 9 EFFECTIVE DATE: JUNE 2014
3. 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. B. Type II Traffic Marker Adhesive. 1. Description. Type II adhesive is designed for machine application and is suitable for bonding ceramic, plastic, or metal markers to concrete pavements. Include the following information with every shipment: proper type of dispensing equipment to be used and weather conditions, during application, that are detrimental to material performance. 2. Physical Requirements. Table 2 describes the requirements for traffic marker adhesive. Physical Property 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) Table 2 Type II Test Method Requirement 7 Min 200 (1.40) Min 20 Max 15 Max 1,800 (12.40) Min 6-1/2 (9.0) Min 270 (1.85) Min 0.2 (5.0) Max TEXAS DEPARTMENT OF TRANSPORTATION 3 9 EFFECTIVE DATE: JUNE 2014
Table 3 indicates the approximate set time for field conditions for traffic marker adhesive. Table 3 Approximate Set Time for Type II Epoxy Pavement Temperature Set Time (Hr.) 115 F (46 C) 0.5 95 F (35 C) 1.0 77 F (25 C) 2.0 60 F (16 C) 4.0 50 F (10 C) 7.0 3. 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. C. Type III Dowel, Tie Bar, and Anchoring Adhesive. 1. Description. Type III adhesives are used to anchor dowels and tie bars in concrete and are suitable to bond steel to hardened concrete. There are four classes. a. Class C. This formulation is a standard cure cartridge-dispensed material or a bulk material for machine application only. Class C is used for either horizontal or vertical down application of dowel and tie bars. (See NOTE.) b. Class D. This formulation is a fast cure cartridge-dispensed material or a bulk material for machine application only. Class D is used for either horizontal or vertical down applications of dowel and tie bars. This adhesive can be used in cold weather conditions. (See NOTE.) c. Class E. This formulation is a standard cure cartridge-dispensed material for use in anchoring applications where the anchor is placed in either horizontal or vertical down applications. (See NOTE.) d. Class F. This formulation is a fast cure cartridge-dispensed material for use in anchoring applications where the anchor is placed in either horizontal or vertical down applications. This adhesive can be used in cold weather conditions. (See NOTE.) NOTE: Vertical overhead applications are not allowed. TEXAS DEPARTMENT OF TRANSPORTATION 4 9 EFFECTIVE DATE: JUNE 2014
2. Physical Requirements. a. Class C and Class D. Table 4 describes the requirements for Class C and Class D dowel and tie bar adhesives. Table 4 Type III, Class C and Class D Physical Property Test Requirements Method Class C Class D Gel Time 1 Tensile Bond @ 6 hr., psi (MPa) Tensile Bond @ 120 F (49 C), psi (MPa) Thixotropy @ 120 F (49 C), mils (mm) 6 min. Min 2 hr. Max at 40 F 200 (1.40) Min 200 (1.40) Min 400 (2.8) Min 400 (2.8) Min 30 (0.75) Min 30 (0.75) Min Wet Pullout 1 Strength, 4,500 (20) Min 4,500 (20) Min lbf. (kn) 1. For Class D, perform gel time at 40 F and perform pullout at 4 hr. under dry conditions. b. Class E. An approved building code evaluation service must evaluate Class E adhesives in accordance with AC308 prior to pre-qualification. Approved code evaluation services include International Code Council Evaluation Service (ICC-ES), the International Association of Plumbing and Mechanical Officials (IAPMO), or any other service accredited by ANSI in accordance with ISO/IEC Guide 65. Refer to DMS-6110 for pre-qualification requirements. Class E adhesives also have the following properties. Maximum cure time of 24 hr. at 77 F Minimum gel time of 25 min. at 77 F c. Class F. An approved building code evaluation service must evaluate Class F adhesives in accordance with AC308 prior to pre-qualification. Approved code evaluation services include International Code Council Evaluation Service (ICC-ES), the International Association of Plumbing and Mechanical Officials (IAPMO), or any other service accredited by ANSI in accordance with ISO/IEC Guide 65. Refer to DMS-6110 for pre-qualification requirements. Class F adhesives also have the following properties. Maximum cure time of 2 hr. at 77 F Maximum gel time of 2 hr. at 40 F D. Type IV Bridge Deck Sealant and Adhesive. 1. Description. Type IV adhesive is a low viscosity epoxy intended for use in sealing cracks in concrete and restoring its structural integrity. TEXAS DEPARTMENT OF TRANSPORTATION 5 9 EFFECTIVE DATE: JUNE 2014
2. Physical Requirements. Table 5 describes the requirements for bridge deck epoxy. Table 5 Type IV Viscosity of Mixed Components, centipoise (Pa-s) Compressive Stress, @ 5% strain after 48-hr. cure @ 77 F (25ºC), psi (MPa) Wet Strength, psi (MPa) Track-Free Time, @ 77 F (25ºC), hr. ASTM C 679 40 mil thickness 125 (0.125) Max 25 Min 5,000 (34.5) Min 350 (2.4) Min 5 Min 8 Max 3. 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. E. Type V and Type VII Concrete Adhesives. 1. Description. Type V and Type VII adhesives are used to bond fresh concrete to existing concrete and to bond hardened concrete to hardened concrete. a. Type V. This formulation is suitable for sealing the surface of fine cracks in concrete or for waterproofing applications and designed for applying to horizontal and vertical surfaces. b. Type VII. This formulation 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. 2. Physical Requirements. Table 6 describes the requirements for concrete adhesives. Table 6 Type V and Type VII s Type V Type VII 30 Min 30 Min Tensile Bond @ 6 hr., psi (MPa) 200 (1.40) Min 200 (1.40) Min 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) 400 (40) Max 1,200 (120) Min 20 Max 20 Max 350 (2.4) Min 300 (2.10) Min TEXAS DEPARTMENT OF TRANSPORTATION 6 9 EFFECTIVE DATE: JUNE 2014
3. 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. F. Type VIII Binder for Producing Grout or Concrete. 1. Description. Type VIII epoxies are binder materials mixed with select aggregates to form a quick-setting epoxy for use in concrete repair. There are two classes. a. Class A. This formulation is a low-modulus epoxy grout used to repair spalls, chipped areas, and other defects in precast concrete. b. Class B. This formulation is a high strength epoxy grout used to repair potholes, cracks or spalls, and other defects in concrete. 2. Physical Requirements. Table 7 describes the requirements for binder components of the epoxy grout without aggregate. Table 7 Type VIII (Binder) 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) Class A Class B 30 Min 30 Min 20 Max 20 Max 200 (1.40) Min 200 (1.40) Min Water Gain, % 0.5 Max - Elongation, % Tex-618-J 40 Min - Table 8 describes requirements for the complete epoxy grout (binder and aggregate). Table 8 Type VIII (Grout) Class A Class B Compressive Strength, psi (MPa) 500 (3.4) Min 5,000 (34.5) Min Tex-618-J Resilience, % 70 Min - Old concrete to new grout mix, psi (MPa) Thixotropy (sag on test panel), in. (mm) 200 (1.4) Min 290 (2.0) Min 0.2 (5.0) Max 0.2 (5.0) Max TEXAS DEPARTMENT OF TRANSPORTATION 7 9 EFFECTIVE DATE: JUNE 2014
3. 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. G. Type IX Epoxy for Crack Injection. 1. Description. Type IX epoxy is a low viscosity epoxy adhesive to be pressure-injected into cracks in concrete to restore its structural integrity. 2. Physical Requirements. Table 9 describes the requirements for epoxy for crack injection. Table 9 Type IX Viscosity of Mixed Components, centipoise (Pa-s) Wet Strength, psi (MPa) 20 Min 1,000 (1.0) Max 250 (1.7) Min 3. 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. H. Type X Epoxy Coating for Concrete. 1. 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. 2. Physical Requirements. Table 10 describes the requirements for the resin component of epoxy coating for concrete. Table 10 Type X (Resin Component) Grind (Fineness of Dispersion), Hegman 4 Min TEXAS DEPARTMENT OF TRANSPORTATION 8 9 EFFECTIVE DATE: JUNE 2014
Table 11 describes the requirements for the mixed resin and hardener components of epoxy coating for concrete. Table 11 Type X (Mixed Resin and Hardener Components) Thixotropy, mil (mm) Thickness retained from a coating of 10 mil (0.25 mm) Hiding Power (contrast ratio) 80 Min, 160 Max 8 (0.20) Min 0.80 Min 6100.6. 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. 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 quantity contained therein. 6100.7. 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. 6100.8. 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. 6100.9. Archived Versions. Archived versions are available. TEXAS DEPARTMENT OF TRANSPORTATION 9 9 EFFECTIVE DATE: JUNE 2014