Testing & Evaluation of Concrete Repair Materials for the Cheyenne Airport Taxiways: FHWA-WY-04-05F
Because of harsh winters, deteriorated concrete surfaces are common throughout Wyoming. Usually caused by cyclic freezing and thawing, deteriorated surfaces consist of scaling, spalling and cracking. Common methods of repair include thick concrete overlays and full-depth repairs. Both methods are costly and time consuming.
Recently, a Wyoming company developed a thin polymer-cement overlay repair material called Seal-Crete specifically designed for rehabilitating scaled and spalled concrete surfaces. A thin-overlay repair method can provide a quick and economical means to repair or extend the service life of concrete surfaces.
This research project was undertaken to evaluate and assess the highway potential for using Seal-Crete or similar materials to repair pavements, curbs and gutters, bridge decks, and other concrete surfaces encountered by the Wyoming Department of Transportation. Specific objectives of this investigation were: 1) evaluate the application and performance of Seal-Crete on a large test project at the Cheyenne Airport, 2) to make recommendations regarding “where to use” and “how to use” Seal-Crete or similar products to repair damaged or deteriorated concrete surfaces.
Scope of work included: a condition survey of the deteriorated concrete taxiways, evaluation of various surfaceâEuro¨preparation methods, repair 149,400 sq ft of concrete taxiways using a thin overlay of Seal-Crete, monitoring andâEuro¨performance evaluation of the repaired concrete surfaces over a three year period. Included in this investigation:âEuro¨compressive strength testing of cores, visual inspections, chain drag and sounding tests, a petrographic examination, bond strength testing, laboratory freeze/thaw testing, and a field performance study.
After three years of service, the Seal-Crete performance has been excellent. Considering the poor condition of the concrete substrate, the Seal-Crete and repaired concrete surface performance has surpassed all expectations. By bonding together, filling damaged areas and sealing the surface against moisture infiltration, this thin-overlay is extending the service life of the pavement. From this investigation, it appears a thin polymer-cement overlay (i.e., Seal-Crete) is a viable and effective method for repairing deteriorated concrete pavements and extending pavement service life.
This report presents all laboratory results, condition survey and bond test results, and options for surface preparation including bond test results, Seal-Crete technical information, overlay application techniques, and material performance results. Discussions, conclusions and recommendations including design and construction checklists for using Seal-Crete or a similar thin polymer-cement overlay material are presented.