Case Study

Procedure & Observations:
CERATECH personnel traveled to the above referenced site to observe the preparation and repair for a typical joint failure on a bridge deck on Stony Battery Road. The preparation work and the material placement were to be performed by the Penn DOT maintenance personnel on site.

When the CERATECH personnel arrived on site, the Penn DOT personnel were in the process of removing an existing repair patch (asphalt patch) from the proposed repair location. The repair was located on the north side of the northern most control joint on the above stated bridge. Due to the extent of the failure, the Penn DOT crew elected to perform the repair as a full depth repair. Demo of the existing repair and subsequent removal of damaged or unsound concrete was also performed by the Penn DOT crew utilizing an air assisted demo hammer. Demolition of the damaged repair and concrete uncovered reinforcing steel that was part of the original reinforcing mat placed on the deck.

Corrosion of the reinforcing steel was noted, however, the steel appeared to be intact, and was left in place. Scaled material was removed from the reinforcement bars, prior to placement of the Pavemend materials. The repair site was blown free of dust and debris using compressed air.

The prepared repair area measured approximately 10.25 feet X 0.75 feet X 0.625 feet (depth), calculated to an approximate volume of 4.8 cubic feet. The repair area was formed using a combination of plywood (1/2 inch), expanding foam (spray applied), and insulation board.

The forming was performed to minimize or eliminate the material from leaking into the open area, and to preserve the existing control joint at this location. It was suggested by CERATECH that the formwork be sealed to further prevent material loss from the repair site.

A grout mixer was utilized in the repair to eliminate multiple layering. CERATECH recommended grout mixing procedures were followed, with ten units of Pavemend SL™ (15.0) and the corresponding water. The material temperature was 52°F and the water temperature was 80°F. It was then mixed to temperature (95°F, 7 minutes) and placed.

During placement the unsealed forms shifted resulting in a material loss of approximately 4 units. The lost material was replaced by mixing individual buckets with a drilled paddle. The surface was brought to grade and broom finished. An additional repair was performed to utilize the remaining material approximately 50 feet south of the main repair site in the north bound lane.